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CROSS-REFERENCE TO RELATED APPLICATION
This application claims priority to German Patent Application No. 102007043032.0 filed Sep. 11, 2007, which application is herein expressly incorporated by reference.
FIELD
The disclosure relates to a device for coupling a universal joint shaft of an agricultural implement to a power take-off shaft of a tractor. The device has a first coupling mechanism that is non-rotatably arranged on the universal joint shaft. A second coupling mechanism is non-rotatably arranged on the power take-off shaft of the tractor. The first coupling mechanism can be coupled to the second coupling mechanism for torque transmission. Furthermore, a coupling shield is provided that at least indirectly rotatably supports the first coupling mechanism. A locking mechanism interacts with a locking device to transfer the coupling shield into a coupling position and to its locked position.
BACKGROUND
A device is known from DE 33 02 379 C2. A retainer is provided on a carrier arm that is displaceably mounted, via a rolling contact bearing, onto an agricultural implement. A coupling sleeve is rotatably supported, by the rolling contact bearing, which is non-rotatably connected to a joint yoke of a universal joint of a universal joint shaft. The coupling sleeve can be non-rotatably connected to a coupling hub by longitudinal teeth. The coupling sleeve is again non-rotatably connected to a power take-off shaft of a tractor. The coupling sleeve has an inner circumferential groove. In the coupled position, locking balls are pushed by a releasing flange radially outwards into the inner circumferential groove. This prevents an unintended detachment of the coupling sleeve. Only by displacing the releasing flange can the locking balls move inward, so that the coupling sleeve can be pulled off the coupling hub.
The tractor is reversed towards the implement until the coupling sleeve is connected to the coupling hub coupling the two. Beforehand, the carrier arm has to be exactly aligned to the height and the lateral position of the coupling hub. Thus, a direct coupling is enabled between the coupling sleeve and the coupling hub.
EP 1 637 024 A1 shows a coupling frame that is attached on a three point linkage of a tractor. Coupling hooks for a three-point coupling of an implement are provided on the coupling frame. Furthermore, a coupling element is rotatably and axially displaceably supported on the coupling frame. The coupling element is connected to a universal joint shaft. Also, the coupling is connected to the power take-off shaft of the tractor. As soon as the implement is coupled to the coupling frame, the coupling element on the coupling frame is arranged in a centered position relative to the coupling element on the implement. The position relative to the three-point coupling of both coupling elements is identical. The coupling element on the coupling frame is then manually displaced by a moving lever axially in the direction toward the implement. The coupling elements, in the form of a jaw clutch coupling, are brought into engagement.
EP 1 563 723 A1 shows a device for coupling a universal joint shaft to a power take-off shaft of a tractor. A yoke-like coupling element is provided on the tractor and is axially displaceable parallel to the rotational axis of the power take-off shaft of the tractor. In an extended position, a coupling element of the universal joint shaft can be inserted radially into the rotational axis between two arms of the yoke-like coupling element. The coupling element of the universal joint shaft has a groove and is formed rotationally symmetrically to the rotational axis. The yoke-like coupling element engages the coupling element. The yoke-like coupling element can be pulled axially towards the power take-off shaft. The coupling element of the universal joint shaft is also axially displaced. Due to the pulling, the coupling element of the universal joint shaft is pulled onto the power take-off shaft. The longitudinal teeth provide a non-rotatable connection between the power take-off shaft and the coupling element of the universal joint shaft.
SUMMARY
It is an object of the disclosure to provide a device to couple a universal joint shaft to a tractor power take-off shaft. The device has a simple structure and ensures an easy and reliable coupling.
The object is solved by a device comprising a first coupling mechanism that is non-rotatably arranged on the universal joint shaft A second coupling mechanism is non-rotatably arranged on the power take-off shaft of the tractor. The first and second coupling mechanisms are non-rotatably coupled together to transmit torque. A coupling shield is provided to couple the coupling mechanisms. The first coupling mechanism is at least indirectly rotationally supported by the coupling shield. The first coupling mechanism includes a locking mechanism. A bracket with at least one locking device is attachable on the rear of the tractor. The locking device is displaceable between an unlocking position and a locking position. The locking device is displaced from the unlocking position into the locking position. The interaction of the locking device with the locking mechanism causes the coupling shield to be pulled towards the bracket. As this occurs, the first coupling mechanism is transferred into a coupling position to couple with the second coupling mechanism.
The tractor is initially reversed to couple with the implement. During this, the universal joint shaft is still not connected to the power take-off shaft. The universal joint shaft does not have to be exactly aligned with the power take-off shaft beforehand. Further, the driver does not have to drive exactly to the implement to couple the universal joint shaft to the power take-off shaft. The coupling shield is initially moved into a starting position where the locking device can grip the locking mechanism. The actual coupling process takes place by displacing the locking device. Accordingly, the locking device interacts with the locking mechanism so that the coupling shield is pulled towards the tractor. As this occurs, the universal joint shaft is coupled to the power take-off shaft or, as will be explained later, is transferred into a position, where a self-actuated coupling of the two coupling mechanism can take place.
The locking device serves, besides the pulling of the coupling shield, also to lock the coupling mechanisms to each other to prevent an unintended detachment.
A large advantage of the present disclosure is that no cumbersome components, such as coupling frames, are necessary. Further, the universal joint shaft is only moved in one direction. This applies to the approaching movement of the tractor as well as to the actual coupling process of the universal joint shaft to the power take-off shaft. A further coupling direction, transverse to the rotational axes, is not necessary. Thus, a simple coupling process is achieved.
Preferably, the first coupling mechanism is represented by a first coupling element. It can be non-rotatably connected to the universal joint shaft. Furthermore, the second coupling mechanism is represented by a second coupling element. It can be non-rotatably connected to the power take-off shaft of the tractor. Thus, two coupling elements are provided that can be connected to a conventional power take-off shaft of a tractor and a conventional universal joint shaft. However, it is also possible for the first coupling mechanism to be represented by a joint yoke with a coupling sleeve. The coupling sleeve has a bore with inner longitudinal teeth. In this case, the second coupling mechanism can be represented by outer longitudinal teeth on the power take-off shaft.
The locking mechanism may be provided by locking faces on the coupling shield. In this case, the locking device comprises, preferably, rocker levers. The levers are pivotable between an unlocking position and the locking position. The levers can engage behind the locking faces. The locking faces of the coupling shield can be gripped by the rocker lever and pulled close by engaging behind the locking faces.
One or more hydraulic cylinders may be provided to actuate the rocker levers. The rocker levers may be rigidly connected to each other. Thus, they can be pivoted together. In this case, one hydraulic cylinder is sufficient to actuate the rocker levers. When, however, the rocker levers are separately pivotable and are not connected to each other, it may be necessary to provide two hydraulic cylinders.
A simple constructed locking mechanism is provided insofar, as they comprise two studs projecting laterally from the coupling shield.
The rocker levers can be locked mechanically in their locking position to prevent an unintended decoupling. A retaining arm is provided on at least one rocker lever to prevent the decoupling. The retaining arm can be pivoted between a retaining position and a releasing position. In the retaining position, the retaining arm engages with a first retaining face behind the rocker lever in its locking position and retains it in the locking position.
The coupling shield is provided with a first centering mechanism to make the coupling process simple and secure. The first centering mechanism interacts with a second centering mechanism of the bracket. When the coupling shield is pulled toward the bracket, such that it is pulled into a tight position, a first rotational axis of the first coupling mechanism is aligned to a second rotational axis of the second coupling mechanism. The first centering mechanism may comprise first guide faces and the second centering mechanism may comprise second guide faces.
Preferably, the first guide faces are formed by portions of the outer circumferential face of the coupling shield. The second guide faces are formed by guide arms projecting axially from the bracket.
Four guide arms are provided and arranged in pairs opposite to each other. They are distributed around the second rotational axis. The distance at a right angle relative to the second rotational axis, increase between the second guide faces of two opposite guide arms in the direction towards the free ends of the guide arms.
The guide arms and the guide faces form, preferably, a rough centering of the coupling shield relative to the bracket. Thus, when driving the tractor closer or when pulling the coupling shield close, initially the coupling shield is inserted between the guide arms and is centered roughly relative to the second rotational axis.
For fine centering, the first centering mechanism is provided with a first centering face arranged concentrically to the rotational axis. The second centering mechanism includes a second centering face arranged concentrically to the second rotational axis. One of the centering faces is formed as an outer circumferential face. The other centering faces are formed as an inner circumferential face. At least one of the centering faces is formed conically.
In a preferred embodiment, the first centering face may be formed by an outer face of the first coupling mechanism. The second centering face may be formed by a conical inner face of a centering sleeve on the second coupling mechanism.
Thus, in the further coupling process, fine centering generally takes place by pulling close the coupling shield utilizing the locking device.
Rough centering relative to the stationary components, namely the coupling shield and the bracket, takes places initially by driving the tractor close to the implement or by pulling close the coupling shield. When pulling the coupling shield close to the bracket, by the locking elements, fine centering relative to the rotating components takes place. For this, centering faces are provided on the coupling mechanism.
Preferably, the first coupling mechanism is connected to a joint component of a joint of the universal joint shaft. The first coupling mechanism is rotatably supported on the coupling shield.
The universal joint shaft is preferably a cardan joint shaft. The joint yoke of the cardan joint is indirectly supported, via the first coupling mechanism, on the coupling shield.
Preferably, the first coupling mechanism has axially projecting first driving pawls. The second coupling mechanism has axially projecting second driving pawls. The driving pawls engage in a coupled condition of the two coupling mechanism, respectively, in gaps between the driving pawls of the other coupling element.
A simple coupling mechanism is provided insofar, as one of the coupling mechanism is axially displaceable between a position, where it is pushed forward in direction towards the other coupling mechanism. For a retracted position, springs mechanism are provided to act upon the axially displaceable coupling mechanism with a force in the direction towards the pushed forward position.
In this case, the second coupling mechanism is axially displaceably guided relative to the power take-off shaft.
Therefore, in the coupling position of the first coupling mechanism, two positions of the two coupling mechanisms relative to each other are possible. The pawls of the first coupling mechanism engage, directly after the transferral of the first coupling mechanism into the coupling position, into gaps between the driving pawls of the second coupling mechanism. Thus, a direct non-rotatable connection is achieved. When the coupling mechanisms are arranged in a different rotational position relative to each other, the driving pawls rotate about each other at the ends and do not engage with the other. In the latter case, one of the coupling mechanisms is axially displaced. As soon as the power take-off shaft is rotated, the one coupling mechanism is rotated relative to the other coupling mechanism. Thus, the driving pawls of both coupling mechanisms can engage each other.
In this case, it may, preferably, be provided that the second coupling mechanism is axially displaceably guided relative to the power take-off shaft.
Further areas of applicability will become apparent from the description provided herein. The description and specific examples in this summary are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure.
DRAWINGS
A preferred embodiment is described in detail in the following by the drawings.
FIG. 1 is a perspective view of a device according to the disclosure in the unlocking position, where no universal joint shaft is coupled to the power take-off shaft.
FIG. 2 is a perspective view of the device according to FIG. 1 with the coupling shield in a locked position.
FIG. 3 is an enlarged perspective view according to FIG. 2 without the coupling shield.
FIG. 4 is a side partial cross-sectional view of the locker levers including their actuation elements.
FIG. 5 is a longitudinal sectional view through the second coupling element on the power take-off shaft.
FIG. 6 is a longitudinal sectional view through the first and the second coupling element.
FIG. 7 is a perspective view of the coupling shield with the first coupling element.
DETAILED DESCRIPTION
FIGS. 1 and 2 show perspective views of a device according to the disclosure at the rear of a tractor.
In FIG. 1 the power take-off shaft 1 of the tractor is shown, which is rotatable around a second rotational axis D 2 . A fastening frame 4 is provided at the rear of the tractor and is part of the tractor. A bracket 2 is mounted by fastening screws 3 to the frame 4 . The bracket 2 carries two rocker levers 5 , 5 ′ that are pivotable around a first pivot axis S 1 between an unlocked position, shown in FIG. 1 and a locked position, shown in FIG. 2 . The rocker levers 5 , 5 ′ have, respectively, a catching profile 6 , 6 ′, interacting with locking faces on a coupling shield 7 , not shown here and described later. The rocker levers 5 , 5 ′ are part of a locking device on the bracket 2 . The coupling shield 7 has a locking mechanism in the form of laterally projecting studs, which form locking faces. When pivoting the rocker levers 5 , 5 ′ from the unlocking position into the locking position, the catching profiles 6 , 6 ′ engage behind the studs on the coupling shield 7 and pull close to the bracket 2 , to couple, as later described, the universal joint shaft to the power take-off shaft 1 .
The coupling shield 7 has a central bore 16 to rotationally support a joint yoke 15 of a universal joint of a universal joint shaft (here not completely shown). Initially, a rough pre-centering has to take place, to ensure a perfect coupling when moving the coupling shield 7 closer to the bracket 2 . To accomplish this, initial guide plates 19 , 19 ′ are provided. The guide plates 19 , 19 ′ are projectingly arranged to the rear on the side plates 21 , 21 ′ of the bracket 2 . The guide plates 19 , 19 ′ have guide faces 20 , 20 ′ that oppose one another. Starting from the side plates 21 , 21 ′, the length of the guide plates 19 , 19 ′ increases in a direction towards the implement. Thus, initially a rough centering of the coupling shield 7 will take place, such that the laterally projecting studs are guided along the guide faces 20 , 20 ′ of the guide plates 19 , 19 ′ and are centered.
A base plate 14 , which is part of the bracket 2 , is arranged at a right angle to the second rotational axis D 2 of the power take-off shaft 1 . Guide arms 10 , 10 ′, 11 , 11 ′ project from the base plate 14 to the rear in a direction towards the implement. The guide arms 10 , 10 ′, 11 , 11 ′ form, respectively, a second guide face 12 , 12 ′, 13 , 13 ′. The guide arms 10 , 10 ′, 11 , 11 ′ are distributedly arranged around the second rotational axis D 2 and are arranged in pairs opposite to each other. The second guide faces 12 , 12 ′, 13 , 13 ′ are arranged in pairs opposite to each other. The distance, at a right angle to the second rotational axis D 2 between the second guide faces 12 , 12 ′, 13 , 13 ′, increases in direction towards the free ends of the guide arms 10 , 10 ′, 11 , 11 ′.
The coupling shield 7 has first guide faces 8 , 8 ′, 9 , 9 ′ on an outer circumference face. The first guide faces 8 , 8 ′, 9 , 9 ′ are arranged in pairs opposite to each other. When pulling the coupling shield 7 close or when driving the tractor close to the implement, the first guide faces 8 , 8 ′, 9 , 9 ′ abut, respectively, one of the second guide faces 12 , 12 ′, 13 , 13 ′. Thus, a rough centering of the coupling shield 7 takes place.
As it is visible from FIG. 1 , the device further comprises a second coupling mechanism in the form of a second coupling element 17 that has second driving pawls 18 . The second driving pawls 18 project at the end side in a direction of the second rotational axis D 2 and are formed with gaps between them. The second coupling element 17 can be coupled with first coupling mechanism in the form of a first coupling element, which will be described in detail later, and is correspondingly formed to the second coupling element 17 . In the locking position shown in FIG. 2 , the driving pawls of both coupling elements engage each other, so that between these a rotationally fast connection is achieved. The first coupling element is non-rotatably connected with the joint yoke 15 . The second coupling element 17 is non-rotatably held via a bore 22 with longitudinal teeth on the power take-off shaft 1 , that also has longitudinal teeth.
FIG. 3 shows an enlarged view of the device without the coupling shield. The rocker levers 5 , 5 ′ are in the locking position. The two rocker levers 5 , 5 ′ are connected to each other by a bridge 23 so that they are pivoted together. Thus, a single driving unit, e.g. a hydraulic cylinder, is sufficient, to pivot both rocker levers 5 , 5 ′. In the present case a double acting hydraulic cylinder is used, as described in detail later. However, it is generally also possible, that the two rocker levers 5 , 5 ′ are not connected to each other. Then, they may be pivoted together via a common actuation element by a single driving unit or by two separate driving units.
The rocker levers 5 , 5 ′ are pivotable around the first pivot axis S 1 . At their free ends 24 , 24 ′, two retaining faces 25 , 25 ′ are provided. They are directed to the rear in the locking position. On the bracket 2 , two retaining arms 27 , 27 ′ are provided. A first retaining face 26 , 26 ′ is formed on the two retaining arms 27 , 27 ′. The rocker levers 5 , 5 ′ have their second retaining faces 25 , 25 ′ supported against the first retaining face 26 , 26 ′ in the locked position. The rocker levers 5 , 5 ′ are, therefore, prevented from transferring into the unlocked position.
The retaining arms 27 , 27 ′ can be transferred, by mechanism of a Bowden cable 28 from the above described retaining position around a second pivot axis S 2 into a released position. Here, the rocker levers 5 , 5 ′ are released, so that they can be transferred from the locked position shown in FIG. 3 to their unlocked position shown in FIG. 1 . Instead of a Bowden cable, other actuation mechanism are possible, e.g. pneumatical or electro-mechanical components.
The advantage of this mechanical locking of the rocker levers 5 , 5 ′ is that with a hydraulic activation of the rocker levers 5 , 5 ′ in the locking position no hydraulic pressure has to be exerted onto the driving hydraulic cylinder. Rather, the rocker levers 5 , 5 ′ are held by mechanism of the mechanical locking in the locking position. This also leads to the fact, that even when the pressure decreases in the hydraulic system, the universal joint shaft remains securely coupled.
Generally, in the present embodiment with a bridge 23 connecting the two rocker levers 5 , 5 ′ to each other, it would be sufficient to provide one retaining arm 27 , 27 ′.
When moving the rocker levers 5 , 5 ′ from their unlocked position into their locked position, the retaining arms 27 , 27 ′ do not have to be externally actuated, to be transferred from the retaining position into the released position. For this, one actuation face 29 , 29 is provided for each retaining arm 27 , 27 ′. The free ends 24 , 24 ′ of the rocker levers 5 , 5 ′ abut the actuation faces 29 , 29 and move the retaining arms 27 , 27 ′ from their retaining position into the releasing position, until the retaining arms 27 , 27 ′ engage behind the rocker levers 5 , 5 ′. Thus, the first retaining faces 26 , 26 ′ are self-actuated and transferred into their retaining position. For this, spring elements 30 are provided that act upon the retaining arms 27 , 27 ′ to take up their retaining position.
FIG. 4 shows, how the rocker levers 5 , 5 ′ are actuated. A hydraulic cylinder 31 is pivotably mounted on the piston-side on the bracket 2 and is pivotably mounted on the piston-rod-side at the actuation element 32 . The actuation element 32 is again pivotably mounted around a third pivot axis S 3 on the bracket 2 . The hydraulic cylinder 31 is eccentrically attached to the third pivot axis S 3 at the actuation element 32 . The actuation element 32 has a first tooth portion 33 that is coaxially arranged to the third pivot axis S 3 . The first tooth portion 33 engages with a second tooth portion 34 of one of the rocker levers 5 . The second tooth portion 34 is coaxially arranged with the first pivot axis S 1 . Thus, by actuating the hydraulic cylinder 31 , the actuation element 32 is pivoted around the third pivot axis S 3 . Due to the teeth engagement of the two tooth portions 33 , 34 , the rocker lever 5 is pivoted. The rocker lever 5 is, as already described, connected by the bridge 23 to the other rocker lever 5 ′, so that both rocker levers 5 , 5 ′ are moved synchronously. If no bridge 23 is provided, a further actuation element has to be provided, which actuates the other rocker lever 5 , 5 ′. Thus, either the two actuation elements, then provided, are non-rotatably connected to each other or a further hydraulic cylinder is necessary.
FIGS. 5 and 6 show the coupling mechanism in detail. The coupling procedure will be described in detail.
FIG. 5 shows the power take-off shaft 1 with its longitudinal teeth 35 . A circumferential groove 36 is formed in the longitudinal teeth 35 . The groove 36 is coaxially provided on the second rotational axis D 2 . The second coupling component 17 is pushed onto the power take-off shaft 1 by a hub 38 . The hub 38 has a central bore with longitudinal teeth corresponding to the longitudinal teeth 35 of the power take-off shaft 1 .
The hub 38 of the second coupling element 17 has an elongated hole 39 . The hole 39 is axially limited and extends parallel to the second rotational axis D 2 . The elongated hole 39 is radially formed as a trough extending through opening. A locking ball 40 rests in the elongated hole 39 . The ball 40 engages in the groove 36 of the power take-off shaft 1 . A sleeve 41 is coaxially provided around the hub 38 . The sleeve 41 holds the locking ball 40 in the groove 36 . The sleeve 41 is rotatably held on the hub 38 and has a through opening across its circumference. Thus, the sleeve 41 can be rotated such, that the through opening aligns with the elongated hole 39 and the ball can radially leave the groove 36 . Thus, the second coupling element 17 can be removed from the power take-off shaft 1 .
The second coupling element 17 further forms a driving portion 42 , in the form of a flange. The flange has driving pawls 18 axially projecting. The second coupling element 17 is acted upon by a spring 43 in the direction of an extended position. The spring 43 is supported on the one hand on the driving portion 42 of the second coupling element 17 and on the other hand on a retaining plate 44 . The retaining plate 44 has a central bore 45 . The bore cross-section corresponds to the longitudinal teeth 35 of the power take-off shaft 1 . Thus, the retaining plate 44 is rotationally securely held and is supported on the end of the longitudinal teeth and offers an axial abutment for the spring 43 .
In FIG. 5 the second coupling element 17 is shown in an intermediate position. In a completely extended position, not shown here, the second coupling element 17 is supported with a first abutment 46 , which is formed by the elongated hole 39 , on locking ball 40 , held in the groove 36 . In a completely retracted position, as shown in FIG. 6 , the second coupling element 17 is supported with a second abutment 47 , which is formed by the elongated hole 39 , on the locking ball 40 . Thus, pre-defined positions of the second coupling element 17 are achieved.
FIG. 6 shows the second coupling element 17 as well as the coupling shield 7 together with the first coupling element 48 . The first coupling element 48 has first driving pawls 49 pointing towards the second coupling element 17 . The first coupling element 48 is connected by a fastening screw 50 to the yoke 15 of a universal joint shaft, not shown here. The first coupling element 48 and also the joint yoke 15 are indirectly rotatably supported in the coupling shield 7 by a rolling contact bearing 51 .
In the represented position, the first driving pawls 49 abut its first end faces 52 with second end faces 53 of the second driving pawls 18 . In this position, the second coupling element 17 is transferred into a retracted position. The second coupling element 17 is supported with the second abutment 47 on the locking ball 40 . The power take-off shaft 1 is rotated. This rotates the second coupling element 17 relative to the first coupling element 48 . The first driving pawls 18 reach a position where they align with the gaps between the first driving pawls. Thus, the first coupling element 17 is coupled to the second coupling element 48 . The second coupling element 17 is released into an intermediate position and the first driving pawls 49 engage the second driving pawls 18 .
After the above described rough centering, a fine centering is carried out. For this, the first coupling element has a first centering face 56 that is provided on an outer circumferential face of the first coupling element 48 . The second coupling element 17 has a second centering face 55 in form of a conical inner face. Face 55 is formed by a centering sleeve 54 . The centering sleeve 54 rests externally on the driving portion 42 of the second coupling element 17 . When transferring the first coupling element 48 into the position shown in FIG. 6 , the first coupling element 48 , with the first centering face 56 , is inserted into the centering sleeve 54 . It is centered by the second centering face 55 , in the form of a conical inner face.
FIG. 7 shows a perspective view of the coupling shield 7 . The coupling shield has two laterally projecting studs 57 . The studs 57 form, respectively, with their outer circumferential face a locking face 58 . The studs 57 are engaged by the rocker levers 5 , 5 ′ according to FIGS. 1 to 3 and are pulled towards the bracket 2 .
The coupling shield 7 is pivotably mounted on a pivot bearing 59 . The coupling shield can be pivoted around a vertical pivot axis S 4 relative to the pivot bearing 59 . The pivot bearing 59 is again pivotable on a retaining arm 60 , around a horizontal pivot axis S 5 . The retaining arm is mounted on an agricultural implement. The coupling shield 7 is freely adjustable relative to the implement and, thus, can be roughly pre-centered for a successful coupling process.
The foregoing description of the embodiments has been provided for purposes of illustration and description. It is not intended to be exhaustive or to limit the disclosure. Individual elements or features of a particular embodiment are generally not limited to that particular embodiment, but, where applicable, are interchangeable and can be used in a selected embodiment, even if not specifically shown or described. The same may also be varied in many ways. Such variations are not to be regarded as a departure from the disclosure, and all such modifications are intended to be included within the scope of the disclosure. | A device for coupling a universal joint shaft to a power take-off shaft ( 1 ) of a tractor has a first coupling mechanism ( 48 ) that is non-rotatably arranged on the universal joint shaft. A second coupling mechanism ( 17 ) is non-rotatably arranged on the power take-off shaft ( 1 ) of the tractor. The first and second coupling mechanisms can be non-rotatably coupled to transmit torque. A coupling shield ( 7 ) is provided to couple the coupling mechanism ( 17, 48 ). The first coupling mechanism ( 48 ) is at least indirectly rotationally supported on the coupling shield ( 7 ). A locking mechanism ( 58, 58 ′) projects from the coupling shield ( 7 ). A bracket ( 2 ) is attachable on the rear of the tractor. The bracket ( 2 ) has at least one locking device ( 5, 5 ′) that is displaceable between an unlocked position and a locked position. The locking device ( 5, 5 ′) is displaced from the unlocked position into the locked position. The locking device ( 5, 5 ′) interacts with the locking members ( 58, 58 ′) of the coupling shield ( 7 ) to pull it towards the bracket ( 2 ). The first coupling mechanism ( 48 ) is transferred into a coupling position to couple it the second coupling mechanism ( 17 ). | 0 |
This application is a CIP of U.S. Ser. No. 07/806,928, filed Dec. 12, 1991, which is in turn a divisional application of Ser. No. 07/574,786, filed Aug. 30, 1990, now U.S. Pat. No. 5,112,960, a CIP of Ser. No. 07/559,152, filed Jul. 25, 1990, abandoned, itself a divisional application of Ser. No. 07/367,772, filed Jul. 17, 1989 abandoned and Ser. No. 07/140,197 filed Dec. 31, 1987, abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention pertains to chemiluminescent 1,2-dioxetane derivatives which can be enzymatically activated to decompose and, through decomposition, release light. The dioxetanes are particularly characterized by the presence of an aromatic (phenyl or naphthyl) ring bonded to the dioxetane, which ring bears a meta-substituted or disjoint enzymatically cleavable group, which when cleaved, leaves the phenoxyanion or naphthyloxyanion of the dioxetane, and, at the four or preferably the five position, an electron donating or electron withdrawing group. By selecting the identity of the substituent at the four or five position (the Z moiety) particular aspects of the chemiluminescent properties of the dioxetane, including half life, quantum yield, S/N ratio, etc., can be altered.
2. Background of the Invention
1,2-dioxetane enzyme substrates have been well established as highly efficient chemiluminescent reporter molecules for use in enzyme immunoassays of a wide variety of types. These assays provide a preferred alternative to conventional assays that rely on radioisotopes, fluorophores, complicated color shifting, secondary reactions and the like. Dioxetanes developed for this purpose include those disclosed in U.S. Pat. No. 4,978,614 as well as U.S. Pat. No. 5,112,960. U.S. Pat. No. 4,978,614 discloses, among others, 3-(2'-spiroadamantane)4-methoxy-4-(3"-phosphoryloxy)phenyl-1,2-dioxetane, which has received world-wide attention, and is commercially available under the trade name AMPPD. U.S. Pat. No. 5,112,960, discloses similar compounds, wherein the adamantyl stabilizing ring is substituted, at either bridgehead position, with a variety of substituents, including hydroxy, halogen, and the like, which convert the otherwise static or passive adamantyl stabilizing group into an active group involved in the kinetics of decomposition of the dioxetane ring. Compounds of this type have similarly received international attention, giving a faster and stronger signal than AMPPD in many applications. CSPD corresponds to AMPPD with a chlorine substituent on the adamantyl group, and, like AMPPD, is available from Tropix, Inc. of Bedford, Mass.
Compounds of this type have been particularly developed for enhanced sensitivity in assays for the presence of analytes in concentrations as low as 10 -12 M and lower. In certain applications, compounds of this type are used in conjunction with enhancers to detect analytes in concentration of 10 -12 M or lower. These enhancement agents, which include natural and synthetic water-soluble macromolecules, are disclosed in detail in U.S. Pat. No. 5,145,772. Preferred enhancement agents include water-soluble polymeric quaternary ammonium salts, such as poly(vinylbenzyltrimethylammonium chloride) (TMQ), poly(vinylbenzyltributylammonium chloride) (TBQ) and poly(vinylbenzyldimethylbenzylammonium chloride) (BDMQ).
These enhancement agents improve the chemiluminescent signal of the dioxetane reporter molecules, apparently by providing a hydrophobic environment in which the dioxetane is sequestered. Water, an unavoidable aspect of most assays, due to the use of body fluids, is a natural "quencher" of the dioxetane chemiluminescence. The enhancement molecules apparently exclude water from the microenvironment in which the dioxetane molecules, or at least the excited state emitter species reside, resulting in enhanced chemiluminescence. Other effects associated with the enhancer-dioxetane interaction could also contribute to the chemiluminescence enhancement.
Additional advantages can be secured by the use of selected membranes, including nylon membranes and treated nitrocellulose, providing a similarly hydrophobic surface for membrane-based assays, and other membranes coated with the enhancer-type polymers described.
Nonetheless, it remains a general goal of the industry to improve the performance of these stabilized, chemiluminescent dioxetane reporter molecules, to improve the machine readability, sensitivity, and performance aspects of the immunoassays, dependent on the chemiluminescent signal released by the dioxetanes.
By way of background, and as disclosed in all the patents referenced above, the enzymatically-activated dioxetanes are used as reporter molecules, as substrates for enzymes which cleave the enzyme-labile group bonded to an aromatic substituent on the dioxetane ring. Thus, the enzyme, e.g., alkaline phosphatase is covalently linked or otherwise complexed with either an antigen or antibody, in conventional antigen/antibody ligand binding assays, or a nucleic acid probe in nucleic acid assays. The enzyme-bearing antigen or antibody, or nucleic acid probe, is then admixed with the analyte suspected of containing the target antigen, or nucleic acid sequence, under conditions which permit complexing or hybridization between the antigen/antibody or probe/nucleic acid sequence. After washing away or separating off all noncomplexed or nonhybridized material, the dioxetane substrate is added. If the suspected analyte is present, the enzyme will cleave the enzyme-labile group on the aromatic substituent on the dioxetane, e.g., phenyl or naphthyl, yielding the phenoxy or naphthyloxy anion intermediate. This anion decomposes, by electron transfer through the aromatic ring, cleaving the dioxetane ring, and yielding two carbonyl-based products. The cleavage/decomposition event is the light-releasing event.
To automate clinical assays, and to provide for substantial throughput, continued reductions in the halflife, or T.sub. 1/2 of the dioxetane, as well as a reduction in the amount of time required to reach the maximum emission of light of the reporter molecule, is desirable. At the same time, to detect analytes in extremely low concentrations, below, e.g., about 10 -12 M, it is desirable to improve the intensity of the signal of the dioxetane reporter molecule, and simultaneously desirable to avoid increasing the background noise due to nonenzymatically-induced light release, so as to improve the overall sensitivity of the assay. Thus, further improvements in chemiluminescent dioxetane reporter molecules are sought.
SUMMARY OF THE INVENTION
The above goals, and others, are met by a new class of dioxetanes, particularly characterized by a substituent on the aromatic ring bonded to the dioxetane, in addition to the meta-substituted enzyme-labile group. Thus, the novel dioxetanes of this invention have the generalized structure I, II or III below. ##STR1## wherein R is C1-12 alkyl, aralkyl, or aryl, preferably C1-6 alkyl, X is an enzyme labile group cleavable by a specific enzyme which recognizes that group to leave the phenoxy or naphthoxy anion, and is preferably a phosphate or galactoside, Y 1 and Y 2 are independently hydrogen, or an electron donating or withdrawing group, and are preferably hydrogen, methoxy, carboxy or halogen, and most preferably one of Y 1 and Y 2 is hydrogen while the other is chlorine, and Z is an electron-active group, most preferably chlorine, alkoxy, alkyl or amido. When Z is on a phenyl ring, Z is in the four or five position, preferably the five position. When OX and Z are substituted on a naphthyl group, OX is substituted such that the substitution is disjoint, that is the total number of ring atoms between the point of attachment to the dioxetane ring and the point of substitution, including the point of attachment and substitution, is an odd number, as disclosed in U.S. Pat. No. 4,952,707. Substituent Z may be substituted on the naphthyl ring at any position other than those adjacent the one position, or the point of attachment to the dioxetane ring.
By selecting the particular identity of Z, as an electron-withdrawing or an electron-donating group, specific characteristics of the chemiluminescent behavior of the dioxetane, including its T 1/2 , time to maximum emission, maximum emission wavelength, and chemiluminescent signal intensity can be affected.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1 and 2 are electrophotographic duplications of X-ray film images of DNA sequencing obtained by use of the dioxetanes of the claimed invention. These are compared against the current commercial standard, CSPD.
FIGS. 3-12 are electrophotographic duplications of dot blot assay results on membranes as indicated, employing dioxetanes of the claimed invention, dioxetanes outside the scope of the claimed invention and the commercial standards CSPD and AMPPD. The membrane on which these assays were conducted is set forth in the figures.
DETAILED DESCRIPTION OF THE INVENTION
The dioxetanes of this invention are critically characterized by the substituents on the aromatic ring attached to the dioxetanes, which ring determines the electron transfer in the aryloxy anion, leading to decomposition and chemiluminescence. Thus, dioxetanes of the invention have the following and generalized structure (I). ##STR2##
Thus, the adamantyl-stabilized dioxetanes of the claimed invention bear two substituents on the phenyl ring, as well as 0, 1 or 2 non-hydrogen substituents on the adamantyl ring. These substituents critically characterize the electronic characteristics of the dioxetane, the oxyanion, and its decomposition behavior. The identities of each substituent are set forth below.
R may be alkyl, aralkyl, cycloalkyl, or aryl, having 1-12 carbon atoms. R is preferably C1-C3 alkyl, most preferably, methyl. The identity of R may be optimized with regard to solubility concerns, where unusual analytes, or buffers, may pose particular problems. Each of Y 1 and Y 2 represent, individually, hydrogen, a hydroxyl group, a halo substituent, a hydroxy lower alkyl group, a halo lower alkyl group, a phenyl group, a halophenyl group, an alkoxy phenyl group, an alkoxy phenoxy group, a hydroxyalkoxy group, a cyano group, an amide group, a carboxyl group or substituted carboxyl group, an alkoxy group and other similar electron-active species. Preferred identities for Y 1 and Y 2 are chlorine, hydroxy, and methoxy.
X is an enzyme-cleavable moiety. Thus, upon proper contact with a suitable enzyme, X is cleaved from the molecule, leaving the oxygen attached to the phenyl ring, and thus, the phenoxy anion. X is ideally phosphate, galactoside, acetate, 1-phospho-2,3-diacylglyceride, 1-thio-D-glucoside, adenosine triphosphate, adenosine diphosphate, adenosine monophosphate, adenosine, α-D-glucoside, β-D-glucoside, β-D-glucuronide, α-D-mannoside, β-D-mannoside, β-D-fructofuranoside, β-glucosiduronate, P-toluenesulfonyl-L-arginine ester, and P-toluenesulfonyl-L-arginine amide. X is preferably phosphate or galactoside, most preferably phosphate. It is important to note that when substituted on the phenyl ring, OX is meta with respect to the point of attachment to the dioxetane ring, that is, it occupies the three position.
Z may occupy either the four or five position, most preferably the five position. Z is an electron-active substituent, the character of the electron-active species (electron-donating or electron-withdrawing), optimizing various aspects of the dioxetane moiety. As an example, an electron-donating group, such as a methoxy group, may enhance the dioxetane phenoxy anion decomposition process, by facilitating the transferability of the free electrons from the aromatic ring O - donor group, to the dioxetane ring. In contrast, an electron-withdrawing group would reduce or impair the ability to transfer the free electrons to the dioxetane, thus slowing the decomposition reaction and light emission, although ultimately giving a light signal of greater intensity. This should be contrasted with the impact of the electron-withdrawing substituent on the adamantyl group, such as chlorine, which substantially accelerates light emission, sharply reducing T 1/2 . Of surprising significance is the fact that substitution in the six position is particularly undesirable. Such six-substituted phenyl dioxetanes exhibit extraordinarily fast decomposition kinetics, and nearly no light emission. While Applicants do not wish to be restricted to this theory, it is believed that this behavior is due to steric considerations, that is, the ortho substituent "turns" the phenyl ring such that it destabilizes the dioxetane ring (destabilization through steric forces, not electron transfer) and a substituent at the six position, e.g., methoxy, does not participate in electron transfer. As discussed below, experiments involving 6-substituted phenyl dioxetanes give essentially no signal.
The phenyl substituent on the dioxetane ring may instead be naphthyl (structures II and III) as ##STR3## In the naphthyl dioxetane, identities for R, Y 1 and Y 2 , X and Z remain the same. Instead of being restricted to the "meta" position, OX may occupy corresponding positions in the naphthyl ring, that is, non-conjugated positions, or positions such that the number of carbon atoms between the point of substitution and the point of attachment to the dioxetane ring, including the carbons at both point of attachment and point of substitution, are odd, as set forth in U.S. Pat. No. 4,952,707. Phenyl meta-substituted dioxetanes, and naphthyl dioxetanes substituted according to the pattern described above, may generally be expected to give higher quantum yields than the corresponding para and conjugated systems.
As noted above, Z can be any electron-active substituent that does not interfere with the chemiluminescent behavior of the dioxetane, and thus can be selected from a wide variety of identities. Preferred electron-active substituents include chloro, alkoxy (--OR), aryloxy (--OAr), trialkylammonium (--NR 3 +), alkylamido (--NHCOR, --NRCOR'), arylamido (--NHCOAr, --NRCOAr, --NArCOAr), arylcarbamoyl (--NHCOOAr, --NRCOOAr), alkylcarbamoyl (--NHCOOR, --NRCOOR'), cyano (--CN), nitro (--NO 2 ), ester (--COOR, --COOAr), alkyl- or arylsulfonamido (--NHSO 2 R, --NHSO 2 Ar), trifluoromethyl (--CF 3 ), aryl (--Ar), alkyl (--R), trialkyl-, triaryl-, or alkylarylsilyl (--SiR 3 , SiAr 3 , --SiArR 2 ), alkyl- or arylamidosulfonyl (--SO 2 NHCOR, --SO 2 NHCOAr), alkyl or aryl sulfonyl (--SO 2 R, SO 2 Ar) alkyl- or arylthioethers (--SR, SAr). The size of the Z substituent is generally limited only by solubility concerns. Where reference is made to alkyl or R, R' etc. the alkyl moiety should have 1-12 carbon atoms. Suitable aryl moieties include phenyl and naphthyl as exemplary moieties. Particularly preferred species include chloro and alkoxy.
Dioxetanes of the type described above, without the inclusion of the Z substituent, as previously noted, are disclosed in patents commonly assigned herewith. Patents addressing dioxetanes of this type without the inclusion of the Y and Z substituents have also been assigned to Wayne State University, such as U.S. Pat. No. 4,962,192. Substitution of the Z substituent on the dioxetanes required development of the synthesis of trisubstituted phenyl phosphonates which is described below, under the title Novel Tri-substituted Phenyl 1,2-Dioxetane Phosphates. The same general synthesis route can be employed for naphthyl dioxetanes embraced herein, bearing in mind the substitution patterns required, as discussed above. The synthesis of these compounds through the route described below involves the preparation of novel tri-substituted benzenes. Thus, as described below, an exemplary compound involved in the synthesis of the dioxetanes of this class includes 3-chloro-5-methoxybenzaldehyde. These tri-substituted compounds constitute key intermediates in a variety of synthetic pathways, the 1,3,5 substitution pattern being a generally preferred and widely applicable pattern. It is Applicants' belief that these intermediates have never previously been prepared, and are marked, in the synthesis route described below, with an asterisk.
NOVEL TRI-SUBSTITUTED PHENYL 1,2-DIOXETANE PHOSPHATES
Synthesis
General
Commercial reagents were used as obtained without further purification. Baker silica gels (60-200 mesh for gram scale, and 230-400 mesh for milligram scale) were used for flash chromatography. 31 P NMR spectra were reported in parts per million relative to a phosphoric acid standard. High resolution mass spectral analyses were run by J. L. Kachinski at Johns Hopkins University. Syntheses of dioxetanes 3 and 4 were carded out following the procedure described below for dioxetanes 1 and 2 respectively. Yields, melting points (uncorrected) and spectral data are summarized for isolated intermediates. ##STR4##
3-Chloro-5-methoxy-4-trifluoromethanesulfonyloxy benzaldehyde (5).
A solution of 5-Cl-vanillin 1 (13.0 g, 70 mmol), chloroform (4 ml) and pyridine (16 ml) was stirred at 0° C. Addition of trifluoromethanesulfonic anhydride (12.4 ml, 75 mmol) at 0° C. over 30 min gave clean formation of the trillate. The reaction mixture was partitioned between EtOAc and 3N HCl, washed with dilute brine, dried over Na 2 SO 4 , and evaporated under reduced pressure. Purification of the resulting yellow oil by silica gel chromatography (30% EtOAc/hexanes) yielded 18.5 g (83%) triflate 5 as yellow crystals.
IR (CHCl 3 , cm -1 ): 1705, 1590, 1461, 1425, 1225, 1205, 1132, 1049, 875, 624
1 H NMR (ppm): 3.99 (3H, s), 7.44 (1H, d, J=1.6 Hz), 7.57 (1H, d, J=1.7 Hz), 9.92 (1 H, s) ##STR5##
3-Chloro-5-methoxybenzaldehyde (6)
Triflate 5 (9 g, 28 mmol), palladium(II) acetate (120 mg, 0.5 mmol), 1,1'-bis(diphenyiphosphino)ferrocene (620 mg, 1 mmol) and hplc grade CH 3 CN (10 ml) were mixed well in a teflon-lined stainless steel bomb. After adding freshly made, pulverized proton sponge formate 2 (7.84 g, 30 mmol), the bomb was sealed and heated at 90° C. for 4 h. The cooled reaction was then filtered to remove proton sponge crystals, partitioned between EtOAc and 3N HCl, washed once each with dilute brine and dilute NaHCO 3 , dried over Na 2 SO 4 , and evaporated. Silica gel chromatography (15% EtOAc/hexanes) yielded 4.25 g (88.5%) of chloromethoxybenzaldehyde 6, mp 45° C.
IR (CHCl 3 , cm -1 ): 2835, 1700 (C═O), 1590, 1576, 1461, 1425, 1380, 1320, 1280, 1265, 1144, 1050, 850, 695
1 H NMR (ppm): 3.84 (3H, s), 7.13 (1H, m), 7.26 (1H, m), 7.41 (1H, m), 9.89 (1H, s)
Mass spectrum (El, 70 eV): exact mass calcd for C 8 H 7 ClO 2 170.0135, found 170.0134. ##STR6##
3-Chloro-5-methoxybenzaldehyde dimethyl acetal (7)
A methanol solution (20 ml) of benzaidehyde 6 (8.76 g, 51 mmol) was cleanly converted to dimethyl acetal 7 in the presence of trimethyl orthoformate (5.62 ml, 51 mmol) and a catalytic amount of p-toluenesulfonic acid. The reaction was quenched with triethylamine to pH 7, evaporated to a small volume and partitioned between EtOAc and NaHCO 3 . The organic layer was dded, evaporated under reduced pressure and purified by silica gel chromatography (10% EtOAc/hexanes) to give 10.68 g (96%) of acetal 7 as a light yellow oil. IR (CHCl 3 , cm -1 ): 2960, 2938, 2830, 1596, 1578, 1458, 1270, 1104, 1050, 989, 872, 865, 840
1 H NMR (ppm): 3.31 (6H, s), 3.79 (3H, s), 5.31 (1H, s), 6.85 (1H, s), 6.88 (1H, s), 7.04 (1H, s). ##STR7##
Diethyl 1-methoxy, 1-(3-chloro-5-methoxyphenyl)methane phosphonate 8
Triethyl phosphite (3.2 ml, 19 mmol) was added dropwise to a solution of acetal 7 (4.0 g, 18.5 mmol), boron trifluoride etherate (2.3 ml, 19 mmol) and CH 2 Cl 2 (20 ml) at 0° C. After slowly warming the reaction to room temperature (30 min), the solution was partitioned with dilute NaHCO 3 , dried over Na 2 SO 4 , evaporated and purified on silica gel (40%-100% EtOAc/hexanes) to give 4.6 g (77.5%) of phosphonate 8 as a light yellow oil.
IR (CHCl 3 , cm -1 ): 2990, 1591, 1573, 1458, 1254 (P═O), 1050 (P--O), 1025 (P--O), 969, 870, 687
1 H NMR (ppm): 1.24 (3H, t, J=7 Hz), 1.26 (3H, t, J=7 Hz), 3.37 (3H, s), 3.78 (3H, s), 4.01-4.09 (4H, m), 4.40 (1H, d, J=16 Hz), 6.83 (1H, t, J=2 Hz), 6.88 (1H, qt, J=2 Hz), 6.98 (1H, qt, J=2 Hz) ##STR8##
3-Chloro-5-methoxy-1-(methoxytdcyclo[3.3.1, 3 .7 ]dec-2-ylidenemethyl)benzene (9)
Phosphonate 8 (4.62 g, 14 mmol) and 2-adamantanone (2.58 g, 17 mmol) were dissolved in anhydrous THF (35 ml) under argon and cooled to -68° C. Dropwise addition of lithium diisopropylamide (18.6 mmol) in anhydrous THF (20 ml) at -68° C. generated the ylid, followed by subsequent olefination of the ketone. The reamion was slowly warmed to room temperature over 2 h and then stirred at 75° C. for 1 h. The solution was partitioned between EtOAc/NH 4 Cl, dried over Na 2 SO 4 , evaporated and purified by silica gel chromatography (2% EtOAc/hexanes), yielding 2.5 g (55%) of enol ether 9 as an oil.
1 H NMR (ppm): 1.55-1.95 (12H, m), 2.61 (1H, br s), 3.21 (1H, br s), 3.28 (3H, s), 3.78 (3H, s), 6.74 (1H, s), 6.80 (1H, s), 6.87 (1H, s) ##STR9##
3-Chloro-5-hydroxy-1-(methoxytricyclo[3.3.1.1 3 .7 ]dec-2-ylidene-methyl)benzene (10)
Demethylation to enol ether phenol 10 proceeded cleanly upon heating enol ether 9 (2.5 g, 7.8 mmol) in DMF (14 ml) at 155° C. in the presence of sodium ethane thiolate (11.7 mmol). Upon cooling, the mixture was partitioned between EtOAc and NH 4 Cl, dried over Na 2 SO 4 and evaporated under high vacuum to remove residual DMF. Chromatographic purification (silica gel, 20% EtOAc/hexanes) produced 2.3 g (96%) of phenol 10 as an oil which crystallized upon standing. Trituration of the solid with 5% EtOAc/hexanes gave white crystals, mp 133° C.
IR (CHCl 3 , cm -1 ): 3584 (OH), 3300 (OH), 2910, 1590, 1310, 1285, 1163, 1096, 1080, 1011,900, 840
1 H NMR (ppm): 1.73-1.96 (12H, m), 2.62 (1H, brs), 3.20 (1H, br s), 3.32 (3H, s), 5.65 (1H, br s), 6.73 (1H, s), 6.79 (1H, m), 6.85 (1H, s) ##STR10##
Pyridinium 3-chloro-5-(methoxytricyclo[3.3.1.1 3 .7 ]dec-2-ylidenemethyl)-1-phenyl phosohate (11)
Triethylamine (450 μl, 3.2 mmol) was added under an argon atmosphere to enol ether 10 (709 mg, 2.3 mmol) dissolved in anhydrous THF (10 ml). The solution was cooled to 0° C., at which time 2-chloro-2-oxo-1,3,2-dioxaphospholane (Fluka, 285 μl, 3.0 mmol) was added dropwise. The reaction was warmed to room temperature, quickly passed through an argon-flushed column under inert atmosphere to remove triethylammonium hydrochloride crystals. After rinsing the crystal cake once with THF, the solution was evaporated and pumped dry to give crude phospholane 11a.
Opening the phospholane dng upon reaction of 11a with NaCN (vacuum dried, 179 mg, 3.65 mmol) in anhydrous DMF (6 ml) under argon, produced the desired β-cyanoethyl diester phosphate 11b, as well as regenerating enol ether phenol 10. Removal of DMF under high vacuum while warming the flask to 55° C., left a mixture of compounds 10 and 11b as a yellow-orange oil.
The above mixture was dissolved in methanol (8 ml) and stirred at 40° C. in the presence of NaOMe (1 ml of 4.25M NaOMe/MeOH, 6.4 mmol), effecting β-elimination of the cyanoethyl group to give enol ether phosphate 11 as the disodium salt. After evaporating the methanol, the solid was dissolved in water and partitioned with minimal EtOAc to recover phenol 10 (333 mg). Purification of the aqueous phase by preparative HPLC, using a CH 3 CN/H 2 O gradient through a polystyrene column (PLRP-S, Polymer Laboratories), followed by ion exchange with pyridinium toluenesulfonate (Amberlyst-IR 120+ resin) and lyophilization, yielded 448 mg (78% over 3 steps, accounting for recovered phenol) of enol ether phosphate 11 as a fluffy, off-white powder.
IR (CHCl 3 , cm -1 ): 2910, 1590, 1567, 1278, 1160, 1095, 945
1 H NMR (ppm): 1.73-1.96 (12H, m), 2.63 (1H, br s), 3.20 (1H, br s), 3.32 (3H, s), 5.89 (1H, s), 6.72 (1H, m), 6.79 (1H, t, J=2 Hz), 6.85 (1H, d, J=2 Hz)
31 P NMR (ppm): 54 (1P). ##STR11##
Disodium 3-chloro-5-(methoxyspiro[1,2-dioxetane-3,2'-tricyclo[3,3,1,1 3 .7 ]-decan]-4-yl)-1-phenyl phosphate (1)
A solution of enol ether phosphate 11 and 5,10,15,20-tetraphenyl-21H, 23H-porphine (TPP, 0.5 ml of a 2% solution in CHCl 3 by weight) in CHCl 3 (8 ml) was irradiated with a 250 W, high pressure sodium lamp at 10° C. while passing a stream of oxygen through the solution. A 5-mil piece of Kapton polyimide film (DuPont) placed between the lamp and the reaction mixture filtered out unwanted UV radiation. Analytical HPLC (UV detector at 270 nm) showed complete dioxetane formation upon irradiating 5 min. After evaporation of the chloroform at 0° C., the residue was dissolved in ice water in the presence of Na 2 CO 3 (27 mg, 0.25 mmol) and purified by preparative HPLC as described above. The fractions were frozen and lyophilized at 0° C., yielding 65.3 mg (90%) of dioxetane 1 as a fluffy white powder. TLC of the dioxetane exhibited blue chemiluminescence by thermal decomposition upon heating. Enzymatic cleavage of the phosphate also induced chemiluminescent decomposition in aqueous solutions.
1 H NMR (D 2 O, ppm): 0.93 (1H, d, J=13 Hz), 1.21 (1H, d, J=13 Hz), 1.44-1.69 (10H, m), 2.16 (1H, br s), 2.78 (1H, br s), 3.14 (3H, s), 7.20 (2H, br s), 7.30 (1H, s)
31 P NMR (D 2 O, ppm): 24 (1P). ##STR12##
3-Chloro-5-hydroxy benzaldehyde dimethyl acetal (12)
5-Chloro-3-methoxy benzaldehyde dimethyl acetal (7, 3.21 g, 14.8 mmol) was demethylated with sodium ethane thiolate (19 mmol)in DMF (14 ml) while heating at 150° C. The resultant phenol 12 was cooled, partitioned between EtOAc and NH 4 Cl, dried over Na 2 SO 4 , evaporated and pumped to dryness on high vacuum to remove residual DMF. Chromatographic purification (silica gel, 20% EtOAc/hexanes) afforded 2.75 g (92%) of phenol 12 as a yellow oil. An analytical sample of the oil crystallized upon further purification, mp 153° C.
IR (CHCl 3 , cm -1 ): 3580 (OH), 3325 (OH), 2940, 2830, 1599, 1585, 1449, 1350, 1155, 1105, 1055,894, 845
1 H NMR (ppm): 3.32 (6H, s), 5.30 (1H, s), 5.73 (1H, br s), 6.81 (2H, m), 7.01 (1H, s). ##STR13##
3-Chloro-5-plyaloyloxybenzaldehyde dimethyl acetal (13)
Phenol 12 (2.7 g, 13.3 mmol)) and triethylamine (2.8 ml, 20 mmol)in CH 2 Cl 2 (20 ml) were stirred at 0° C. Addition of trimethylacetyl chloride (1.64 ml, 13.3 mmol) cleanly yielded the pivaloyl ester. Standard workup provided crude pivaloate 13 as an oil which was carried on to the next reaction without purification; no weight was taken. A small sample was purified by prep TLC for spectral characterization.
IR (CHCl 3 , cm -1 ): 2980,2940, 1749 (C═O), 1585, 1448, 1349, 1250, 1150, 1109, 1056, 898
1 H NMR (ppm): 1.34 (9H, s), 3.31 (6H, s), 5.36 (1H, s), 7.06 (2H, br s), 7.31 (1H, s) ##STR14##
Diethyl 1-methoxy-1-(3-chloro-5-pivaloyloxyphenyl)methane phosphonate (14)
A solution of acetal 13, boron tnfluoride etherate (2.6 ml, 21 mmol) and CH 2 Cl 2 (10 ml) was stirred at -78° C. Addition of triethyl phosphite (3.0 ml, 17.5 mmol) converted the acetal to phosphonate 14. Workup and purification (silica gel, 10% EtOAc/hexanes) yielded 2.43 g oil (47% over 2 steps).
IR (CHCl 3 , cm -1 ): 2995, 2980, 1750 (C═O), 1600, 1581, 1442, 1247 (P═O), 1110, 1028 (P--O), 975, 890
1 H NMR (ppm): 1.22-1.26 (6H, d of t, J=2 Hz, 7 Hz), 1.31 (9H, s), 3.39 (3H, s), 4.02-4.08 (4H, m), 4.44 (1H, d, J=16 Hz), 7.04 (2H, m), 7.27 (1H, br s) ##STR15##
3-Chloro-5-pivaloyloxy-1-(methoxy-5-chloro-tricyclo[3.3.1.1 3 .7 ]-dec-2-ylidenemethyl)benzene (15)
Phosphonate 14 (2.4 g, 6.1 mmol) was dissolved in anhydrous THF (10 ml) under argon and cooled to -68° C. Dropwise addition of lithium diisopropylamide (6.6 mmol) in anhydrous THF (7 ml) at low temperature generated the ylid, evident by deep coloration. After 5 min, a THF solution of 5-chloro-2-adamantanone (941 mg, 5 mmol) was added and the reaction was slowly warmed to room temperature over 40 min, followed by heating at 75° for 1 h to complete olefination. The solution was partitioned between EtOAc/NH 4 Cl, dried over Na 2 SO 4 and evaporated to give a crude mixture of enol ether pivaloate 15 and the corresponding enol ether phenol 16. The crude oil was used without purification in the following hydrolysis. A small sample was purified by prep TLC for spectral characterization.
IR (CHCl 3 , cm -1 ): 2935, 1750 (C═O), 1595, 1571, 1450, 1420, 1397, 1275, 1160, 1110, 1024, 918, 906, 887, 829
1 H NMR (ppm): 1.34 (9H, s), 1.68-1.78 (4H, m), 2.14-2.25 (7H, m), 2.77 (1H, br s), 3.30 (3H, s), 3.42 (1H, br s), 6.88 (1H, d, J=1.5 Hz), 7.04 (1H, m), 7.11 (1H, d, J=1.5 Hz) ##STR16##
3-Chloro-5-hydroxy-1-(methoxy-5-chloro-tricyclo[3.3.1.1 3 .7 ]-dec-2-ylidenemethyl)benzene (16)
Crude pivaloate 15 was hydrolyzed at room temperature with K 2 CO 3 (1.45 g, 10.5 mmol) in 10 ml methanol. Evaporation of methanol, followed by standard workup and purification (silica gel, 30% EtOAc/hexanes) afforded 1.095 g (63% over 2 steps) of a slightly yellow oil which solidified upon standing. Trituration of the solid produced white crystalline enol ether phenol 16, mp 130° C.
IR (CHCl 3 , cm -1 ): 3590 (OH), 3300 (OH), 2935, 1595, 1163, 1100, 1082, 1030, 911
1 H NMR (ppm): 1.69-1.83 (4H, m), 2.14-2.27 (7H, m), 2.77 (1H, br s), 3.30 (3H, s), 3.41 (1H, br s), 5.21 (1H, br s), 6.67 (1H, d, J-1.5 Hz), 6.81 (1 H, m), 6.84 (1H, d) ##STR17##
Disodium 3-chloro-5-(methoxyspiro[1,2-dioxetane-3,2'-(5-chloro-)tricyclo-[3.3.1.1.sup.3.7 ]- -decan]-4-yl)-1-phenyl phosphate (2)
Triethylamine (230 μl, 1.65 mmol) was added under an argon atmosphere to enol ether 16 (356 mg, 1.05 mmol) dissolved in anhydrous THF (5 ml). The solution was cooled to 0° C., at which time 2-chloro-2-oxo-1,3,2-dioxaphospholane (Fluka, 143 pl, 1.55 mmol) was added dropwise. The reaction was warmed to room temperature and quickly passed through an argon-flushed column under inert atmosphere to remove triethylammonium hydrochloride crystals. After rinsing the crystal cake once with THF,the solution was evaporated and pumped dry to give crude phospholane 17a.
Opening the phospholane ring upon reaction with NaCN (vacuum dded, 69 mg, 1.4 mmol) in anhydrous DMF (5 ml) under argon, produced the desired β-cyanoethyl diester phosphate 17b. Removal of DMF under high vacuum while warming the flask to 55° C. left the crude diester phosphate as an orange oil.
A solution of cyanoethyl phosphate 17b and 5,10,15,20-tetraphenyl-21H, 23H-porphine (TPP, 1.5 ml of a 2% solution in CHCl 3 by weight) in CHCl 3 (10 ml) was irradiated with a 250 W, high pressure sodium lamp at 10° C. while passing a stream of oxygen through the solution. A 5-mil piece of Kapton polyimide film (DuPont) placed between the lamp and the reaction mixture filtered out unwanted UV radiation. Analytical HPLC (UV detector at 270 nm) showed complete dioxetane formation upon irradiating 15 min. After evaporation of the chloroform at 0° C., the residue was dissolved in methanol and deprotected to the disodium phosphate dioxetane with NaOMe (0.5 ml of 4.25 M NaOMe/MeOH, 2 mmol). Upon β-elimination of the cyanoethyl group, the solvent was evaporated at 0° and the residue dissolved in ice water. Purification by preparative HPLC, as described above, followed by lyophilization at 0° C., yielded 289 mg (60% over 4 steps) of dioxetane 2 as a fluffy white powder.
1 H NMR (D 2 O, ppm, mixture of syn/anti isomers): 0.86 (1H, d), 1.13 (1H, d, J=14 Hz), 1.30 (1H, d), 1.37 (1H, d), 1.45-2.07 (18H, m), 2.27 (1H, br s), 2.32 (1H, br s), 2.95 (2H, br s), 3.09 (3H, s), 3.11 (3H, s), 7.0-7.3 (4H, br s), 7.25 (1H, s), 7.28 (1H, s) ##STR18##
3.5-Dimethoxybenzaldehyde dimethyl acetal (18)
IR (CHCl 3 , cm -1 ): 2958, 2935, 1598, 1460, 1426, 1357, 1190, 1154, 1101, 1053, 840
1 H NMR (ppm): 3.32 (6H, s), 3.78 (6H, s), 5.28 (1H, s), 6.41 (1H, m), 6.60 (2H, m). ##STR19##
3-Hydroxy-5-methoxybenzaldehvde dimethyl acetal (19)
IR (CHCl 3 cm -1 ): 3590 (OH), 3345 (OH), 2940, 2830, 1600, 1462, 1432, 1355, 1190, 1150, 1110, 1055, 841
1 H NMR (ppm): 3.32 (6H, s), 3.77 (3H, s), 5.28 (1H, s), 6.37 (1H, d, J=2 Hz), 6.53 (1H, br s), 6.58 (1H, brs). ##STR20##
3-Methoxy-5-pivaloyloxybenzaldehyde dimethyl acetal (20).
(73% over 3 steps, oil)
IR (CHCl 3 , cm -1 ): 2960, 2935, 1741 (C═O), 1608, 1597, 1462, 1350, 1273, 1190, 1139, 1115, 1056, 999, 902, 848
1 H NMR (ppm): 1.34 (9H, s), 3.31 (6H, s), 3.80 (3H, s), 5.35 (1H, s), 6.57 (1H, d, J=2 Hz), 6.75 (1H, br s), 6.87 (1H, br s) ##STR21##
Diethyl 1-methoxy-1-(3-methoxy-5-pivaloyloxyphenyl)methane phosphonate (21), (40%, oil)
IR (CHCl 3 , cm -1 ): 2990, 2980, 1742 (C═O), 1606, 1590, 1463, 1272, 1240, 1136, 1110, 1100, 1055, 1023, 970
1 H NMR (ppm): 1.21 (3H, t, J=3 Hz), 1.23 (3H, t), 1.32 (9H, s), 3.39 (3H, s), 3.78 (3H, s), 4.06 (4H, m), 4.44 (1H, d, J=16 Hz), 6.56 (1H, m), 6.72 (1H, m), 6.85 (1H, m). ##STR22##
3-Methoxy-5-pivaloyloxy-1-(methoxytricyclo[3.3.1.1 3 .7 ]dec-2-ylidenemethyl)-benzene (22a)
IR (CHCl 3 , cm -1 ): 2910, 1740 (C═O), 1600, 1580, 1460, 1325, 1272, 1140, 1114, 1097, 1079, 1055
1 H NMR (ppm): 1.35 (9H, s), 1.56-1.96 (12H, m), 2.68 (1H, br s), 3.23 (1H, br s), 3.31 (3H, s), 3.80 (3H, s), 6.53 (1H, t, J=2 Hz), 6.61 (1H, br s), 6.72 (1H, m). ##STR23##
3-Hydroxy-5-methoxy-1-(methoxytricyclo[3,3,1.1 3 .7 ]dec-2-ylidenemethyl)-benzene (22) (64%, white crystals, mp 159° C.)
IR (CHCl 3 , cm -1 ): 3590 (OH), 3320 (OH), 2910, 1591, 1342, 1150, 1098
1 H NMR (ppm): 1.78-1.97 (12H, m), 2.68 (1H, brs), 3.23 (1H, brs), 3.33 (3H, s), 3.78 (3H, s), 5.49 (1H, s), 6.37 (1H, m), 6.45 (2H, m). ##STR24##
Pyridinium 5-methoxy-3-(methoxytricyclo[3,3,1.1 3 .7 ]dec-2-ylidenemethyl)-1-phenyl phosphate (23) (62%, off-white fluffy powder)
IR (CHCl 3 , cm -1 ): 2911, 1584, 1448, 1425, 1328, 1149, 1099, 960, 870
1 H NMR (ppm): 1.68-1.92 (12H, m), 2.63 (1H, br s), 3.17 (1H, brs), 3.23 (3H, s), 3.68 (3H, s), 6.55 (1H, br s), 6.72 (1H, br s), 6.76 (1H, br s), 6.98 (1H, br s) ##STR25##
Disodium 5-methoxy-3-(methoxyspiro[1,2-dioxetane-3.2'-tricyclo[3,3,1.1 3 .7 ]-decan]-4-yl)-1-phenyl phosphate (3). (85%, white fluffy powder)
1 H NMR (D 2 O, ppm): 0.98 (1H, br d), 1.22 (1H, br d), 1.46-1.76 (10H, m), 2.20 (1H, br s), 2.78 (1H, brs), 3.14 (3H, s), 3.74 (3H, s), 6.91 (1H, brs), 6.68-6.97 (2H, very broad signal)
31 P NMR (D 2 O, ppm): 44.8 (1P) ##STR26##
3-Hydroxy-5-methoxy-1-(methoxy-5-chloro-tricyclo[3,3,1.1 3 .7 ]- dec-2-ylidenemethyl)benzene (24) (63% white crystals mp 134° C.)
IR (CHCl 3 , cm -1 ): 3590 (OH), 3330 (OH), 2930, 1610, 1591, 1450, 1430, 1341, 1150, 1100, 1080, 1056, 1028, 829
1 H NMR (ppm): 1.68-2.40 (11H, m), 2.82 (1H, brs), 3.31 (3H, s), 3.42 (1H, br s), 3.78 (3H, s), 6.37-6.41 (3H, m) ##STR27##
Disodium 5-methoxy-3-(methoxyspiro[1,2-dioxetane-3,2'-(5-chloro-)tricyclo-,[3,3,1.1 3 .7 ]-decan]-4-yl)-1-phenyl phosphate (4). (57% over 4 steps, white fluffy powder) powder.
1 H NMR (D 2 O, ppm, mixture of syn/anti isomers): 0.94 (1H, br d), 1.19 (1H, brd), 1.42 (1H, brd), 1.50 (1H, brs), 1.58 (1H, br d), 1.67-2.16 (17H, m), 2.38 (1H, br s), 2.40 (1H br s), 3.00 (2H, br s), 3.15 (3H, s), 3.16 (3H, s), 3.73 (3H, s), 3.74 (3H, s), 6.90 (1H, br s), 6.93 (1H, br s), 6.65-7.00 (4H, very broad signal)
31 P NMR (D 2 O, ppm, mixture of syn/anti isomers): 44.8 (2P).
REFERENCES
1. 5-Chlorovaniilin was synthesized as described by Hann and Spencer (J. Am. Chem. Soc., 1927, 49:535-537), mp 163° C.
2. Proton sponge formate (N,N,N',N',-tetramethyl-1,8-naphthalenediammonium formate): Formic acid (98%, 1.2 ml, 31 mmol) was added to a solution of proton sponge (6.8 g, 32 mmol) and CH 2 Cl 2 (8 ml) at 0° C. After warming to room temperature, the solvent was evaporated and the proton sponge formate crystallized as white crystals while drying on high vacuum with minimal warming. Proton sponge formate crystals (mp 79° C.) must be used soon after preparation since formic acid will evaporate upon standing, leaving proton sponge (mp 50° C.). ##STR28##
3-Methoxy-5-nitro-4-hydroxybenzaldehyde dimethyl acetal (25)
A methanol solution (30 ml) of 5-nitrovanillin (5.0 g, 97%, 18.4 mmol) was cleanly converted to dimethyl acetal 25 in the presence of trimethyl orthoformate (2.8 ml, 25 mmol) and a catalytic amount of p-toluenesulfonic acid. The reaction was quenched with triethylamine to pH 8, evaporated to a small volume and partitioned between EtOAc and NaHCO 3 . The aqueous layer was washed once with EtOAc. The organic layers were dried over Na 2 SO 4 , decanted and evaporated to an orange-red oil that crystallized upon pumping. Recrystallization from 50% EtOAc/hexanes gave 5.55 g (93%) acetal 25 as red-orange crystals, mp 58°-59° C.
IR (CHCl 3 , cm -1 ): 3300, 3010, 2930, 2820, 1620, 1543, 1460, 1445, 1392, 1341, 1320, 1254, 1132, 1101, 1058, 990, 865
1 H NMR (ppm): 3.31 (6H, s), 3.94 (3H, s), 5.31 (1H, s), 7.22 (1H, d, J=1.7 Hz), 7.78 (1H, d) ##STR29##
3-Methoxy-5-nitro-4-trifluoromethanesulfonyloxy benzaldehyde dimethyl acetal (26)
A solution of dimethyl acetal 25 (5.0 g, 20.6 mmol), chloroform (3 ml) and pyridine (8 ml) was stirred at 0° C. under argon. Addition of trifluoromethanesulfonic anhydride (4.0 ml, 23.8 mmol) at 0° C. over 10 min, followed by stirring at room temperature overnight gave clean formation of the triflate. The solvents were evaporated under high vacuum while warming the oil to 45° C. and traces of pyridine were chased with 4 ml toluene. The resulting oil was pumped well under high vacuum, taken up in 50% EtOAc/hexanes and triturated with 50% EtOAc/hexanes to separate the desired triflate (in solution) from the fine pyridinium triflate crystals. Evaporation of the trituration solution, followed by purification of the oil on a silica gel column, eluting with 30% EtOAc/hexanes, yielded 6.43 g (84%) of triflate 26.
IR (CHCl 3 , cm -1 ):
1 H NMR (ppm): 3.35 (6H, s), 4.00 (3H, s), 5.42 (1H, s), 7.42 (1H, d, J=1.6 Hz), 7.73 (1H, d) ##STR30##
3-Methoxy-5-nitro-benzaldehyde dimethyl acetal (27)
5-Nitrophenyl triflate 26 (7 g, 18.7 mmol), palladium (II) acetate (88 mg, 0.39 mmol), 1,1'-bis(diphenylphosphino)ferrocene (430 mg, 0.78 mmol) and hplc grade CH 3 CN (10 ml) were mixed well in a teflon-lined stainless steel bomb. After adding freshly made, pulverized proton sponge formate (5.1 g, 19.6 mmol), the bomb was sealed and heated at 90° C. for 2 h. The reaction mixture was taken up in EtOAc, passed through a silica gel plug, and then purified on a silica gel column, eluting with 0-30% EtOAc/hexanes to yield 1.5 g (35%) methoxynitrobenzaldehyde acetal 27.
IR (CHCl 3 , cm -1 ): 3005, 2960, 2935, 2835, 1532 (--NO 2 ), 1463, 1450, 1343 (--NO 2 ), 1280, 1190, 1158, 1104, 1055, 990, 871
1 H NMR (ppm): 3.33 (6H, s), 3.89 (3H, s), 5.41 (1H, s), 7.33 (1H, s), 7.68 (1H, s), 7.92 (1H, s) ##STR31##
Diethyl 1-methoxy-1-(3-methoxy-5-nitrophenyl)methane phosphonate (28)
Triethyl phosphite (0.98 ml, 5.7 mmol) was added dropwise to a solution of dimethyl acetal 27 (1.08 g, 4.7 mmol), boron trifluoride etherate (1.2 ml, 9.8 mmol) and CH 2 Cl 2 (10 ml) at 0° C. After warming the reaction to room temperature overnight, the solution was partitioned with 3N HCl and the aqueous layer was washed with CH 2 Cl 2 twice. The organic layers were washed with dilute NaHCO 3 , dried over Na 2 SO 4 , decanted and evaporated. The crude residue was purified on a silica gel column, eluting with 0-80% EtOAc/hexanes, to give 1.36 g (86%) phosphonate 28 as a slightly yellow oil.
IR (CHCl 3 , cm -1 ): 2995, 1532 (--NO 2 ), 1350 (--NO 2 ), 1280, 1258, 1243, 1096, 1053, 1025, 973, 721
1 H NMR (ppm): 1.28 (6H, t, J=7.1 Hz), 3.44 (3H, s), 3.90 (3H, s), 4.08-4.15 (4H, m), 4.55 (1H, d, J=16 Hz), 7.34 (1H, d), 7.69 (1H, d, J=2.1 Hz), 7.87 (1H, d, J=1.6 Hz) ##STR32##
Diethyl 1-methoxy-1-(3-amino-5-methoxyphenyl)methane phosohonate (29)
Nitro phosphonate 28 is dissolved in methylene chloride and added to a 1M NaOH solution containing nBu 4 NBr and sodium hydrosulfite. The biphasic solution is stirred vigorously, with warming if necessary, until reduction of the nitro substituent to aniline 29 is complete. The cooled solution is partitioned between CH 2 Cl 2 and minimal water, and the aqueous layer is washed with CH 2 Cl 2 as needed to obtain the crude aniline. The combined organic layers are dried, decanted and evaporated. The residue is then passed through a short silica gel plug to give aniline 29.
IR (CHCl 3 , cm -1 ):
1 H NMR (ppm):
(References for other reduction conditions are appended to the synthesis summary.) ##STR33##
Diethyl 1-methoxy-1-(3-methoxy-5-trifluoroacetamidophenyl)methane phosphonate (30)
Phosphonate 29 is quantitatively acetylated by addition of trifluoroacetic anhydride (1 eq) and triethylamine (1.3 eq) in 10 ml CH 2 Cl 2 at 0° C. Evaporation of solvents, followed by silical gel column purification yields trifluoroacetamide 30.
IR (CHCl 3 , cm -1 ):
1 H NMR (ppm): ##STR34##
3-Methoxy-5-trifluoroacetamido-1-(methoxytricyclo[3,3,1.1 3 .7 ]dec-2-ylidene-methyl)benzene (31)
Phosphonate 30, dissolved in anhydrous THF, is cooled to -68° C. under an argon atmosphere. Similarly, 2-adamantanone (1.1 eq) is dissolved in anhydrous THF and cooled to -68° C. under argon in a separate flask. To the phosphonate solution is added 2.5M nBuLi at -68° C. under argon until the red color of the ylid persists. At this point, 1.2 eq nBuLi is added to complete the ylid formation and the resulting colored solution is stirred at -68° C. for 5 min. While maintaining the low temperature, 2-adamantanone in THF is slowly added to the ylid over an hour. After the final addition of ketone, the reaction mixture is stirred for 2 h while warming to room temperature. The reaction is then heated at reflux for 1 h, cooled and quenched by partitioning with EtOAc and saturated NH 4 Cl. The organic layer is dried over Na 2 SO 4 and chromatographed with EtOAc/hexanes on a silica gel column to give enol ether 31.
IR (CHCl 3 , cm -1 ):
1 H NMR (ppm): ##STR35##
3-Amino-5-methoxy-1-(methoxytricyclo[3.3.1.1 3 .7 ]dec-2-ylidenemethyl)benzene (32)
Trifluoroacetamide enol ether 31 is hydrolyzed at 60° C. with finely ground K 2 CO 2 (3 eq) in MeOH continning trace water. Work up by partitioning the mixture with EtOAc/H 2 O, followed by silica gel chromatography provides enol ether aniline 32.
IR (CHCl 3 , cm -1 ):
1 H NMR (ppm):
3-Carbamoyl-5-methoxy Derivatives (3-NHCO 2 X): ##STR36##
3-para-Methoxyphenylcarbamoyl-5-methoxy-1-(methoxytricyclo[3,3,1.1 3 .7 ]dec-2-ylidenemethyl)benzene (33)
Enol ether aniline 32 in methylene chloride is carboxylated with 4-methoxyphenyl chloroformate (1.1 eq) in the presence of triethylamine (2.0 eq) at 0° C. The reaction mixture is partitioned with CH 2 Cl 2 /H 2 O, washed with dilute NaHCO 3 , dried over Na 2 SO 4 , evaporated and chromatographed on silica gel to yield enol ether p-methoxyphenylcarbamate 33.
IR (CHCl 3 , cm -1 ):
1 H NMR (ppm): ##STR37##
3-tert-Butylcarbamoyl-5-methoxy-1-(methoxytricyclo[3,3,1.1 3 .7 ]dec-2-ylidenemethyl)benzene (34)
A methylene chloride solution of enol ether aniline 32, triethylamine (1.5 eq) and BOC-On (1.3 eq) is stirree at 55° C. in a tightly capped Kimax tube to effecl t-butyl carbamate formation, The solution is cooled, evaporated to a small volume and, upon addition of MeOH to the residue, the desired carbamate 34 precipitates.
IR (CHCl 3 , cm -1 ):
1 H NMR (ppm): ##STR38##
3-N-Suffonamido-5-methoxy Derivatives (3--NHSO 2 X);
3-N-Toluenesuffonamido-5-methoxy-1-(methoxytricyclo[3,3,1.1 3 .7 ]dec-2-ylidenemethyl)benzene (35)
A methylene chloride solution of enol ether aniline 32 is sullonylatecl wrm tosyl chloride (1.1 eq) in the presence of triethytamine (2.0 eq) at 0° C. The reaction mixture is partitioned with CH 2 Cl 2 /H 2 O, washed with dilute NaHCO 3 , dried over Na 2 SO 4 , evaporated and chromatographed on silica gel to yield N-toluenesulfonamido enol ether 35.
IR (CHCl 3 , cm -1 ):
1 H NMR (ppm): ##STR39##
3-N-Trifluoromethylsulfonamido-5-methoxy-1-(methoxytricyclo[3,3,1.1 3 .7 ]dec-2-ylidenemethyl)benzene (36)
A methylene chloride solution of enol ether aniline 32 is sulfonylated with trifluoromethylsultonic anhydride (1.1 eq) at 0° C. The reaction mixture is partitioned with CH 2 Cl 2 /H 2 O, dried over Na 2 SO 4 , evaporated and chromatographed on silica gel to yield N-trifluoromethylsulfonamido enol ether 36.
IR (CHCl 2 , cm -1 ):
1 H NMR (ppm): ##STR40##
3-Amido-5-methoxy Derivatives (3-NHCOX):
3-N-Benzamido-5-methoxy-1-(methoxytricyclo[3,3,1.1 3 .7 ]dec-2-ylidenemethyl)benzene (37)
A pyndine solution of enol ether aniline 32 is reacted with benzoyl chloride (1.1 eq) at 0° C. The solvent is evaporated and pumped well to yield a crude oil, which is partitioned between CH 2 Cl 2 /H 2 O, dried and evaporated. Chromatography on silica gel yields benzamido enol ether 37.
IR (CHCl 3 , cm -1 ):
1 H NMR (ppm):
The 3-nitrogen-substituted phenyl enol ethers (compounds 33-37) are demethylated with sodium ethane thiolate, and then phosphorylated and photooxygenated as described for dioxetanes 1 and 2 to obtain the analogous dioxetanes.
EXAMPLES
Various dioxetanes within the scope of this invention have been prepared and tested for essential properties, such as quantum yield (performed by an independent laboratory according to the procedure listed below), T 1/2 and the emission wavelength maxima. These dioxetanes are identified by number, and in the tables following after the number, the identity of the substituent on the adamantyl ring, if any followed by the identity of the Z substituent is given. In the compounds tested, X is phosphate. Values for quantum yield and T 1/2 are obtained both for the dioxetane alone in 0.1 molar DEA, and in the presence of an ehancement agent, Sapphire II.
Protocol for Quantum Yields Determination
500 μL of 3.2×10 -4 M solution of a dioxetane in 0.1M Na 2 CO 3 , pH 9.5 was placed in a 12×75 mm tube, at 20° C. The solution was equilibrated to 20° C. in a refrigerated water bath for 10 minutes. 2 μL of alkaline phosphatase suspension was added to the tube containing dioxetane and immediately vortexed for 1 sec and placed in the 20° C. water bath. The tube was then placed in MGM Optocomp® I luminometer and the light signal was measured at 1 sec integration times. After the light signal was measured, the tube was placed back into the 20° C. water bath and the measurement was repeated. The total counts for the dioxetane were determined from the intensity data. Total counts observed for a given concentration of dioxetane is the product of Photon Detection Efficiency (PDE) of the luminometer, the quantum yield of dioxetane and the number of molecules capable of emitting light (concentration of dephosphorylated dioxetanes). PDE for the MGM Optocomp I luminometer was determined to be 2.56×10 -3 measured with a Biolink® absolute standard and utilizing the known spectral response of the luminometer's PMT and the known emission spectrum of the dioxetanes. The quantum yield is calculated by dividing the total counts measured by the PDE and the concentration of the dioxetane.
Calculation of Half Life or Half Time to Steady State Light Emission
From the Turner luminometer readout, the maximum signal was measured. The maximum signal minus the Turner light unit readings at 30, 150, 300, or 600 second intervals was calculated and graphed vs. time in seconds. From the graphs, an exponential equation was calculated to determine the half life.
The half lives of the dioxetanes were also determined directly from the Turner luminometer printouts.
Emission Maxima
To 2 ml of a pH 10 solution of 0.4 mM dioxetane, 0.1M diethanolamine, 1 mM MgCl 2 was added 9.9×10 -11 M alkaline phosphatase. The solution was equilibrated 5 minutes in a Spex Fluorolog Fluorimeter and then scanned 5 times at 0.5 sec/nm for chemiluminescent emission. The chemiluminescence emission wavelength maximum was recorded.
Chemiluminescent DNA Sequencing
DNA sequencing with chemiluminescent detection was performed as described in the Tropix SEQ-Light™ protocol. Briefly, DNA sequencing reactions were initiated with biotinylated primers using M13 single stranded phage DNA as a template. The reactions were separated by 8M urea denaturing PAGE, transferred horizontally to Tropilon-Plus nylon membrane by capillary action, and cross-linked to the membrane by exposure to UV light using a Spectronics SpectroLinker XL-1500 at 200 mJ/cm 2 . The membranes were incubated with blocking buffer (0.2% I-Block™, 0.5% sodium, dodecyl sulphate/SDS, in phosphate buffered saline/PBS [20 mM sodium phosphate, pH 7.2, 150 mM NaCl]) for 10 minutes, incubated with a 1/5000 dilution of Avidx-AP streptavidin-alkaline phosphatase in blocking buffer for 20 minutes, washed for 5 minutes in blocking buffer, washed 3×5 minutes with wash buffer (0.5% SDS, PBS), washed 2×5 minutes with assay buffer (0.1M diethanolamine, 1 mM MgCl 2 pH 10), and then incubated with dioxetane solution (either CSPD, 140-17 or 128-87 diluted to 0.25 mM in assay buffer) for 5 minutes. The membranes were drained, sealed in a plastic folder and exposed to Kodak XAR-5 X-ray film. For the dioxetane 128-87, the exposure time was 70 minutes and for 140-17, 80 minutes, both 65 minutes after substrate addition. For the comparison of dioxetane 128-87 versus CSPD, the membrane exposure time was 5 minutes after a 24 hour incubation with substrate. The details of this type of protocol are reflected in Tropix SEQ-Light™ DNA sequencing system, commercially available from Tropix, Inc. 0.1M DEA, pH, 25° C. Dioxetane concentration 3.7×10 -7 M to 6×10 -6 M
______________________________________ QuantumCompound Yield T 1/2 (min) μL em______________________________________128-70 (H, 5-Cl) 1.4 × 10.sup.-4 35.55 471128-87 (Cl, 5-Cl) 1.2 × 10.sup.-4 9.03 470140-20 (H, 5-OMe) 1.5 × 10.sup.-5 1.55 476140-17 (Cl, 5-OMe) 2.3 × 10.sup.-5 1.09 475140-62 (H, 6-OMe) 1.1 × 10.sup.-6 2.4 490140-73 (Cl, 6-OMe) 6.8 × 10.sup.-7 2.0 487AMPPD 1.5 × 10.sup.-5 2.1 477CSPD 5.2 × 10.sup.-5 1.6 475______________________________________
0.09M DEA+0.1% Sapphire II, pH 9.95, 25° C. Dioxetane concentration 1.8×10 -7 M to 6.1×10 -9 M
______________________________________ QuantumCompound Yield T 1/2 (min)______________________________________128-70 (H, 5-Cl) 5.2 × 10.sup.-2 172128-87 (Cl, 5-Cl) 3.5 × 10.sup.-2 70.6140-20 (H, 5-OMe) 2.4 × 10.sup.-3 4.34140-17 (Cl, 5-OMe) 1.9 × 10.sup.-3 1.1140-62 (H, 6-OMe) 3.8 × 10.sup.-5 6.49140-73 (Cl, 6-OMe) 5.5 × 10.sup.-5 2.22AMPPD 6.4 × 10.sup.-4 8.2CSPD 6 × 10.sup.-3 4.5______________________________________
To demonstrate positively the interaction of the dioxetane, or at least the excited-state emitter, with enhancement agents of the type known for use in connection with dioxetanes, the wavelength for the emission maximum was detected in the absence of any enhancement agent, in the presence of BDMQ, and on a nylon membrane. The data are set forth in the following table.
______________________________________ Emission Max, nmDioxetane No Addition +BDMQ On Nylon______________________________________128-70 471 463 461128-87 470 464 459140-20 476 466 461140-17 475 464 463140-62 490 482 477140-73 487 479 481______________________________________
DOT BLOT ASSAYS
As noted above, the dioxetanes of this invention are suitable for use in dot blot assays. The dioxetanes synthesized according to the synthesis route described above were employed in dot blot assays. In confirmation of the absence of chemiluminescence of the dioxetanes bearing a Z substituent at the six position, it should be noted that Compound 140-62 gave a consistent absence of signal, or, under optimum conditions, a barely detectable signal. Similarly, the dioxetane with the methoxy substituent at the six position with a chlorine substituent on the adamantyl ring, 140-73, gave no signal in dot blot assay, again confirming the lack of chemiluminescent activity in six-substituted metaphosphate phenyl dioxetanes.
Nitrocellulose and nylon membrances were spotted with a biotinylated 35 base oligonucleotide probe. The probe was diluted in 1X SSC to yield a starting dilution of 210 pg. Successive 1:2 dilutions of the starting dilution were spotted on the membranes, 12 spots total. The membranes were dried, subjected to optimum U.V. crosslinking (120 mJ/cm 2 ), blocked for 30 minutes in blocking buffer (nitrocellulose: 0.2% I-Block, 0.1% Tween-20, 1X PBS; nylon: 0.2% I-Block, 0.5% SDS, 1X PBS), incubated 20 minutes in a 1/5000 dilution of streptavidin-aklaline phosphatase conjugate diluted in blocking buffer, and washed as follows: 1×5 minutes in blocking buffer; 3×5 minutes in 1X PBS, 0.3% Tween-20 (nitrocellulose) or 3×5 minutes in 1X PBS, 0.5% SDS (nylon); 2×5 minutes in substrate buffer (0.1M diethanolamine, 0.1 mM MgCl 2 , pH 10); 1×5 minutes in a 1/20 dilution of Nitro-Block (Tropix, Inc. Bedford, Mass.) diluted in substrate buffer (Nitrocellulose Experiment Only); and 2×5 minutes in substrate buffer (Nitrocellulose Experiment Only). The membranes were incubated with 0.25 mM dioxetane diluted in substrate buffer for 5 minutes. Several membranes in both the nitrocellulose and nylon experiments were incubated with 0.25 mg/ml Calfax DB-45, Calfax 10L-45 or Calsoft T-60 (Pilot Chemical Company, Los Angeles, Calif.), 1.0 mg/ml Tween-20, 1.0 mg/ml NitroBlock, and 0.25 mM dioxetane diluted in substrate buffer for 5 minutes. These membranes were not subjected to a 1/20 dilution of Nitro-Block. The membranese were then exposed to x-ray film and developed.
Thus, as can be seen from the results above, electron withdrawing groups added to the aromatic ring of the dioxetane slow the kinetics of light emissions while tending to increase the chemiluminescent signal. In contrast, electron-donating groups accelerate T 1/2 apparently by facilitating electron transfer from the oxygen, through the aromatic group, to the dioxetane. Thus, by proper selection of the nature and ability of the electron-donating or electron-withdrawing Z substituent, and simultaneous selection of the appropriate substituent for the adamantyl ring, if desired, dioxetanes of specific characteristics, including optimized signal intensity, optimized speed, specific emission wavelength, and the like, can be obtained.
These dioxetanes can be used for assays of all types in which an enzyme capable of cleaving the dioxetane can be attached to one element of the ultimate complex which the analyte, if present, will form. Conventional assay formats are known to those of skill in the art, and are described in the patents set forth above in the Background of the Invention. Exemplary disclosure of suitable assays appears in U.S. Pat. No. 5,112,960, and the same is incorporated herein by reference. The assay format, per se, save for the enhanced performance therein by the dioxetanes of this invention, does not constitute an aspect of the invention.
The dioxetanes of this invention, as well as the intermediates therefore, have been disclosed by reference to both generic description and specific embodiment. Additionally, dioxetane performance has been described generally, and exemplified. The examples are not intended as limiting, and should not be construed as such. Variations in substituent pattern, identity, and the like, consistent with the disclosure will occur to those of ordinary skill in the art. Such variations and modifications remain within the scope of the invention, save as excluded by the positive limitations set forth in the claims below. | Spiroadamantyl dioxetanes bearing an alkoxy substituent, and an aromatic substituent of phenyl or naphthyl on the dioxetane ring can be activated to chemiluminesce if the aromatic substituent bears a moiety designated OX, wherein the X is cleaved by an enzyme with which the dioxetane is permitted to come in contact with. The T.sub. 1/2 kinetics of the chemiluminescent reaction, as well as the signal intensity, or quantum yield of the chemiluminescent reaction, can be altered by selection of an electron-withdrawing or an electron-donating group Z, at positions on the aromatic substituent other than those adjacent the point of attachment to the dioxetane. Signal strength can further be enhanced by recognized chemiluminescent enhancers. | 2 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is related to provisional application Ser. No. 60/004,576, filed Sept. 29, 1995, now abandoned which is incorporated herein by reference in its entirety, including any drawings and figures.
FIELD OF THE INVENTION
This invention relates generally to the fields of detecting and disposing of microorganisms. In particular, the invention relates to the use of incubators for detecting microorganisms and the use of storage containers for the disposal of the microorganisms.
BACKGROUND OF THE INVENTION
The following description of the background of the invention is provided to aid the reader in the understanding of the invention, but it is not admitted to constitute or describe prior art to the invention.
The collection of biological samples from the field, such as the sampling of water for microbiological contamination testing is an important aspect of maintaining the purity of water supplies.
Samples are often maintained under conditions which will allow for the later growth of any microorganisms present. However, little or no growth of any microorganisms in the sample occurs on site and during shipment of the sample to the testing laboratory. Growth based detection of any microorganism in the sample must await arrival at the testing facility, which delays the detection of the presence of microorganisms. Also, microbiological testing requires incubation of samples at elevated temperatures and such testing is usually done in a laboratory setting.
The use of portable incubation devices for the growth of biological samples, such as cells or tissues in culture is known. Such devices rely on the use of electrical elements such as batteries, heating coils and thermostats to maintain the proper temperature required for cellular growth. See, G. M. Eastham and K. H. Rieckmann, Journal of Tropical Medicine and Hygiene, 84:27-28 (1981) and, Geoffrey A. R. Mealing and Jean-Louis Scwhartz, Brain Research Bulletin, 23:161-162 (1989).
Lemberg et al. U.S. Pat. No. 4,458,674 disclose an infant incubator relying on convection flow from a heating element.
SUMMARY OF THE INVENTION
The present invention provides a portable incubation kit which relies on non-electromechanical devices in order to facilitate growth of a microorganism in a sample such that growth during shipment may occur. It also provides the option to conduct the microbiological testing on-site rather than shipping the sample to a laboratory. Surprisingly, the kit does not utilize any electrical components. The sample container and the vessel cap of the sample container, as described in detail below, provide a means for disinfecting a sample at a desired time and safely disposing the sample. By separating the sample from the disinfectant with a membrane or barrier, contact between the sample and the disinfectant can be prevented until the user breaks or removes the barrier or membrane and thereby allows contact and disinfection.
Thus, in one aspect the invention features a kit which advantageously provides for the incubation of a sample for on-site testing, which may contain a microorganism. It can also be used for concurrent shipment and incubation of a sample that may contain a microorganism. Instead of shipping the sample to a testing facility, the growth based detection of the organism can be conducted on-site, so that a signal generated by the growth of the organism may be rapidly detected by field personnel. If it is used as a shipping container, upon arrival at a testing facility, the growth of the organism(s) is complete or nearly complete and the result can be rapidly detected by facility personnel.
The kit includes a sample container for growth of a microorganism which may be present in a sample, and a heat pack. The kit is configured so that the heat pack is located to provide proper temperature for the growth of any such microorganism(s).
The "sample container" is generally any sterile vessel into which may be placed a sample which may contain a microorganism. The sample container may be made of plastic, glass or other nonporous substances which can contain a liquid or fluid without leaking. Such a sample container will allow growth of the microorganism to be detected and will generally contain from 10-100 ml liquid with appropriate space for gases as needed.
By "sample" is meant a fractional portion of a liquid to be tested, or if from a dry surface a transfer of some portion of material from the surface into the chamber. By "microorganism" is meant any one of a procaryotic, such as bacterial, or eucaryotic, such as molds, yeast, plant, animal and other eucaryotic organisms, all of which are too small to be easily seen with the naked eye.
By "heat pack" is meant a chemical heat source which may contain the following components: Iron particles, activated charcoal particles, cellulose, zeolite and moisture. Such packs are well known in the art, and are widely available. They are of the type used by, for example, skiers to warm their hands or feet. Any equivalent such heat packs are well known in the art and can be designed for use in this invention. Such packs are activated to generate heat without need for any special equipment. Generally, they can be activated by shaking after exposure of the pack to the air. In other embodiments, the heat pack may be a microwaveable gel able to maintain and dissipate heat over a several hour period. Such gels however do require some external source of heat energy for activation. Preferably, such a heat pack will maintain 10 or 100 mls of fluid in a chamber at above 30 degrees or 35 degrees C and below about 40 or 45 degrees C for about 20 to 30 hours when coupled with a proper insulating container.
In preferred embodiments, the kit also contains a heat shield located between the heat pack and the sample container; an insulating container which surrounds the sample container, the heat pack and if present the heat shield; and a microorganism growth and indicator medium which may be provided in the sample container (e.g., Colilert® medium for detection of coliforms and Escherichia coli, available from IDEXX Laboratories, Inc., Westbrook, Me.).
By "heat shield" is meant an element which may fit between the sample container and the heat pack to moderate the heat transfer between the heat pack and the sample container in order to provide proper sample temperature for the growth of targeted microorganism(s). The heat shield may be formed of, for example, cardboard, paper or perforated styrofoam or any other material suitable to moderate heat transfer.
By "insulating container" is meant a container which decreases the ability for heat to be transferred from or to the interior of the container. The insulating container may be formed of cardboard, or a material such as plastic surrounding a vacuum, for example a Thermos® type container. In a preferred embodiment the container is formed of polyfoam or Styrofoam™.
By "microorganism growth and indicator medium" is meant a medium which provides for the growth of specific target organisms but not others. For example, the presence of the specific bacterial, mold or yeast species may be made known by a signal generated on the basis of the cleavage of a nutrient-indicator releasing the indicator portion of the molecule by a specific enzyme, particular to a specific, bacterial, mold or yeast species. See Edberg, U.S. Pat. No. 5,429,933 (hereby incorporated by reference in its entirety, including any drawings and figures).
In preferred embodiments, the kit contains an observation window which allows comparison of a detectable signal generated by the growth of a microorganism with a standard which indicates the presence of a microorganism. The signal generating means may include a nutrient-indicator media, such as Colilert® nutrient-indicator media.
By "signal generated by the growth of a microorganism" is meant a detectable change in the contents of the sample container by, for example, human visual inspection or by detection in a device. Preferably, the signal comprises a change in the light emission or absorption characteristics of the contents of the sample in the sample container. Most preferably the alteration of the color of a signal is used. Signal generating means such nutrient-indicator media may also be used. Other signal detection systems may be employed. Examples of such signal detection systems include, but are not limited to, spectrophotometer, calorimeters, luminometers, fluorometers, and devices that measure the decay of radioisotopes. In a preferred embodiment, a dual color system is used for detection of coliforms and Escherichia coli in water samples. If coliform is present in a sample, the yellow color is generated due to ortho- nitrophenol (ONP) cleaved from nutrient indicator ortho- nitrophenol beta-D-galactopyranoside (ONPG) by β-D-glactosidase; the green color is generated in the sample due to cleavage of both nutrient indicators--ONPG and 5-bromo-4-chloro-3-indolyl beta-D-glucopyranoside(X-glcA)- are cleaved by β-D-galactosidase and β-D-glucuronidase from E. coli. The indicator portions of ONPG and X-glcA are yellow and blue respectively. When both color indicator are present in a sample, the sample appears to be green due to the mixture of yellow and blue colors.
In other aspects the invention features a method for use of the above kit. The method includes addition of sample to the sample container and activation of the heat pack. The heat pack is located near the sample container to heat the sample container and to maintain it at a temperature suitable for microorganism growth. If present, the heat shields can be placed appropriately to insure that proper temperature is maintained in the sample container. After a defined time, the results of the incubation can be scored by standard methods.
In another aspect the invention features a sample container capable of holding a sample that may contain a microorganism. The sample container may be used as a component of the kits described herein or independently of such kits. The sample container includes a sample vessel and a removable vessel cap. The vessel cap includes a barrier separating the sample from a material capable of disinfecting the sample, thereby preventing contact of the sample and the material for a desired time period. Thus, a user may remove the barrier at the desired time and bring the material in contact with the sample in order to disinfect the sample.
By "sample vessel" is meant any object having at least one opening that is capable of holding a sample added to the vessel through the opening. In preferred embodiments the sample vessel is generally cylindrical (although other shapes, such as rectangular, conical, spherical, as well as a wide variety of regular and irregular shapes, may be used) with an open end portion that has a first set of grooves and the vessel cap, defined below, contains a corresponding second set of grooves capable of interlocking with the first set and securing the vessel cap on the sample vessel. Of course, a wide variety of other means may also be used to secure the vessel cap to the sample vessel, including, among others, snap on lids
By "vessel cap" is meant any object capable of attaching to the sample vessel to form a container dividing the contents of the container (e.g., the sample and air or another gas) from the exterior environment. The vessel cap may contain an aperature and the sample container may include a blister protruding through the aperature in the vessel cap. For example, the sample container may include a chlorine tablet in the blister, a membrane sealing the blister, and a washer. Thus, the vessel cap may contain a set of grooves so that the washer rests against the set of grooves, thereby holding the washer in place, thereby holding the membrane in place, thereby holding the chlorine tablet in place.
By "barrier" is meant any means of dividing the sample from the disinfectant material. Commonly, the barrier will be a sealable foil membrane that separates disinfectant material, such as a chlorine tablet, from the sample. Such a foil membrane may be opened simply by applying pressure through the chlorine tablet and thereby puncturing the membrane. Other barriers, such as sliding dividers or opening panels, could also easily be adapted to deliver the material to the sample or vice versa.
By "material capable of disinfecting the sample" is meant any substance that is capable of rendering safe a sample infected with a microorganism. The disinfectant preferably kills the microorganisms and thereby renders them incapable of causing infection. The material may be a chlorine tablet, for example a 100 mg rapid-release chlorine tablet.
In another aspect, the invention provides a removable vessel cap. The vessel cap may be used in conjunction with the sample container and/or kits described herein, or independently in other applications. The cap includes a material capable of disinfecting a sample and a barrier separating the material from the sample, thereby preventing contact of the material and the sample for a desired time period.
Other features and advantages of the invention will be apparent from the following description of the preferred embodiments thereof, and from the claims.
DETAILED DESCRIPTION OF THE INVENTION
The drawings will first briefly be described.
Drawings:
FIG. 1 is a longitudinal cross-sectional illustration of one embodiment of a kit of the present invention.
FIG. 2 illustrates the temperature range in a 10 ml sample heated by one heat pack over a 28 hour period.
FIG. 3 illustrates the temperature range in a 100 ml sample heated by two heat packs placed in an insulating container over a 33 hour period.
FIG. 4 illustrates the temperature range in a 100 ml sample initially at room temperature (about 23 degrees C) or initially at 4 degrees C heated by two heat packs placed in an insulated container over a 50 hour period.
FIG. 5 illustrates a preferred embodiment of the sample container and vessel cap, including a chlorine tablet in a blister and separated from the sample by a barrier which is held in place by a washer resting against the grooves of the sample container.
Kit
The kit of the present invention provides for the ability to conduct sampling for the presence of microorganisms. Generally, incubation times of 24 hours or less at temperatures between 30 degrees and 45 degrees Centigrade are provided for by the present invention. Other temperatures can be accommodated by use of more heat packs or by larger or smaller such packs.
Referring to FIG. 1, in one preferred embodiment, kit 10 contains one Colilert® microorganism growth and indicator medium 12 (IDEXX Laboratories, Westbrook, Maine); these media are similar to those described by Edberg, supra, and allow rapid detection of the specified microbes in 24 hours after incubation at about 35 degrees C), one sterile 100 ml sample container 14, two commercially available heat packs 16 (Heat Pack™available from Eastern Mountain Sports, which generates between 135 degrees F (58 degrees C) and 158 degrees F (70 degrees C) for up to eight hours without using insulating materials. The pack weighs about 20-30 grams and is formed from iron dust, activated charcoal powder, cellulose, zeolite and moisture), and one insulated container 18 which may be a polyfoam box (which snugly contains the heat packs and the chamber) with built in or separate heat shields 20 (cardboard having a thickness of about 0.2 mm). (The kit could include appropriate aperatures to act as an observation window and a built-in color comparator)
Use of the invention is simple and includes the steps of: (1) Adding a sample, which may be 100 ml, to sterile sample container 14, and adding the microorganism growth and indicator medium (in alternative embodiments the medium is prepackaged in the sterile sample container 14). Upon mixing of the sample with the nutrient-indicator media and subsequent incubation, if specific species of target bacteria are present a signal will be generated. More specifically, for the media needed above coliforms in the sample will produce a yellow color and E. coli will produce a green color. (2) Activating the heat packs. (3) Placing the sample container and heat packs in the insulating container. (4) The result can be scored after about 24 hours by visually inspecting the color of the sample. The order of the first three steps can be altered as recognized by those in the art.
Sample Container
FIG. 5 shows a preferred sample container of the present invention. The sample vessel 60 has an open end and holds a sample 70. The vessel cap 30 attaches to sample container 60. Disinfectant material 20, preferably a chlorine tablet, is held in a blister 10 protruding through the opening in vessel cap 30. Blister 10 preferably is a flexible dome shaped center piece forming a chamber and is sealed with moisture resistant membrane 40, which is held in place by washer 50. Washer 50 is held in place and rests against the grooves in sample vessel 60.
EXAMPLE 1
Validation of Kit
Table 1 illustrates the growth of various strains of E. coli in Colilert® reagent from various sources (the actual source is of no relevance to the experiment) at 35 degrees C in an air incubator for 24 hours versus the results obtained by incubation in the kit described above after 24 hours.
35° C. Incubator vs. Current Invention
______________________________________ 35° C. Air Incubator Current invention Bacterial strains at 24 hours at 24 hours______________________________________Escherichia coli ATCC positive positive 25922 (3.5 cfu/100 ml) Escherichia coli EPA positive positive Q/C (6 cfu/100 ml) Escherichia coli positive positive #3407A, Yale (4.4 cfu/100 ml) Escherichia coli 19015 positive positive Yale (7 cfu/100 ml) Escherichia coli #27 positive positive Yale (6.6 cfu/100 ml) Escherichia coli positive positive ground turkey isolates (5.3 cfu/100 ml) Escherichia coli positive positive Quanti-Cult (4.3 cfu/100 ml) Escherichia coli positive positive English Q/C III-80B4 (3.6 cfu/100 ml) Negative Control negative negative______________________________________
These data indicate that equivalent results to those obtained under standard conditions are obtained with a kit of this invention.
EXAMPLE 2
Temperature Ranges
As illustrated in FIG. 2, a graph of the temperature of a 10 ml sample plotted against hours after activation of one heat pack (in the kit described above) shows that the temperature did not rise above approximately 38 degrees centigrade and was maintained at 26 degree centigrade after 24 hours incubation. All temperature measurements were made with a thermocouple implanted in each sample, and readout was via a digital thermometer.
A graph of the temperature of a 100 ml sample plotted against hours after activation of two heat packs (FIG. 3) shows that after 24 hours a temperature of approximately 35 degrees centigrade is still maintained, and the temperature did not rise above approximately 40 degrees centigrade.
EXAMPLE 3
Initial Sample Temperature at 4 Degrees C or Room Temperature
As illustrated in FIG. 4, a graph of the temperature of a 100 ml sample plotted against hours after activation of the heat pack shows that whether the sample is initially at 4 degrees centigrade or at room temperature (about 23 degrees C) the sample heat profile over time is very similar, with only a 1 degree difference between the samples over most of the incubation period.
EXAMPLE 4
Colilert® Medium Test
Table 2 illustrates the testing of well water samples with Colilert® Media. The table illustrates that using Colilert®, incubation in both a 35 degree C air incubator and using the present kit resulted in negative results for all samples tested ("unspiked"). When 3.6 to 7.3 colony forming units (cfu) per 100 ml of C. freundii ATCC 8090 were added ("spiked") to the samples both incubation in both a 35 degree C air incubator and using the present kit resulted in positive results for all samples tested. All results are taken after 24 hours of incubation.
35° C. Air Incubator vs. Current Invention: Testing Well Water with Colilert®
______________________________________ 35° C. Incubator Current inventionSample Unspiked Spiked Unspiked Spiked______________________________________Site 1: raw neg pos neg pos Site 1: filtered neg pos neg pos Site 2: raw neg pos neg pos Site 2: filtered neg pos neg pos Site 3: filtered neg pos neg pos Site 4: filtered neg pos neg pos Site 5: filtered neg pos neg pos Site 6: filtered neg pos neg pos Site 7: raw neg pos neg pos Negative control neg neg______________________________________
EXAMPLE 5
Operation of Sample Container and Vessel Cap Containing Chlorine Tablet
The following example describes a test of a vessel cap containing a chlorine tablet for use in the safe disposal samples which may contain harmful bacteria. As described above, the cap includes a dome shape flexible centerpiece with a breakable moisture resistant bottom layer forming a chamber to contain a chlorine tablet. Upon the completion of a test the user pushes the chlorine tablet downward to release it into the vessel containing the test sample. The rapid release chlorine tablet disinfects the test sample for safe disposal.
In the following example the cap was used with an IDEXX 100 ml Colilert® test vessel using Palintest® 100 mg rapid release chlorine tablet. Ten 100 ml positive Colilert® samples with approximately 10 6 cfu per mililiter of E. coli ATCC#25922 were used to test the effectiveness of such chlorine tablet released from the prototype cap. The effectiveness of disinfection was checked by streaking samples onto blood agar plates in 1 minute intervals upon the releasing of the chlorine tablet. Blood agar plates were then incubated at 35° C. for 30 hours to observe the regrowth of bacteria.
The following table shows the test results
______________________________________Time after chlorine tablet releasing 1 minute 2 minutes 3 minutes 4 minutes______________________________________Bacteria re-growth Yes Yes No No______________________________________
The tests showed that samples were safe for disposal after 3 minutes of disinfection.
It will be readily apparent to one skilled in the art that various substitutions and modification may be made to the invention disclosed herein without departing from the scope and spirit of the invention.
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 such 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. One skilled in the art will readily appreciate that the present invention is well adapted to carry out the objects and obtain the ends and advantages mentioned, as well as those inherent therein. The methods, procedures, treatments, and devices described herein are presently representative of preferred embodiments, are exemplary and are not intended as limitations on the scope of the invention. Changes therein and other uses will occur to those skilled in the art which are encompassed within the spirit of the invention as defined by the scope of the claims. | A self-contained incubator for growth of microorganism kit and methods for use of such a kit are provided. The kit and methods may detect the presence of microorganisms and may utilie a microorganism growth and indicator medium provided in a sample container along with a heat source, preferably generating heat through chemical means, and optionally heat shields, allowing for on-site testing of a microorganism present in a sample. The sample container may also include a removable vessel cap that includes a barrier separating the sample from a material capable of disinfecting the sample, thereby preventing contact of the sample and the material for a desired time period. The vessel cap may also be used independently in other applications. | 5 |
BACKGROUND OF THE INVENTION
Diabetes mellitus is a metabolic disorder which afflicts a significant percentage of the human population. It is characterized by reduced carbohydrate utilization, leading to hyperglycemia, with resulting glycosuria and polyurea, giving symptoms of thirst, hunger, emaciation and finally diabetic coma. Although the short-term adverse effects of diabetes (e.g. diabetic coma) can usually be controlled by the administration of an oral hypoglycemic agent or insulin, in many cases of diabetes long-term complications develop, especially neuropathy and ocular problems such as retinopathy and cataract formation.
One approach to the control of the long-term adverse effects of diabetes is treatment with an inhibitor of the aldose reductase enzyme, with a view to blocking the reduction of glucose to sorbitol. One such aldose reductase inhibitor which is of use in controlling the chronic complications of diabetes is sorbinil, the chemical compound having the following structural formula: ##STR1## Thus, sorbinil is one of the optical antipodes of 6-fluoro-spiro[chroman-4,4'-imidazoline]-2',5'-dione. Specifically, it is the dextrorotatory isomer of 6-fluoro-spiro[chroman-4,4'-imidazolidine]-2',5'-dione, and it has the (S)-configuration at its asymmetric center based on the Cahn-Ingold-Prelog system of designating absolute configurations. (Sarges, U.S. Pat. No. 4,130,714).
A key raw material for the preparation of sorbinil is the bicyclic ketone, 6-fluoro-4-chromanone (II). In one method of producing sorbinil, 6-fluoro-4-chromanone is converted in several steps into racemic (RS)-6-fluoro-4-ureidochroman-4-carboxylic acid (III), from which the desired isomer, (S)-6-fluoro-4-ureidochroman-4-carboxylic acid (IV), is obtained by resolution with an optically active amine, and cyclized to sorbinil using glacial acetic acid. Cue and Moore, U.S. Pat. No. 4,435,578--see SCHEME I.
However, resolution of the racemic ureido-acid (III) produces, as a by-product, (R)-6-fluoro-4-ureidochroman-4-carboxylic acid (V), i.e. the isomer with the wrong stereochemistry at C-4 for cyclization to sorbinil. The (R)-ureido-acid (V) can be recovered from the resolution step, and in practice it is usually contaminated with varying amounts of the (RS)-ureido-acid (III).
Accordingly, it is an object of the present invention to provide a process for converting the (R)-ureido-acid (V), and mixtures thereof with (RS)-ureido-acid (III), back into 6-fluoro-4-chromanone by oxidation with a metal permanganate. The regenerated chromanone (II) can be reconverted into racemic ureido-acid (III) and thence to additional sorbinil. This recycling technique of (R)-ureido-acid (V) avoids economic losses and waste disposal problems in sorbinil synthesis, and thereby greatly increases overall synthesis efficiency. ##STR2##
One method for regenerating 6-fluoro-4-chromanone from (R)-ureido-acid (V), or a mixture with its racemic counterpart, has been described in U.S. Pat. No. 4,431,828. However, the process of the present invention possesses advantages over the prior regeneration process. The present process involves a single oxidation step, which is easy to carry out, operates directly on the ureido-acid, and produces the chromanone (II) in pure form. The prior art process requires a hydrolysis step prior to oxidation, and the chromanone (II) produced contains a 4-chloroimino contaminant, which has to be removed by hydrogenation.
SUMMARY OF THE INVENTION
This invention provides a process for the regeneration of 6-fluoro-4-chromanone (II) from (R)-6-fluoro-4-ureidochroman-4-carboxylic acid (V) or a mixture of (R)- and (RS)-6-fluoro-4-ureidochroman-4-carboxylic acid (V and III), which comprises:
reacting said (R)-6-fluoro-4-ureidochroman-4-carboxylic acid or mixture of (R)- and (RS)-6-fluoro-4-ureidochroman-4-carboxylic acid with a metal permanganate, in an aqueous or partially aqueous solvent system, at a temperature in the range from 10° to 70° C., and at a pH in the range from 3 to 7, viz.: ##STR3## Alkali metal and alkaline earth metal permaganates can be used for the process of present invention, but the preferred reagent is potassium permanganate. The process is preferably carried out using 0.7 to 2.0 molar equivalents, especially 1.0 to 1.2 equivalents, of potassium permanganate in water-acetic acid mixtures.
DETAILED DESCRIPTION OF THE INVENTION
The present invention provide a process for the oxidation of the (R)-ureido-acid (V), or a mixture of the (R)-ureido-acid (V) and its corresponding racemate (III), to 6-fluoro-4-chromanone, using a permanganate, and it can be used irrespective of the source of the ureido-acid substrate. Moreover, when a mixture of (R)- and (RS)-ureido-acids is used, the process of this invention can be used irrespective of the ratio of the (R)- and (RS)-substrates.
However, the process of this invention is particularly useful for recycling the by-product obtained after removal of (S)-ureido-acid (IV) from racemic ureido-acid (III) in a synthesis of sorbinil (U.S. Pat. No. 4.435,578). Thus, in a typical sorbinil synthesis, the (RS)-ureido-acid (III) is contacted with about one molar equivalent of an optically-active amine in a suitable solvent, under conditions such that the diastereomeric salt containing the (S)-ureido-acid (IV) precipitates from the reaction medium and it can be removed by filtration. Typical optically-active amines which are used are D-(+)-(1-phenylethyl)amine and L-(--)-ephedrine, and a suitable solvent system is aqueous methanol. The precipitated salt containing the (S)-ureido-acid is then converted into sorbinil, usually by treatment with glacial acetic acid. The mother liquors after removal of the salt containing the (S)-ureido-acid (IV) by filtration are then usually freed from the methanol, basified to a pH of about 10 or 11 and extracted with a volatile, water-immiscible, organic solvent to remove the resolving amine. Acidification of the resulting aqueous solution causes precipitation of a mixture of (R)- and (RS)-6-fluoro-4-ureidochroman-4-carboxylic acid which is suitable for recycling to 6-fluoro-4-chromanone by the process of this invention. In such a mixture, the ratio of said (R)-ureido-acid (V) to said (RS)-ureido-acid (III) is usually in the range from 20:1 to 1:2, especially about 2:1.
The process of this invention involves a single step; namely, oxidation with permanganate. The process is normally carried out simply by contacting the ureido-acid substrate with the permanganate in an appropriate solvent system, until conversion into the chromanone (II) is complete. An alkali metal permanganate, e.g. lithium, sodium or potassium permanganate, or an alkaline earth metal permanganate, e.g. calcium or magnesium permanganate, can be used. However, the preferred reagent is potassium permanganate.
An appropriate solvent system is one which will dissolve the ureido-acid substrate to a significant degree, does not have any adverse effect on the starting ureido-acid substrate or the chromanone product, is not oxidized by permanganate to a significant extent, and permits easy isolation of the chromanone product. In practice, water is a convenient solvent which is commonly used. If desired certain organic co-solvents, such as tetrahydrofuran, dioxane, or low-molecular weight ethers of ethylene glycol or diethyleneglycol (e.g. 1,2-dimethoxyethane) can be added. However, it is usually preferable that the reaction medium remains homogeneous. Moreover, it is usually advantageous to conduct the process of this invention at a neutral or acidic pH. In particular a pH in the range form 3.0 to 7.0 is preferred, and this is achieved by the addition of an acidifying agent. A wide variety of acidifying agents can be added, the major requirement of such an agent being that it does not affect the ureido-acid substrate or chromanone product, and it is unaffected by the permanganate oxidant. Both inorganic and organic acidifying agents can be added, and typical agents are hydrochloric acid, sulfuric acid, nitric acid, phosphoric acid, acetic acid, methanesulfonic acid and toluenesulfonic acids. A particularly convenient acidifying agent is glacial acetic acid. Indeed, water containing a small volume of acetic acid represents a preferred solvent system for the process of this invention, especially water containing from 0.5 to 3 percent by volume of acetic acid.
The order of addition of the ureido-acid substrate and the permanganate oxidant to the solvent is not critical, and the two reactants can be added in either order. Also, it is sometimes convenient to treat a solution of the ureido-acid substrate with the permanganate portionwise, either as a solid or as an aqueous solution, as the oxidation proceeds. In that way, permanganate can be added in small amounts until a slight excess persists, i.e. the starting ureido-acid substrate is effectively titrated with the permanganate. This technique is particularly convenient when the ureido-acid substrate contains minor impurities which are also subject to permanganate oxidation. The process of the present invention is carried out at a pH in the range from 3.0 to 7.0. Although this is normally achieved by adding the starting ureido-acid substrate in its free carboxylic acid form, the ureido-acid substrate can by introduced into the reaction medium in the form of a carboxylate salt. The amount of added acidifying agent is then adjusted accordingly, to achieve the required pH for the oxidation. It is, of course, the pH at which the oxidation is run that determines the precise nature of the ureido-acid substrate (free acid or carboxylate salt) which undergoes oxidation. The ureido-acid substrate can be introduced into the reaction medium as a variety of salts. However, it is preferable that the cationic counterion is not susceptible to permanganate oxidation. Thus, favorable salts of the ureido-acid substrate which can be used are alkali metal salts (e.g. lithium, sodium or potassium salts) or alkaline earth metal salts (e.g. calcium or magnesium salts). On the other hand, amine salts, while still operable, are not generally favored.
The oxidation reaction of this invention can be carried out over a wide range of temperature. However, to ensure a convenient rate of reaction and achieve convenient reaction times, reaction temperatures from 10° to 70° C., and preferably 20° to 50° C., are commonly used. At a reaction temperature of 20° to 50° C., reaction times of a few hours, e.g. 2 to 10 hours are quite common.
An advantageous feature of the process of this invention resides in the ease of isolation of the product. At the completion of the oxidation, any excess permanganate and the manganese dioxide by-product can be reduced and solubilized by the addition of bisulfite, e.g. solid sodium meta-bisulfite, and then the 6-fluoro-4-chromanone can be recovered by standard techniques, e.g. filtration or extraction into a water-immiscible, volatile, organic solvent. Evaporation of the organic solvent then affords the desired chromanone II. The chromanone thus obtained directly from the process of this invention is usually of sufficient quality for use in further sorbinil synthesis, e.g. according to the methods of U.S. Pat. Nos. 4,130,714 or 4,435,578; however, the chromanone product can be purified by standard procedure, such as chromatography or recrystallization e.g. from methanol, if desired.
Thus, the 6-fluoro-4-chromanone recovered from the process of this invention can be used according to U.S. Pat. No. 4,435,578, as follows: ##STR4## The 6-fluoro-4-chromanone is reacted with an alkali metal cyanide (e.g. potassium cyanide) and ammonium carbonate in a polar solvent, such as aqueous ethanol, at about 65° C., for several hours, to give the racemic hydantoin (VI). The hydantoin (VI) is hydrolyzed to the racemic amino-acid (VII) under basic conditions, e.g. using about four molar equivalents of sodium hydroxide, or two molar equivalents of barium hydroxide octahydrate, in water, under reflux, for several hours. The amino-acid (VII) is then treated with two molar equivalents of potassium cyanate in water, at room temperature. The reaction proceeds quite rapidly to give the racemic ureido-acid (III) which is resolved by salt formation with an optically-active amine, as described previously. The amine salt of the (S)-ureido-acid (IV) can be converted into sorbinil by treatment with a large excess of glacial acetic acid at about 90° C. for a few hours, e.g. about two hours.
As indicated hereinbefore, sorbinil is an aldose reductase inhibitor, and it is useful for administration to diabetic human subjects for the control of chronic complications of diabetes, such as neuropathy, retinopathy and cataract formation. For such purposes, sorbinil is normally compounded into pharmaceutical compositions, e.g. tablets, capsules, aqueous suspensions or injectable solutions, according to standard pharmaceutical practice, and administered either orally or parenterally. Sorbinil is normally administered to a human patient at a dosage from about 0.05 mg to about 5.0 mg per kilogram of body weight per day, in single or multiple doses. See further U.S. Pat. No. 4,130,714.
The following examples and preparations are provided solely for the purpose of further illustration.
EXAMPLE 1
6-Fluoro-4-chromanone
A mixture of 17.3 g (0.11 mole) of potassium permanganate, 7.2 g (0.12 mole) of glacial acetic acid and 1 liter of water was stirred under an atmosphere of nitrogen at room temperature until a solution was obtained (10 minutes). To the resulting solution was then added, portionwise, with stirring, during about 2 minutes, 25.4 g (0.1 mole) of a mixture of (R)- and (RS)-6-fluoro-4-ureidochroman-4-carboxylic acid (approximate composition: 70 parts (R); 30 parts (RS)). The resulting slurry was stirred for 10 minutes at 22° C., and then it was warmed slowly to 40° C. and the heat source was removed. Stirring was continued for 30 minutes, during which time the reaction temperature rose slowly to 47° C. and then it began to fall. The heat source was reapplied, and the reaction mixture was heated and stirred at 50° C. for 30 minutes.
The reaction mixture was cooled to 23° C., and 41.6 g (0.4 mole) of sodium bisulfite was added in portions during a 30 minute period, with stirring. Stirring was continued for 30 minutes at 22° C., and then the solid was recovered by filtration, washed with water and dried. This gave 30.3 g of a solid, mp 111°-113° C. The latter solid was suspended in 100 ml of water, and 15 ml of 12N hydrochloric acid was added which gave a stable pH of 1.5. The acidified mixture was extracted with dichloromethane, and the combined extracts were washed with water, dried (MgSO 4 ) and concentrated in vacuo to ca 30 ml of a slurry. The slurry was diluted with 100 ml of hexane and the volume was reduced to ca 50 ml by evaporation. The resulting slurry was filtered, and the solid obtained was washed with hexane and dried. This afforded 11.0 g (66% yield) of 6-fluoro- 4-chromanone, mp 112°-114° C.
The nuclear magnetic resonance spectrum (60 MHz) of the product (in CDCl 3 ) showed absorptions at 7.9-7.0 (multiplet, 3H), 4.65 (triplet, 2H) and 2.8 (triplet 2H) ppm, downfield from internal tetramethylsilane.
EXAMPLE 2
6-Fluoro-4-chromanone
The title compound can be prepared by oxidation of (R)-6-fluoro-4-ureidochroman-4-carboxylic acid with potassium permanganate, using the procedure of Example 1.
EXAMPLE 3
6-Fluoro-4-chromanone
When the procedure of Example 1 is repeated, but the potassium permanganate used therein is replaced by an equimolar amount of lithium permanganate, sodium permanganate, calcium permanganate or magnesium permanganate, the title product is obtained.
EXAMPLE 4
6-Fluoro-4-chromanone
A solution 29.47 kg of potassium permanganate in 246 liters of water, preheated to 50° C., was added, with stirring, to 43.27 kg of a mixture of (R)- and (RS)-6-fluoro-4-ureidochroman-4-carboxylic acid (approximate composition: 70 parts (R); 30 parts (RS)) in 946 liters of water, also preheated to 50° C. The addition took 1.5 hours and after about half of the permanganate solution had been added, glacial acetic acid was added as necessary to maintain the pH in the range 4.5 to 5.0. Stirring was continued at 50° C. and a pH of 4.5 to 5.0 for an additional 30 minutes, and then the pH was lowered to 1.5 by the addition of 31.7 liters of concentrated hydrochloric acid. To the resulting mixture was added with stirring 23.85 kg of solid sodium bisulfite, portionwise, at 50° C., while maintaining the pH at 1.5 by the addition of concentrated hydrochloric acid (ca 51.5 liters). Stirring was continued at 50° C. for 30 minutes and then the mixture was filtered. The residue was washed with water at 50° C. and dried at 50° C., giving a first crop of the title product. The mother liquors were stirred at 15°-20° C. for 3 days and then filtered. This afforded a second crop of the title product. The total yield was 25.2 kg (87% yield).
PREPARATION 1
(RS)-4-Amino-6-fluorochroman-4-carboxylic Acid
A stirred slurry of 78 g (0.33 mole) of (RS)-6-fluoro-spiro-[chroman-4,4'-imidazolidine]-2',5'-dione and 208.3 g (0.66 mole) of barium hydroxide octahydrate in 585 ml of water was slowly heated to reflux over 3 hours and refluxed 16 hours. The slurry was cooled to 80° C. and powdered NH 4 CO 3 (78 g) added portionwise over 5 minutes. Moderate foaming was noted. After stirring 1.5 hours at 80° C., the mixture was cooled to 60° C., and filtered over diatomaceous earth with 2×100 ml hot water for wash. The combined filtrate and washes were stripped to 200 ml and allowed to stand overnight. 2-Propanol (600 ml) was added and the mixture heated to 70° C. to dissolve precipitated solids. The hot solution was treated with activated carbon, filtered over diatomaceous earth and washed with hot 1:1 water:2-propanol. The combined filtrate and washes were stripped to 200 ml, and water chased with 3×300 ml fresh 2-propanol. The resulting thick slurry was diluted with 200 ml additional 2-propanol, cooled to 5° C., granulated for 0.5 hour, filtered and air dried to yield title product, 63.5 g, 91.2%, mp 252°-253° C. (dec).
PREPARATION 2
(RS)-6-Fluoro-4-ureidochroman-4-carboxylic Acid
METHOD A
To a stirred slurry of 21.1 g (0.1 mole) of (RS)-4-amino-6-fluorochroman-4-carboxylic acid in 250 ml of water was added, portionwise, 16.2 g (0.2 mole) of potassium cyanate over 2.5 minutes. The almost complete solution was stirred 22 hours at 23° C., during which the pH increased from 6.8 to 9.1 and complete solution occurred. Concentrated HCl (19.0 ml) was added over 1 hour, keeping temperature 25°-29° C. The resulting slurry was granulated 1 hour (pH 3.2-3.5), and title product recovered by filtration with 150 ml water wash, partially dried in air and then for 18 hours at 50°-55° in vacuo, 20.0 g, 79%.
METHOD B
A mixture of 47.2 g (0.2 mole) of (RS)-6-fluoro-spiro[chroman-4,4'-imidazoline]-2',5'-dione, 28 g (0.7 mole) of sodium hydroxide pellets and 600 ml of water was heated under reflux for 40 hours. The reaction mixture was cooled to 24° C., and the pH was lowered from 11.8 to 5.0 with 6N hydrochloric acid. Gassing was noted below pH 8. After stirring the slurry for 20 minutes at pH 5, 32.5 g (0.4 mole) of potassium cyanate was added during 2 minutes. The mixture was stirred for 20 hours, and a small amount of solid was removed by filtration and washed with 50 ml of water. The combined filtrate and washings were adjusted from pH 8.5 to pH 4.0 using 6N hydrochloric acid. The solid which precipitated was recovered by filtration, washed with warm water and air dried to give 39.7 g (78% yield) of the title product, mp 198°-199° C. (dec.).
PREPARATION 3
(R)(+)-(1-Phenylethyl)amine Salts of 6-Fluoro-4-ureido-chroman-4-carboxylic Acid
A slurry of 10.0 g (39.4 mmole) of (RS)-6-fluoro-4-ureidochroman-4-carboxylic acid in 40 ml of methanol was stirred at 45°-50° C. During 4 minutes, 4.87 g (40.1 mmole) of (R)(+)-(1-phenylethyl)amine in 45 ml of methanol was added to the resulting thin slurry, yielding a solution. The heating bath was removed, and the mixture was cooled slowly to ambient temperature, granulated for 16 hours and filtered. This afforded 6.4 g (86.6% yield) of the (R)-(1-phenylethyl)amine salt of (S)-6-fluoro-4-ureidochroman-4-carboxylic acid, mp 206°-210° C., [alpha] D 25 =+54.3° (c=0.3, methanol).
The mother liquors from the filtration were evaporated in vacuo to give 8.3 g of a mixture of the (R)-(1-phenylethyl)amine salts of (R)-6-fluoro-4-ureidochroman-4-carboxylic acid and (RS)-6-fluoro-4-ureidochroman-4-carboxylic acid, mp 198°-200° C., [alpha] D 25 =-35.4° (C=0.5, methanol).
The above mixture of salts is distributed between ethyl acetate and water, with the pH first adjusted to 10. The ethyl acetate layer is separated and optically active amine recovered by evaporation. The pH of aqueous phase is then adjusted to 1-2 with hydrochloric acid and extracted with fresh ethyl acetate. The organic phase is washed with additional small portions of water, dried (MgSO 4 ) and evaporated to yield a mixture of (R)- and (RS)-6-fluoro-4-ureidochroman-4-carboxylic acid.
PREPARATION 4
(1R,2S)(-)-Ephedrine Salts of 6-Fluoro-4-ureidochroman-4-carboxylic Acid
METHOD A
A slurry of 35.6 g (0.14 mole) of 6-fluoro-4-ureidochroman-4-carboxylic acid in 1.07 liters of acetone was stirred at reflux (59° C.) for 30 minutes, and then it was cooled to 54° C. To the resulting slurry was added 24.4 g (0.148 mole) of (1R,2S)-ephedrine all in one portion. The slurry thinned and a near solution resulted. After less than two minutes at 55° C. rapid crystallization began. The slurry was refluxed for 2 hours, cooled to 40° C. and the crystalline solid was recovered by filtration to give 26.1 g of the (1R,2S)-ephedrine salt of (S)-6-fluoro-4-ureidochroman-4-carboxylic acid, mp 204 (dec), [alpha] D 25 =+37.0 (c=1, methanol).
The mothers liquors were cooled to room temperature and the further solid was recovered by filtration to give 1.3 g of material, mp 180°-185° C. (dec), [alpha] D 25 =0 (C=1, methanol). The filtrate was evaporated in vacuo to give 32.9 g of a mixture of the (1R,2S)-ephedrine salts of (R)-6-fluoro-4-ureidochroman-4-carboxylic acid and (RS)-6-fluoro-4-ureidochroman-4-carboxylic acid, mp 72°-90° C., [alpha] D 25 =-55.7° (C=1, methanol).
The latter mixture of salts is partitioned between dichloromethane (150 ml) and water (150 ml) and the pH is adjusted to 11.5. The organic layer is removed and evaporated in vacuo to give recovered (1R,2S)-ephedrine. The pH of the aqueous layer is lowered to 3 to 4 and the solid which precipitates is recovered by filtration to give a mixture of (R)-6-fluoro-4-ureidochroman-4-carboxylic acid and (RS)-6-fluoro-4-ureidochroman-4-carboxylic acid.
A slurry of 25 g of the (1R,2S)-ephedrine salt of (S)-6-fluoro-4-ureidochroman-4-carboxylic acid from above in 250 ml of acetone was stirred and heated under reflux and then the mixture was cooled to 40° C. The solid was recovered by filtration to give 24 g of purified (1R,2S)-ephedrine salt of (S)-6-fluoro-4-ureidochroman-4-carboxylic acid, mp 205° C., [alpha] D 25 =+38.2° (c=1, methanol).
METHOD B
A mixture of 100 g of (RS)-6-fluoro-4-ureidochroman-4-carboxylic acid and 374 ml of methanol was heated under reflux (65° C.) for 30 minutes and then it was cooled to 59° C. To the cooled mixture was added 7.42 ml of water followed by 68 g of (1R,2S)-ephedrine. This resulted in the formation of a heavy precipitate. The resulting mixture was refluxed for 45 minutes and then cooled to 27° C. The solid was recovered by filtration to give 70.4 g of the (1R,2S)-ephedrine salt of (S)-6-fluoro-4-ureidochroman-4-carboxylic acid, [alpha] D 25 =+44.36° (c=1.04, methanol).
The filtrate was evaporated in vacuo to give 116.3 g of a mixture of the (1R,2S)-ephedrine salts of (R)-6-fluoro-4-ureidochroman-4-carboxylic acid and (RS)-6-fluoro-4-ureidochroman-4-carboxylic acid. This mixture of salts can be converted into a mixture of (R)-6-fluoro-4-ureidochroman-4-carboxylic acid and (RS)-6-fluoro-4-ureidochroman-4-carboxylic acid using the method described at the end of Method A, above.
PREPARATION 5
(S)(+)-6-Fluoro-spiro-[chroman-4,4'-imidazolidine]-2',5'-dione(Sorbinil)
A mixture of 9.6 g of the (1R,2S)-ephedrine salt of (S)-6-fluoro-4-ureidochroman-4-carboxylic acid and 68 ml of glacial acetic acid was heated at 95° C. for 1 hour, and then it was evaporated in vacuo at 60° C. This afforded 20 g of an oily residue which was diluted with 50 ml of water at 60° C. and then 50 ml of water at 10° C. The resulting slurry was adjusted to pH 4.5 with 4N sodium hydroxide and the solid was recovered by filtration to give 4.7 g of crude title product, mp 234°-240° C., [alpha] D 25 =+50.5° (c=1, methanol). This crude product (4.0 g) was dissolved in 60 ml of boiling absolute ethanol, and the ethanol solution was filtered and cooled to 24° C. The solid was recovered by filtration, to give 2.0 g of (S)(+)-6-fluoro-spiro-[chroman-4,4'-imidazolidine]-2',5'-dione, mp 240.5-243.0, [alpha] D 25 =+55.4° (c=1, methanol). | 6-Fluoro-4-chromanone can be regenerated from (R)-6-fluoro-4-ureidochroman-4-carboxylic acid, or from mixtures of (R)-6-fluoro-4-ureidochroman-4-carboxylic acid and its racemic modification, by oxidation with a permanganate, especially potassium permanganate. 6-Fluoro-4-chromanone is a chemical intermediate useful for preparing sorbinil, an aldose reductase inhibitor which can be used in clinical medicine for the control of the chronic complications of diabetes. (R)-6-Fluoro-4-ureidochroman-4-carboxylic acid and its racemic modification are by-products from the production of sorbinil from 6-fluoro-4-chromanone. | 2 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This invention claims priority of the Swiss patent application 0977/00 filed May 8, 2000 which is incorporated by reference herein.
FIELD OF THE INVENTION
[0002] The invention concerns a microscope having an apparatus for reducing the illumination intensity of the microscope illumination at a pupil of a patient while an eye is being viewed through the microscope, the illumination beam path remaining directed onto the patient's eye but not causing any absolute darkening.
BACKGROUND OF THE INVENTION
[0003] In order to reduce a potential danger to a patient's eye, the light intensity at the eye being operated on is reduced during pauses in surgery. In practice, this is done by covering the eye with one's hand or with a stop that can be pivoted into the illumination beam path and is imaged onto the pupil of the patient's eye, so that the pupil is shaded by the stop. Such systems are also, inter alia, known as so-called “eclipse filters.”
[0004] Many illumination apparatuses of this kind, of various designs, have become known, for example DE-U-9103433.7 and U.S. Pat. No. 4,715,704.
[0005] DE 3339172 C2 describes a complete stop assemblage. Systems with black-dot darkening devices have been disclosed in DE-AS-1951139. DE-A-2654505 discloses two annular stops in an intermediate image plane of the illumination system, the images of these stops being created in the vicinity of the iris on the lens of eye. DE-U-9301448 describes a comparable stop device having a semitransparent light filter for the same purpose.
[0006] All the known assemblages thus assume that for darkening purposes, something must be introduced into the beam path in order to relieve stress on the patient's eye.
[0007] With the known assemblages, in order to achieve the corresponding imaging effects of the stops, these additionally introduced elements are arranged in the vicinity of the light source or in the vicinity of the light inlet into the system. This results in concentrated heat problems at that point. Because of the high light output in the region of the light source or the light inlet (e.g. from a light guide), considerable heating of the stop occurs. If the light output is present for a sufficiently long period, this can even result in destruction of the stop.
[0008] Leaving this aside, the stop also converts heat from the light radiation and emits it into the microscope interior, so that partial heating can occur there as well. Unpleasant light reflections are also disadvantageous.
[0009] A further disadvantage occurs, in the case of complete stops, from the fact that the pupil region is completely darkened and a great difference in brightness thus occurs between the illuminated and darkened state. The result of this, in some circumstances, is that details which the surgeon would like to recognize in the region of the pupil even during pauses in surgery are no longer sufficiently illuminated. The last-mentioned DE-U-9301448 provides some remedy here, but requires for the purpose the relatively costly filter which, on the other hand, once again brings about the aforesaid heating.
SUMMARY OF THE INVENTION
[0010] It is the object of the invention to create a new, improved system which on the one hand reduces heating in the usual stop region and on the other hand does not require complex filters for darkening.
[0011] This object is achieved by a microscope as defined by the features of Claim 1, and by a method as defined by the features of Claim 5.
[0012] The removal of an optical component, such as a lens, from the beam path annuls the intended function of that component. Since all the optical components in the beam path usually serve to collimate or focus the light, the removal according to the present invention results in diffuse scattering of the light, the effect being a definite darkening of the light intensity in the endangered region.
[0013] “Removal of an optical component” is also to be understood, for purposes of the invention, as removal of a complete assembly of different components, or also as the displacement or pivoting thereof, so that the function of focusing or collimating the light radiated through that assembly no longer exists.
[0014] The remaining diffused illumination will nevertheless still cast sufficient light through the illumination beam path toward the patient's eye that the surgeon or ancillary personnel will still have sufficient illumination for simply observing the surgical location.
[0015] The invention is not limited to problems of ophthalmic surgery, but rather can be used in the field of microscopy wherever illumination intensity needs to be reduced with no change in the light output of the light source. Consistency of color temperature is thus guaranteed.
[0016] The dependent claims describe and protect further improvement actions. An exemplary embodiment of the invention is presented in the drawings and the description pertaining to the Figures.
[0017] Further improvements and details according to the present invention are evident from the drawings and their description.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] The Figures are described in linked fashion. Identical components have identical reference characters. Components of similar function have identical reference characters with different indices. In the drawings:
[0019] [0019]FIG. 1 shows an assemblage with light introduced via a light guide and collector and zoom lenses and prisms; one of the collector lenses is mechanically removable; additionally or alternatively, one of the lenses at the prism is removable;
[0020] [0020]FIG. 2 shows an assemblage comparable to FIG. 1, where instead of removal of a zoom lens, the prism can be laterally pivoted out or pulled out;
[0021] [0021]FIG. 3 shows an assemblage in which the entire illumination optical system is axially displaceable into a defocused position.
DETAILED DESCRIPTION OF THE INVENTION
[0022] [0022]FIG. 1 shows the end of a light guide la which is followed by an assembly 2 a of optical elements for illumination, collimation and focusing. Assembly 2 a comprises, for example, a collector lens 3 , a further collector lens 4 , a zoom lens 5 , and a UV filter 6 .
[0023] These are followed in the illumination beam by a stop 7 , a mirror prism 8 having a convex light exit surface 15 , a concave lens 9 , a stepped mirror prism 10 having a convex lens 11 , and a main objective 12 that is held in an objective mount 13 .
[0024] Additionally or alternatively, convex lens 11 is configured to be removable, i.e. to be pivoted out or pulled out as shown by arrow 18 a. If the convex lens is not removable (as is preferred in some circumstances), it can also be cemented to prism 10 .
[0025] [0025]FIGS. 1 and 2 also indicate a tube lens 14 which is associated with the observation beam path.
[0026] What is special and novel about this assemblage is that collector lens 4 is removable from assembly 2 a by means of a mechanism that is only symbolically depicted. A mount 16 carrying collector lens 4 is joined to a handle or motorized drive (not depicted), and can be displaced in a guide so that it is absent from assembly 2 a and its function is eliminated.
[0027] The resulting effect is that what emerges from assembly 2 a is only more-diffuse light, which in coaction with the refracting surfaces on convex exit surface 15 and with lenses 9 and 11 in combination with the main objective, in turn allows only a defocused, attenuated light on the subject.
[0028] In the case of the assemblage shown in FIG. 2, assembly 2 b remains stationary, but for darkening purposes the light-concentrating optical system with lenses 9 and 11 is pulled out laterally (as indicated by arrow 18 ) by means of mechanical grasping means that are not shown in detail. Instead of pulling out, pivoting out is also conceivable as an alternative. Prism 10 can remain in place in this context, or optionally can also be displaced or pivoted. What is important for the invention is the change in light quality toward maintaining a certain illumination but without collimation in the critical region of the patient's eye, by removal of a light-collimating component.
[0029] In the variant shown in FIG. 3, instead of removal of a component, assembly 2 b is displaced (with means not depicted in detail) in a guide 20 along the illumination beam path, so as thereby to create defocusing or diffusion for darkening.
[0030] A wide variety of further alternatives is conceivable in the context of the invention; common to all of them is the fact that an additional element is not added, but rather an existing element is removed, or its position is changed, so as thereby correspondingly to modify the light beam path. For example, mirror 19 in FIG. 3 could be pivoted or displaced in such a way that the light is no longer incident in focused fashion on subject 21 .
[0031] Parts List
[0032] [0032] 1 a Light guide
[0033] [0033] 1 b Lamp
[0034] [0034] 2 a, b Assembly of optical elements
[0035] [0035] 3 First collector lens
[0036] [0036] 4 Second collector lens
[0037] [0037] 5 Zoom lens
[0038] [0038] 6 UV filter
[0039] [0039] 7 Stop
[0040] [0040] 8 Mirror prism
[0041] [0041] 9 Concave lens
[0042] [0042] 10 Stepped mirror prism
[0043] [0043] 11 Convex lens
[0044] [0044] 12 Main objective
[0045] [0045] 13 Objective mount
[0046] [0046] 14 Tube lens
[0047] [0047] 15 Convex exit surface
[0048] [0048] 16 Mount
[0049] [0049] 17 Guide
[0050] [0050] 18 , 18 a Arrow
[0051] [0051] 19 Mirror
[0052] [0052] 20 Guide
[0053] [0053] 21 Subject | The invention concerns a microscope having an illumination beam path, in which a darkening of the illumination on the subject ( 21 ) is achieved by removing, or changing the position of, an optical component. | 6 |
BACKGROUND OF THE INVENTION
The present invention relates to firearm safety devices of the kind designed to prevent unauthorized access to the trigger by blocking the trigger guard.
Known devices of this type (cf. U.S. Pat. No. 5,535,537, of the present Applicant) comprise a pair of blocking members adapted to be locked to each other around the trigger guard. According to the conventional design one of the blocking members is provided with a selectively rotatable spindle with a series of ratchet teeth thereon. The spindle is receivable within a cavity formed at the other blocking member, which is provided with ratchet rider member. In the operative, locking position the ratchet teeth are meshed, and the separation of the members from each other is thus prevented. In order to release the members, the ratchet teeth spindle must be rotated to disengage the ratchet teeth from the ratchet rider and allow the sliding out of the spindle.
The rotation of the spindle from the engaging to the disengaging position is achieved by a key operated mechanism of various types and designs.
These devices however suffer certain disadvantages. First, the ratchet rider must be spring-urged, and for that purpose the spring must be rather strong to avoid the release of the members by a sharp shock against the device. This, however, entails excessive wear of the ratchet teeth.
Secondly, the manipulation of the spindle by a key for the unlocking of the device is cumbersome and time consuming which is considered specifically disadvantageous when time is of essence, namely when one must reach for the weapon and bring it as quickly as possible to an operative shooting position.
The present invention provides a modified design of the locking mechanism of trigger guard blocking devices, being more simple, compact and easy to manipulate.
Further, the present invention improves the safety of the device against forceful tampering therewith.
Still further, the invention facilitates the operation of the device by electric or remote controlled means.
SUMMARY OF THE INVENTION
Thus provided according to the present invention is a firearm safety device for a firearm including a trigger and a trigger guard over the trigger. The device comprises first and second trigger blocking members adapted to engage and lock to each other around the trigger guard and prevent access to the trigger. The first blocking member comprises a hollow configured to receive a projecting, ratchet-toothed fixed spindle of the second blocking member. A ratchet rider member is installed having a ratchet toothed surface, so that reciprocating movement of the rider towards and away from the hollow is allowed. A spring is provided for urging the ratchet-toothed surface against the ratchet-toothed spindle when inserted into the hollow. The ratchet rider member is further provided with pivot means allowing a rotational movement thereof into a position wherein the toothed surface thereof disengages the ratchet teeth of the spindle. Selectively operable means are provided for immobilizing the movement(s) of the rider member.
The second blocking member comprises a non-rotatable ratchet spindle.
Preferably, the rider member immobilizing means comprise a key-operated push-in lock cooperating with a recess formed in the rider member.
BRIEF DESCRIPTION OF THE DRAWINGS
These and additional constructional features and advantages of the invention will become more clearly appreciated in the light of the ensuing description of preferred embodiments thereof, given by way of example only with reference to the accompanying drawings, wherein:
FIG. 1 a is a schematic three dimensional view of one blocking member;
FIG. 1 b is a schematic three dimensional view of the second, mating blocking member;
FIG. 1 c shows the rider member which is assembled within the second blocking member;
FIG. 2 is an elevation of the second blocking member;
FIG. 3 is a section taken along line III—III of FIG. 2;
FIG. 4 a shows, on an enlarged scale, the operative components of the blocking members in a locking engagement position;
FIG. 4 b shows the components of FIG. 4 a in the releasing position;
FIG. 4 c shows the components of FIG. 4 a in an intermediate, pre-locking position; and
FIG. 5 is a partial cross-sectional view taken along line V—V of FIG. 4 a.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
First blocking member denoted 10 is generally similar to the corresponding member of the traditional design, except for an important and unique feature that its ratchet spindle is not rotatable but rather made integral with the remaining structure. Hence, the member 10 comprises a trigger-guard blocking plate 12 presenting a flat surface 14 which is preferably provided with a rubber pad 16 , as customarily known, and so is guide channel 18 . Ratchet spindle 20 is cylindrical, with ratchet teeth 20 a extending along a planar surface which is cut-away from the cylindrical spindle 20 .
Since the member 10 has no moving parts it can readily be made by casting or press-forming (sintering) with no need for any additional processing or finishing operations.
The other, mating member 22 is shown to be in the form of a block 22 a mounted to a wall W, however this is not necessarily so and is illustrated to amplify the significant advantage of the design according to the invention. The member 22 comprises the counterpart, male portion 24 which slidingly fits into the cavity of the guide channel 18 , and a flat surface 26 with rubber pad 28 .
The block 22 a is formed with a cylindrical hollow cavity 32 of a diameter slightly larger than the spindle 20 for the sliding insertion of the latter in the locking position of the members. The cavity 32 is used in the present embodiment also for receiving one wall mounting screw 34 . A second bore 36 is made for mounting the block by screw 38 (see FIG. 3 ).
Freely seated within a slot 40 is a ratchet rider member denoted 42 . The rider member 42 , which is generally boot-shaped, comprises a slot 44 , a bore 46 , and its tread or base surface is formed with ratchet teeth 48 , engageable with ratchet teeth 20 a of the spindle 20 . The member 42 is coupled by a pivot pin 56 , enabling a limited reciprocating movement, and is further urged downwards by a compression coil spring 52 . The spring 52 is pressed at one end into a receiving bore 54 (see FIG. 4 a ), whereas its other end is clamped within extension recess 40 a . The spring 52 thus functions both as means for urging the rider member 42 downwards, and for allowing its small angle deflection about pivot pin 56 . As more clearly seen in FIGS. 4 and 5, a standard push-in lock 60 is accommodated within a suitable bore extending in a direction perpendicular to the pivoting plane of the rider 40 and so located that its locking detent 60 a is adapted, in the locking position of the device, to become inserted into the bore 46 . Therefore the immobilization of the rider member 42 is simply accomplished by pushing the operative button of the lock 60 , while its release is effected by use of a key 60 b (FIG. 1 b ).
The locking and unlocking process will now be described with particular reference to FIGS. 4 a - 4 c . When the spindle 20 is pushed into the hollow 32 , the ratchet rider is in its inner position (shown in FIG. 4 a ) and is elastically pressed against the spindle 20 which therefore will freely click its way to the desired depth. The locking or immobilization of the rider 42 will be effected by pushing home the button 60 a of the push-in lock 60 . The locking is thus safeguarded without any further manipulation.
The releasing of the members from each other is illustrated in FIG. 4 b , where extraction of the spindle 20 (after unlocking the lock 60 ) will cause the deflection of the rider member 42 , thus the disengagement of the ratchet teeth coupling, as shown.
In the non-operative position of FIG. 4 c it is shown that due to the bending effect of the coil spring 52 the rider member is attracted into an intermediate position wherein the insertion of the spindle 20 will first bring it into the position of FIG. 4 a and then the ratchet effect will take place as already described.
It will be now readily appreciated that the reliability of the device significantly increases, since the amount of resistance against the retrieval of the spindle from the ratchet coupling state no longer depends on the elasticity of the spring urging the ratchet rider member against the spindle as in the conventional devices; in fact, a significantly weaker spring can be used. Furthermore, the unlocking is more simply effected and no longer involves a rotational movement of the spindle.
In addition, more versatile operation modes are made possible in a simple manner, e.g. the electrically or otherwise remotely controlled unlocking, as described in the above mentioned U.S. Pat. No. 5,535,537, which are self-explanatory and need not be described in greater detail.
Those skilled in the art will readily understand that various changes, modifications and variations may be applied to the invention as above exemplified without departing from the scope of the invention as defined in and by the appended claims. | A firearm safeguard device, comprises first ( 22 ) and second ( 10 ) trigger-guard, blocking members. The second member ( 10 ) is provided with a fixed, non-rotating ratchet spindle ( 20 ). The first member ( 22 ) includes a ratchet rider member ( 42 ), mounted by means of a coil compression spring ( 52 ), allowing both reciprocating and deflecting movements. Locking of the device is achieved by a push-in lock ( 60 ) arresting the member ( 42 ). | 5 |
REFERENCE TO RELATED APPLICATIONS
This application claims benefit of the filing date of U.S. Provisional Patent Application No. 60/865,476, filed on Nov. 13, 2006, the contents of which are herein incorporated by reference.
STATEMENT OF COOPERATIVE RESEARCH AGREEMENT
The present invention, as defined by the claims herein, was made by parties to a Joint Research Agreement (“Agreement”) between Arius Research Inc. and Takeda Pharmaceutical Company Limited, as a result of activities undertaken within the scope of that Agreement. The Agreement was in effect prior to the date of the invention.
FIELD OF THE INVENTION
This invention relates to the isolation and production of cancerous disease modifying antibodies (CDMAB) and to the use of these CDMAB in therapeutic and diagnostic processes, optionally in combination with one or more chemotherapeutic agents. The invention further relates to binding assays which utilize the CDMAB of the instant invention.
BACKGROUND OF THE INVENTION
Monoclonal Antibodies as Cancer Therapy: Each individual who presents with cancer is unique and has a cancer that is as different from other cancers as that person's identity. Despite this, current therapy treats all patients with the same type of cancer, at the same stage, in the same way. At least 30 percent of these patients will fail the first line therapy, thus leading to further rounds of treatment and the increased probability of treatment failure, metastases, and ultimately, death. A superior approach to treatment would be the customization of therapy for the particular individual. The only current therapy which lends itself to customization is surgery. Chemotherapy and radiation treatment cannot be tailored to the patient, and surgery by itself, in most cases is inadequate for producing cures.
With the advent of monoclonal antibodies, the possibility of developing methods for customized therapy became more realistic since each antibody can be directed to a single epitope. Furthermore, it is possible to produce a combination of antibodies that are directed to the constellation of epitopes that uniquely define a particular individual's tumor.
Having recognized that a significant difference between cancerous and normal cells is that cancerous cells contain antigens that are specific to transformed cells, the scientific community has long held that monoclonal antibodies can be designed to specifically target transformed cells by binding specifically to these cancer antigens; thus giving rise to the belief that monoclonal antibodies can serve as “Magic Bullets” to eliminate cancer cells. However, it is now widely recognized that no single monoclonal antibody can serve in all instances of cancer, and that monoclonal antibodies can be deployed, as a class, as targeted cancer treatments. Monoclonal antibodies isolated in accordance with the teachings of the instantly disclosed invention have been shown to modify the cancerous disease process in a manner which is beneficial to the patient, for example by reducing the tumor burden, and will variously be referred to herein as cancerous disease modifying antibodies (CDMAB) or “anti-cancer” antibodies.
At the present time, the cancer patient usually has few options of treatment. The regimented approach to cancer therapy has produced improvements in global survival and morbidity rates. However, to the particular individual, these improved statistics do not necessarily correlate with an improvement in their personal situation.
Thus, if a methodology was put forth which enabled the practitioner to treat each tumor independently of other patients in the same cohort, this would permit the unique approach of tailoring therapy to just that one person. Such a course of therapy would, ideally, increase the rate of cures, and produce better outcomes, thereby satisfying a long-felt need.
Historically, the use of polyclonal antibodies has been used with limited success in the treatment of human cancers. Lymphomas and leukemias have been treated with human plasma, but there were few prolonged remission or responses. Furthermore, there was a lack of reproducibility and there was no additional benefit compared to chemotherapy. Solid tumors such as breast cancers, melanomas and renal cell carcinomas have also been treated with human blood, chimpanzee serum, human plasma and horse serum with correspondingly unpredictable and ineffective results.
There have been many clinical trials of monoclonal antibodies for solid tumors. In the 1980s there were at least four clinical trials for human breast cancer which produced only one responder from at least 47 patients using antibodies against specific antigens or based on tissue selectivity. It was not until 1998 that there was a successful clinical trial using a humanized anti-Her2/neu antibody (HERCEPTIN® (trastuzumab)) in combination with CISPLATIN. In this trial 37 patients were assessed for responses of which about a quarter had a partial response rate and an additional quarter had minor or stable disease progression. The median time to progression among the responders was 8.4 months with median response duration of 5.3 months.
HERCEPTIN® (trastuzumab) was approved in 1998 for first line use in combination with TAXOL® (paclitaxel). Clinical study results showed an increase in the median time to disease progression for those who received antibody therapy plus TAXOL® (paclitaxel) (6.9 months) in comparison to the group that received TAXOL® (paclitaxel) alone (3.0 months). There was also a slight increase in median survival; 22 versus 18 months for the HERCEPTIN® (trastuzumab) plus TAXOL® (paclitaxel) treatment arm versus the TAXOL® (paclitaxel) treatment alone arm. In addition, there was an increase in the number of both complete (8 versus 2 percent) and partial responders (34 versus 15 percent) in the antibody plus TAXOL® (paclitaxel) combination group in comparison to TAXOL® (paclitaxel) alone. However, treatment with HERCEPTIN® (trastuzumab) and TAXOL® (paclitaxel) led to a higher incidence of cardiotoxicity in comparison to TAXOL® (paclitaxel) treatment alone (13 versus 1 percent respectively). Also, HERCEPTIN® (trastuzumab) therapy was only effective for patients who over express (as determined through immunohistochemistry (IHC) analysis) the human epidermal growth factor receptor 2 (Her2/neu), a receptor, which currently has no known function or biologically important ligand; approximately 25 percent of patients who have metastatic breast cancer. Therefore, there is still a large unmet need for patients with breast cancer. Even those who can benefit from HERCEPTIN® (trastuzumab) treatment would still require chemotherapy and consequently would still have to deal with, at least to some degree, the side effects of this kind of treatment.
The clinical trials investigating colorectal cancer involve antibodies against both glycoprotein and glycolipid targets. Antibodies such as 17-1A, which has some specificity for adenocarcinomas, has undergone Phase 2 clinical trials in over 60 patients with only 1 patient having a partial response. In other trials, use of 17-1A produced only 1 complete response and 2 minor responses among 52 patients in protocols using additional cyclophosphamide. To date, Phase III clinical trials of 17-1A have not demonstrated improved efficacy as adjuvant therapy for stage III colon cancer. The use of a humanized murine monoclonal antibody initially approved for imaging also did not produce tumor regression.
Only recently have there been any positive results from colorectal cancer clinical studies with the use of monoclonal antibodies. In 2004, ERBITUX® (cetuximab) was approved for the second line treatment of patients with EGFR-expressing metastatic colorectal cancer who are refractory to irinotecan-based chemotherapy. Results from both a two-arm Phase II clinical study and a single arm study showed that ERBITUX® (cetuximab) in combination with irinotecan had a response rate of 23 and 15 percent respectively with a median time to disease progression of 4.1 and 6.5 months respectively. Results from the same two-arm Phase II clinical study and another single arm study showed that treatment with ERBITUX® (cetuximab) alone resulted in an 11 and 9 percent response rate respectively with a median time to disease progression of 1.5 and 4.2 months respectively.
Consequently in both Switzerland and the United States, ERBITUX® (cetuximab) treatment in combination with irinotecan, and in the United States, ERBITUX® (cetuximab) treatment alone, has been approved as a second line treatment of colon cancer patients who have failed first line irinotecan therapy. Therefore, like HERCEPTIN® (trastuzumab), treatment in Switzerland is only approved as a combination of monoclonal antibody and chemotherapy. In addition, treatment in both Switzerland and the US is only approved for patients as a second line therapy. Also, in 2004, AVASTIN® (bevacizumab) was approved for use in combination with intravenous 5-fluorouracil-based chemotherapy as a first line treatment of metastatic colorectal cancer. Phase III clinical study results demonstrated a prolongation in the median survival of patients treated with AVASTIN® (bevacizumab) plus 5-fluorouracil compared to patients treated with 5-fluourouracil alone (20 months versus 16 months respectively). However, again like HERCEPTIN® (trastuzumab) and ERBITUX® (cetuximab), treatment is only approved as a combination of monoclonal antibody and chemotherapy.
There also continues to be poor results for lung, brain, ovarian, pancreatic, prostate, and stomach cancer. The most promising recent results for non-small cell lung cancer came from a Phase II clinical trial where treatment involved a monoclonal antibody (SGN-15; dox-BR96, anti-Sialyl-LeX) conjugated to the cell-killing drug doxorubicin in combination with the chemotherapeutic agent TAXOTERE® (docetaxel). TAXOTERE® (docetaxel) is the only FDA approved chemotherapy for the second line treatment of lung cancer. Initial data indicate an improved overall survival compared to TAXOTERE® (docetaxel) alone. Out of the 62 patients who were recruited for the study, two-thirds received SGN-15 in combination with TAXOTERE® (docetaxel) while the remaining one-third received TAXOTERE® (docetaxel) alone. For the patients receiving SGN-15 in combination with TAXOTERE® (docetaxel), median overall survival was 7.3 months in comparison to 5.9 months for patients receiving TAXOTERE® (docetaxel) alone. Overall survival at 1 year and 18 months was 29 and 18 percent respectively for patients receiving SNG-15 plus TAXOTERE® (docetaxel) compared to 24 and 8 percent respectively for patients receiving TAXOTERE® (docetaxel) alone. Further clinical trials are planned.
Preclinically, there has been some limited success in the use of monoclonal antibodies for melanoma. Very few of these antibodies have reached clinical trials and to date none have been approved or demonstrated favorable results in Phase III clinical trials.
The discovery of new drugs to treat disease is hindered by the lack of identification of relevant targets among the products of 30,000 known genes that could contribute to disease pathogenesis. In oncology research, potential drug targets are often selected simply due to the fact that they are over-expressed in tumor cells. Targets thus identified are then screened for interaction with a multitude of compounds. In the case of potential antibody therapies, these candidate compounds are usually derived from traditional methods of monoclonal antibody generation according to the fundamental principles laid down by Kohler and Milstein (1975, Nature, 256, 495-497, Kohler and Milstein). Spleen cells are collected from mice immunized with antigen (e.g. whole cells, cell fractions, purified antigen) and fused with immortalized hybridoma partners. The resulting hybridomas are screened and selected for secretion of antibodies which bind most avidly to the target. Many therapeutic and diagnostic antibodies directed against cancer cells, including HERCEPTIN® (trastuzumab) and RITUXIMAB, have been produced using these methods and selected on the basis of their affinity. The flaws in this strategy are two-fold. Firstly, the choice of appropriate targets for therapeutic or diagnostic antibody binding is limited by the paucity of knowledge surrounding tissue specific carcinogenic processes and the resulting simplistic methods, such as selection by overexpression, by which these targets are identified. Secondly, the assumption that the drug molecule that binds to the receptor with the greatest affinity usually has the highest probability for initiating or inhibiting a signal may not always be the case.
Despite some progress with the treatment of breast and colon cancer, the identification and development of efficacious antibody therapies, either as single agents or co-treatments, has been inadequate for all types of cancer.
Prior Patents:
U.S. Pat. No. 5,750,102 discloses a process wherein cells from a patient's tumor are transfected with MHC genes which may be cloned from cells or tissue from the patient. These transfected cells are then used to vaccinate the patient.
U.S. Pat. No. 4,861,581 discloses a process comprising the steps of obtaining monoclonal antibodies that are specific to an internal cellular component of neoplastic and normal cells of the mammal but not to external components, labeling the monoclonal antibody, contacting the labeled antibody with tissue of a mammal that has received therapy to kill neoplastic cells, and determining the effectiveness of therapy by measuring the binding of the labeled antibody to the internal cellular component of the degenerating neoplastic cells. In preparing antibodies directed to human intracellular antigens, the patentee recognizes that malignant cells represent a convenient source of such antigens.
U.S. Pat. No. 5,171,665 provides a novel antibody and method for its production. Specifically, the patent teaches formation of a monoclonal antibody which has the property of binding strongly to a protein antigen associated with human tumors, e.g. those of the colon and lung, while binding to normal cells to a much lesser degree.
U.S. Pat. No. 5,484,596 provides a method of cancer therapy comprising surgically removing tumor tissue from a human cancer patient, treating the tumor tissue to obtain tumor cells, irradiating the tumor cells to be viable but non-tumorigenic, and using these cells to prepare a vaccine for the patient capable of inhibiting recurrence of the primary tumor while simultaneously inhibiting metastases. The patent teaches the development of monoclonal antibodies which are reactive with surface antigens of tumor cells. As set forth at col. 4, lines 45 et seq., the patentees utilize autochthonous tumor cells in the development of monoclonal antibodies expressing active specific immunotherapy in human neoplasia.
U.S. Pat. No. 5,693,763 teaches a glycoprotein antigen characteristic of human carcinomas and not dependent upon the epithelial tissue of origin.
U.S. Pat. No. 5,783,186 is drawn to Anti-Her2 antibodies which induce apoptosis in Her2 expressing cells, hybridoma cell lines producing the antibodies, methods of treating cancer using the antibodies and pharmaceutical compositions including said antibodies.
U.S. Pat. No. 5,849,876 describes new hybridoma cell lines for the production of monoclonal antibodies to mucin antigens purified from tumor and non-tumor tissue sources.
U.S. Pat. No. 5,869,268 is drawn to a method for generating a human lymphocyte producing an antibody specific to a desired antigen, a method for producing a monoclonal antibody, as well as monoclonal antibodies produced by the method. The patent is particularly drawn to the production of an anti-HD human monoclonal antibody useful for the diagnosis and treatment of cancers.
U.S. Pat. No. 5,869,045 relates to antibodies, antibody fragments, antibody conjugates and single-chain immunotoxins reactive with human carcinoma cells. The mechanism by which these antibodies function is two-fold, in that the molecules are reactive with cell membrane antigens present on the surface of human carcinomas, and further in that the antibodies have the ability to internalize within the carcinoma cells, subsequent to binding, making them especially useful for forming antibody-drug and antibody-toxin conjugates. In their unmodified form the antibodies also manifest cytotoxic properties at specific concentrations.
U.S. Pat. No. 5,780,033 discloses the use of autoantibodies for tumor therapy and prophylaxis. However, this antibody is an antinuclear autoantibody from an aged mammal. In this case, the autoantibody is said to be one type of natural antibody found in the immune system. Because the autoantibody comes from “an aged mammal”, there is no requirement that the autoantibody actually comes from the patient being treated. In addition the patent discloses natural and monoclonal antinuclear autoantibody from an aged mammal, and a hybridoma cell line producing a monoclonal antinuclear autoantibody.
SUMMARY OF THE INVENTION
This application utilizes methodology for producing patient specific anti-cancer antibodies taught in the U.S. Pat. No. 6,180,357 patent for isolating hybridoma cell lines which encode for cancerous disease modifying monoclonal antibodies. These antibodies can be made specifically for one tumor and thus make possible the customization of cancer therapy. Within the context of this application, anti-cancer antibodies having either cell-killing (cytotoxic) or cell-growth inhibiting (cytostatic) properties will hereafter be referred to as cytotoxic. These antibodies can be used in aid of staging and diagnosis of a cancer, and can be used to treat tumor metastases. These antibodies can also be used for the prevention of cancer by way of prophylactic treatment. Unlike antibodies generated according to traditional drug discovery paradigms, antibodies generated in this way may target molecules and pathways not previously shown to be integral to the growth and/or survival of malignant tissue. Furthermore, the binding affinities of these antibodies are suited to requirements for initiation of the cytotoxic events that may not be amenable to stronger affinity interactions. Also, it is within the purview of this invention to conjugate standard chemotherapeutic modalities, e.g. radionuclides, with the CDMAB of the instant invention, thereby focusing the use of said chemotherapeutics. The CDMAB can also be conjugated to toxins, cytotoxic moieties, enzymes e.g. biotin conjugated enzymes, or hematogenous cells, thereby forming an antibody conjugate.
The prospect of individualized anti-cancer treatment will bring about a change in the way a patient is managed. A likely clinical scenario is that a tumor sample is obtained at the time of presentation, and banked. From this sample, the tumor can be typed from a panel of pre-existing cancerous disease modifying antibodies. The patient will be conventionally staged but the available antibodies can be of use in further staging the patient. The patient can be treated immediately with the existing antibodies, and a panel of antibodies specific to the tumor can be produced either using the methods outlined herein or through the use of phage display libraries in conjunction with the screening methods herein disclosed. All the antibodies generated will be added to the library of anti-cancer antibodies since there is a possibility that other tumors can bear some of the same epitopes as the one that is being treated. The antibodies produced according to this method may be useful to treat cancerous disease in any number of patients who have cancers that bind to these antibodies.
In addition to anti-cancer antibodies, the patient can elect to receive the currently recommended therapies as part of a multi-modal regimen of treatment. The fact that the antibodies isolated via the present methodology are relatively non-toxic to non-cancerous cells allows for combinations of antibodies at high doses to be used, either alone, or in conjunction with conventional therapy. The high therapeutic index will also permit re-treatment on a short time scale that should decrease the likelihood of emergence of treatment resistant cells.
If the patient is refractory to the initial course of therapy or metastases develop, the process of generating specific antibodies to the tumor can be repeated for re-treatment. Furthermore, the anti-cancer antibodies can be conjugated to red blood cells obtained from that patient and re-infused for treatment of metastases. There have been few effective treatments for metastatic cancer and metastases usually portend a poor outcome resulting in death. However, metastatic cancers are usually well vascularized and the delivery of anti-cancer antibodies by red blood cells can have the effect of concentrating the antibodies at the site of the tumor. Even prior to metastases, most cancer cells are dependent on the host's blood supply for their survival and an anti-cancer antibody conjugated to red blood cells can be effective against in situ tumors as well. Alternatively, the antibodies may be conjugated to other hematogenous cells, e.g. lymphocytes, macrophages, monocytes, natural killer cells, etc.
There are five classes of antibodies and each is associated with a function that is conferred by its heavy chain. It is generally thought that cancer cell killing by naked antibodies are mediated either through antibody dependent cellular cytotoxicity or complement dependent cytotoxicity. For example murine IgM and IgG2a antibodies can activate human complement by binding the C-1 component of the complement system thereby activating the classical pathway of complement activation which can lead to tumor lysis. For human antibodies the most effective complement activating antibodies are generally IgM and IgG1. Murine antibodies of the IgG2a and IgG3 isotype are effective at recruiting cytotoxic cells that have Fc receptors which will lead to cell killing by monocytes, macrophages, granulocytes and certain lymphocytes. Human antibodies of both the IgG1 and IgG3 isotype mediate ADCC.
Another possible mechanism of antibody mediated cancer killing may be through the use of antibodies that function to catalyze the hydrolysis of various chemical bonds in the cell membrane and its associated glycoproteins or glycolipids, so-called catalytic antibodies.
There are three additional mechanisms of antibody-mediated cancer cell killing. The first is the use of antibodies as a vaccine to induce the body to produce an immune response against the putative antigen that resides on the cancer cell. The second is the use of antibodies to target growth receptors and interfere with their function or to down regulate that receptor so that its function is effectively lost. The third is the effect of such antibodies on direct ligation of cell surface moieties that may lead to direct cell death, such as ligation of death receptors such as TRAIL R1 or TRAIL R2, or integrin molecules such as alpha V beta 3 and the like.
The clinical utility of a cancer drug is based on the benefit of the drug under an acceptable risk profile to the patient. In cancer therapy survival has generally been the most sought after benefit, however there are a number of other well-recognized benefits in addition to prolonging life. These other benefits, where treatment does not adversely affect survival, include symptom palliation, protection against adverse events, prolongation in time to recurrence or disease-free survival, and prolongation in time to progression. These criteria are generally accepted and regulatory bodies such as the U.S. Food and Drug Administration (F.D.A.) approve drugs that produce these benefits (Hirschfeld et al. Critical Reviews in Oncology/Hematolgy 42:137-143 2002). In addition to these criteria it is well recognized that there are other endpoints that may presage these types of benefits. In part, the accelerated approval process granted by the U.S. F.D.A. acknowledges that there are surrogates that will likely predict patient benefit. As of year-end 2003, there have been sixteen drugs approved under this process, and of these, four have gone on to full approval, i.e., follow-up studies have demonstrated direct patient benefit as predicted by surrogate endpoints. One important endpoint for determining drug effects in solid tumors is the assessment of tumor burden by measuring response to treatment (Therasse et al. Journal of the National Cancer Institute 92(3):205-216 2000). The clinical criteria (RECIST criteria) for such evaluation have been promulgated by Response Evaluation Criteria in Solid Tumors Working Group, a group of international experts in cancer. Drugs with a demonstrated effect on tumor burden, as shown by objective responses according to RECIST criteria, in comparison to the appropriate control group tend to, ultimately, produce direct patient benefit. In the pre-clinical setting tumor burden is generally more straightforward to assess and document. In that pre-clinical studies can be translated to the clinical setting, drugs that produce prolonged survival in pre-clinical models have the greatest anticipated clinical utility. Analogous to producing positive responses to clinical treatment, drugs that reduce tumor burden in the pre-clinical setting may also have significant direct impact on the disease. Although prolongation of survival is the most sought after clinical outcome from cancer drug treatment, there are other benefits that have clinical utility and it is clear that tumor burden reduction, which may correlate to a delay in disease progression, extended survival or both, can also lead to direct benefits and have clinical impact (Eckhardt et al. Developmental Therapeutics: Successes and Failures of Clinical Trial Designs of Targeted Compounds; ASCO Educational Book, 39 th Annual Meeting, 2003, pages 209-219).
The present invention describes the development and use of AR51A165.2 identified by its effect in a cytotoxic assay and in an animal model of human cancer. This invention describes reagents that bind specifically to an epitope or epitopes present on the target molecule, and that also have in vitro cytotoxic properties, as a naked antibody, against malignant tumor cells but not normal cells, and which also directly mediate, as a naked antibody, inhibition of tumor growth. A further advance is of the use of anti-cancer antibodies such as this to target tumors expressing cognate antigen markers to achieve tumor growth inhibition, and other positive endpoints of cancer treatment.
In all, this invention teaches the use of the AR51A165.2 antigen as a target for a therapeutic agent, that when administered can reduce the tumor burden of a cancer expressing the antigen in a mammal. This invention also teaches the use of CDMAB (AR51A165.2), and their derivatives, and antigen binding fragments thereof, and cytotoxicity inducing ligands thereof, to target their antigen to reduce the tumor burden of a cancer expressing the antigen in a mammal. Furthermore, this invention also teaches the use of detecting the AR51A165.2 antigen in cancerous cells that can be useful for the diagnosis, prediction of therapy, and prognosis of mammals bearing tumors that express this antigen.
Accordingly, it is an objective of the invention to utilize a method for producing cancerous disease modifying antibodies (CDMAB) raised against cancerous cells derived from a particular individual, or one or more particular cancer cell lines, which CDMAB are cytotoxic with respect to cancer cells while simultaneously being relatively non-toxic to non-cancerous cells, in order to isolate hybridoma cell lines and the corresponding isolated monoclonal antibodies and antigen binding fragments thereof for which said hybridoma cell lines are encoded.
It is an additional objective of the invention to teach cancerous disease modifying antibodies, ligands and antigen binding fragments thereof.
It is a further objective of the instant invention to produce cancerous disease modifying antibodies whose cytotoxicity is mediated through antibody dependent cellular toxicity.
It is yet an additional objective of the instant invention to produce cancerous disease modifying antibodies whose cytotoxicity is mediated through complement dependent cellular toxicity.
It is still a further objective of the instant invention to produce cancerous disease modifying antibodies whose cytotoxicity is a function of their ability to catalyze hydrolysis of cellular chemical bonds.
A still further objective of the instant invention is to produce cancerous disease modifying antibodies which are useful for in a binding assay for diagnosis, prognosis, and monitoring of cancer.
Other objects and advantages of this invention will become apparent from the following description wherein are set forth, by way of illustration and example, certain embodiments of this invention.
BRIEF DESCRIPTION OF THE FIGURES
FIG. 1 compares the percentage cytotoxicity and binding levels of the hybridoma supernatants against cell lines OCC-1, OVCAR-3 and CCD-27sk.
FIG. 2 represents binding of AR51A165.2 to cancer and normal cell lines. The data is tabulated to present the mean fluorescence intensity as a fold increase above isotype control.
FIG. 3 includes representative FACS histograms of AR51A165.2 and anti-EGFR antibodies directed against several cancer and non-cancer cell lines.
FIG. 4 demonstrates the effect of AR51A165.2 on tumor growth in a prophylactic BxPC-3 pancreatic cancer model. The vertical dashed lines indicate the period during which the antibody was administered. Data points represent the mean +/−SEM.
FIG. 5 demonstrates the effect of AR51A165.2 on body weight in a prophylactic BxPC-3 pancreatic cancer model. Data points represent the mean +/−SEM.
FIG. 6 demonstrates the effect of AR51A165.2 on tumor growth in a prophylactic MDA-MB-231 breast cancer model. The vertical dashed lines indicate the period during which the antibody was administered. Data points represent the mean SEM.
FIG. 7 demonstrates the effect of AR51A165.2 on body weight in a prophylactic MDA-MB-231 breast cancer model. Data points represent the mean +/−SEM.
DETAILED DESCRIPTION OF THE INVENTION
In general, the following words or phrases have the indicated definition when used in the summary, description, examples, and claims.
The term “antibody” is used in the broadest sense and specifically covers, for example, single monoclonal antibodies (including agonist, antagonist, and neutralizing antibodies, de-immunized, murine, chimerized or humanized antibodies), antibody compositions with polyepitopic specificity, single-chain antibodies, immunoconjugates and antibody fragments (see below).
The term “monoclonal antibody” as used herein refers to an antibody obtained from a population of substantially homogeneous antibodies, i.e., the individual antibodies comprising the population are identical except for possible naturally occurring mutations that may be present in minor amounts. Monoclonal antibodies are highly specific, being directed against a single antigenic site. Furthermore, in contrast to polyclonal antibody preparations which include different antibodies directed against different determinants (epitopes), each monoclonal antibody is directed against a single determinant on the antigen. In addition to their specificity, the monoclonal antibodies are advantageous in that they may be synthesized uncontaminated by other antibodies. The modifier “monoclonal” indicates the character of the antibody as being obtained from a substantially homogeneous population of antibodies, and is not to be construed as requiring production of the antibody by any particular method. For example, the monoclonal antibodies to be used in accordance with the present invention may be made by the hybridoma (murine or human) method first described by Kohler et al., Nature, 256:495 (1975), or may be made by recombinant DNA methods (see, e.g., U.S. Pat. No. 4,816,567). The “monoclonal antibodies” may also be isolated from phage antibody libraries using the techniques described in Clackson et al., Nature, 352:624-628 (1991) and Marks et al., J. Mot Biol, 222:581-597 (1991), for example.
“Antibody fragments” comprise a portion of an intact antibody, preferably comprising the antigen-binding or variable region thereof. Examples of antibody fragments include less than full length antibodies, Fab, Fab′, F(ab′) 2 , and Fv fragments; diabodies; linear antibodies; single-chain antibody molecules; single-chain antibodies, single domain antibody molecules, fusion proteins, recombinant proteins and multispecific antibodies formed from antibody fragment(s).
An “intact” antibody is one which comprises an antigen-binding variable region as well as a light chain constant domain (C L ) and heavy chain constant domains, C H 1, C H 2 and C H 3. The constant domains may be native sequence constant domains (e.g. human native sequence constant domains) or amino acid sequence variant thereof. Preferably, the intact antibody has one or more effector functions.
Depending on the amino acid sequence of the constant domain of their heavy chains, intact antibodies can be assigned to different “classes”. There are five-major classes of intact antibodies: IgA, IgD, IgE, IgG, and IgM, and several of these may be further divided into “subclasses” (isotypes), e.g., IgG1, IgG2, IgG3, IgG4, IgA, and IgA2. The heavy-chain constant domains that correspond to the different classes of antibodies are called α, δ, ε, γ, and μ, respectively. The subunit structures and three-dimensional configurations of different classes of immunoglobulins are well known.
Antibody “effector functions” refer to those biological activities attributable to the Fc region (a native sequence Fc region or amino acid sequence variant Fc region) of an antibody. Examples of antibody effector functions include C1q binding; complement dependent cytotoxicity; Fc receptor binding; antibody-dependent cell-mediated cytotoxicity (ADCC); phagocytosis; down regulation of cell surface receptors (e.g. B cell receptor; BCR), etc.
“Antibody-dependent cell-mediated cytotoxicity” and “ADCC” refer to a cell-mediated reaction in which nonspecific cytotoxic cells that express Fc receptors (FcRs) (e.g. Natural Killer (NK) cells, neutrophils, and macrophages) recognize bound antibody on a target cell and subsequently cause lysis of the target cell. The primary cells for mediating ADCC, NK cells, express FcγRIII only, whereas monocytes express FcγRI, FcγRII and FcγRIII. FcR expression on hematopoietic cells is summarized in Table 3 on page 464 of Ravetch and Kinet, Annu. Rev. Immunol 9:457-92 (1991). To assess ADCC activity of a molecule of interest, an in vitro ADCC assay, such as that described in U.S. Pat. No. 5,500,362 or 5,821,337 may be performed. Useful effector cells for such assays include peripheral blood mononuclear cells (PBMC) and Natural Killer (NK) cells. Alternatively, or additionally, ADCC activity of the molecule of interest may be assessed in vivo, e.g., in a animal model such as that disclosed in Clynes et al. PNAS (USA) 95:652-656 (1998).
“Effector cells” are leukocytes which express one or more FcRs and perform effector functions. Preferably, the cells express at least FcγRIII and perform ADCC effector function. Examples of human leukocytes which mediate ADCC include peripheral blood mononuclear cells (PBMC), natural killer (NK) cells, monocytes, cytotoxic T cells and neutrophils; with PBMCs and NK cells being preferred. The effector cells may be isolated from a native source thereof, e.g. from blood or PBMCs as described herein.
The terms “Fc receptor” or “FcR” are used to describe a receptor that binds to the Fc region of an antibody. The preferred FcR is a native sequence human FcR. Moreover, a preferred FcR is one which binds an IgG antibody (a gamma receptor) and includes receptors of the FcγRI, FcγRII, and FcγRIII subclasses, including allelic variants and alternatively spliced forms of these receptors. FcγRII receptors include FcγRIIA (an “activating receptor”) and FcγRIIB (an “inhibiting receptor”), which have similar amino acid sequences that differ primarily in the cytoplasmic domains thereof. Activating receptor FcγRIIA contains an immunoreceptor tyrosine-based activation motif (ITAM) in its cytoplasmic domain. Inhibiting receptor FcγRIIB contains an immunoreceptor tyrosine-based inhibition motif (ITIM) in its cytoplasmic domain. (see review M. in Daëron, Annu. Rev. Immunol. 15:203-234 (1997)). FcRs are reviewed in Ravetch and Kinet, Annu. Rev. Immunol 9:457-92 (1991); Capel et al., Immunomethods 4:25-34 (1994); and de Haas et al., J. Lab. Clin. Med. 126:330-41 (1995). Other FcRs, including those to be identified in the future, are encompassed by the term “FcR” herein. The term also includes the neonatal receptor, FcRn, which is responsible for the transfer of maternal IgGs to the fetus (Guyer et al., J. Immunol. 117:587 (1976) and Kim et al., Eur. J. Immunol. 24:2429 (1994)).
“Complement dependent cytotoxicity” or “CDC” refers to the ability of a molecule to lyse a target in the presence of complement. The complement activation pathway is initiated by the binding of the first component of the complement system (C1q) to a molecule (e.g. an antibody) complexed with a cognate antigen. To assess complement activation, a CDC assay, e.g. as described in Gazzano-Santoro et al., J. Immunol. Methods 202:163 (1996), may be performed.
The term “variable” refers to the fact that certain portions of the variable domains differ extensively in sequence among antibodies and are used in the binding and specificity of each particular antibody for its particular antigen. However, the variability is not evenly distributed throughout the variable domains of antibodies. It is concentrated in three segments called hypervariable regions both in the light chain and the heavy chain variable domains. The more highly conserved portions of variable domains are called the framework regions (FRs). The variable domains of native heavy and light chains each comprise four FRs, largely adopting a β-sheet configuration, connected by three hypervariable regions, which form loops connecting, and in some cases forming part of, the 1-sheet structure. The hypervariable regions in each chain are held together in close proximity by the FRs and, with the hypervariable regions from the other chain, contribute to the formation of the antigen-binding site of antibodies (see Kabat et al., Sequences of Proteins of Immunological Interest, 5th Ed. Public Health Service, National Institutes of Health, Bethesda, Md. (1991)). The constant domains are not involved directly in binding an antibody to an antigen, but exhibit various effector functions, such as participation of the antibody in antibody dependent cellular cytotoxicity (ADCC).
The term “hypervariable region” when used herein refers to the amino acid residues of an antibody which are responsible for antigen-binding. The hypervariable region generally comprises amino acid residues from a “complementarity determining region” or “CDR” (e.g. residues 24-34 (L1), 50-56 (L2) and 89-97 (L3) in the light chain variable domain and 31-35 (H1), 50-65 (H2) and 95-102 (H3) in the heavy chain variable domain; Kabat et al., Sequences of Proteins of Immunological Interest, 5th Ed. Public Health Service, National Institutes of Health, Bethesda, Md. (1991)) and/or those residues from a “hypervariable loop” (e.g. residues 2632 (L1), 50-52 (L2) and 91-96 (L3) in the light chain variable domain and 26-32 (H1), 53-55 (H2) and 96-101 (H3) in the heavy chain variable domain; Chothia and Lesk J. Mol. Biol. 196:901-917 (1987)). “Framework Region” or “FR” residues are those variable domain residues other than the hypervariable region residues as herein defined. Papain digestion of antibodies produces two identical antigen-binding fragments, called “Fab” fragments, each with a single antigen-binding site, and a residual “Fc” fragment, whose name reflects its ability to crystallize readily. Pepsin treatment yields an F(ab′) 2 fragment that has two antigen-binding sites and is still capable of cross-linking antigen.
“Fv” is the minimum antibody fragment which contains a complete antigen-recognition and antigen-binding site. This region consists of a dimer of one heavy chain and one light chain variable domain in tight, non-covalent association. It is in this configuration that the three hypervariable regions of each variable domain interact to define an antigen-binding site on the surface of the V H -V L dimer. Collectively, the six hypervariable regions confer antigen-binding specificity to the antibody. However, even a single variable domain (or half of an Fv comprising only three hypervariable regions specific for an antigen) has the ability to recognize and bind antigen, although at a lower affinity than the entire binding site. The Fab fragment also contains the constant domain of the light chain and the first constant domain (CHI) of the heavy chain. Fab′ fragments differ from Fab fragments by the addition of a few residues at the carboxy terminus of the heavy chain CH1 domain including one or more cysteines from the antibody hinge region. Fab′-SH is the designation herein for Fab′ in which the cysteine residue(s) of the constant domains bear at least one free thiol group. F(ab′) 2 antibody fragments originally were produced as pairs of Fab′ fragments which have hinge cysteines between them. Other chemical couplings of antibody fragments are also known.
The “light chains” of antibodies from any vertebrate species can be assigned to one of two clearly distinct types, called kappa (κ) and lambda (λ), based on the amino acid sequences of their constant domains.
“Single-chain Fv” or “scFv” antibody fragments comprise the V H and V L domains of antibody, wherein these domains are present in a single polypeptide chain. Preferably, the Fv polypeptide further comprises a polypeptide linker between the V H and V L domains which enables the scFv to form the desired structure for antigen binding. For a review of scFv see Plückthun in The Pharmacology of Monoclonal Antibodies , vol. 113, Rosenburg and Moore eds., Springer-Verlag, New York, pp. 269-315 (1994).
The term “diabodies” refers to small antibody fragments with two antigen-binding sites, which fragments comprise a variable heavy domain (V H ) connected to a variable light domain (V L ) in the same polypeptide chain (V H -V L ). By using a linker that is too short to allow pairing between the two domains on the same chain, the domains are forced to pair with the complementary domains of another chain and create two antigen-binding sites. Diabodies are described more fully in, for example, EP 404,097; WO 93/11161; and Hollinger et al., Proc. Natl. Acad. Sci. USA, 90:6444-6448 (1993).
An “isolated” antibody is one which has been identified and separated and/or recovered from a component of its natural environment. Contaminant components of its natural environment are materials which would interfere with diagnostic or therapeutic uses for the antibody, and may include enzymes, hormones, and other proteinaceous or nonproteinaceous solutes. Isolated antibody includes the antibody in situ within recombinant cells since at least one component of the antibody's natural environment will not be present. Ordinarily, however, isolated antibody will be prepared by at least one purification step.
An antibody “which binds” an antigen of interest is one capable of binding that antigen with sufficient affinity such that the antibody is useful as a therapeutic or diagnostic agent in targeting a cell expressing the antigen. Where the antibody is one which binds the antigenic moiety it will usually preferentially bind that antigenic moiety as opposed to other receptors, and does not include incidental binding such as non-specific Fc contact, or binding to post-translational modifications common to other antigens and may be one which does not significantly cross-react with other proteins. Methods, for the detection of an antibody that binds an antigen of interest, are well known in the art and can include but are not limited to assays such as FACS, cell ELISA and Western blot.
As used herein, the expressions “cell”, “cell line”, and “cell culture” are used interchangeably, and all such designations include progeny. It is also understood that all progeny may not be precisely identical in DNA content, due to deliberate or inadvertent mutations. Mutant progeny that have the same function or biological activity as screened for in the originally transformed cell are included. It will be clear from the context where distinct designations are intended.
“Treatment or treating” refers to both therapeutic treatment and prophylactic or preventative measures, wherein the object is to prevent or slow down (lessen) the targeted pathologic condition or disorder. Those in need of treatment include those already with the disorder as well as those prone to have the disorder or those in whom the disorder is to be prevented. Hence, the mammal to be treated herein may have been diagnosed as having the disorder or may be predisposed or susceptible to the disorder.
The terms “cancer” and “cancerous” refer to or describe the physiological condition in mammals that is typically characterized by unregulated cell growth or death. Examples of cancer include, but are not limited to, carcinoma, lymphoma, blastoma, sarcoma, and leukemia or lymphoid malignancies. More particular examples of such cancers include squamous cell cancer (e.g. epithelial squamous cell cancer), lung cancer including small-cell lung cancer, non-small cell lung cancer, adenocarcinoma of the lung and squamous carcinoma of the lung, cancer of the peritoneum, hepatocellular cancer, gastric or stomach cancer including gastrointestinal cancer, pancreatic cancer, glioblastoma, cervical cancer, ovarian cancer, liver cancer, bladder cancer, hepatoma, breast cancer, colon cancer, rectal cancer, colorectal cancer, endometrial or uterine carcinoma, salivary gland carcinoma, kidney or renal cancer, prostate cancer, vulval cancer, thyroid cancer, hepatic carcinoma, anal carcinoma, penile carcinoma, as well as head and neck cancer.
A “chemotherapeutic agent” is a chemical compound useful in the treatment of cancer. Examples of chemotherapeutic agents include alkylating agents such as thiotepa and cyclosphosphamide (CYTOXAN™); alkyl sulfonates such as busulfan, improsulfan and piposulfan; aziridines such as benzodopa, carboquone, meturedopa, and uredopa; ethylenimines and methylamelamines including altretamine, triethylenemelamine, triethylenephosphoramide, triethylenethiophosphoramide and trimethylolomelamine; nitrogen mustards such as chlorambucil, chlomaphazine, cholophosphamide, estramustine, ifosfamide, mechlorethamine, mechlorethamine oxide hydrochloride, melphalan, novembichin, phenesterine, prednimustine, trofosfamide, uracil mustard; nitrosureas such as carmustine, chlorozotocin, fotemustine, lomustine, nimustine, ranimustine; antibiotics such as aclacinomysins, actinomycin, authramycin, azaserine, bleomycins, cactinomycin, calicheamicin, carabicin, carnomycin, carzinophilin, chromomycins, dactinomycin, daunorubicin, detorubicin, 6-diazo-5-oxo-L-norleucine, doxorubicin, epirubicin, esorubicin, idarubicin, marcellomycin, mitomycins, mycophenolic acid, nogalamycin, olivomycins, peplomycin, potfiromycin, puromycin, quelamycin, rodorubicin, streptonigrin, streptozocin, tubercidin, ubenimex, zinostatin, zorubicin; anti-metabolites such as methotrexate and 5-fluorouracil (5-FU); folic acid analogues such as denopterin, methotrexate, pteropterin, trimetrexate; purine analogs such as fludarabine, 6-mercaptopurine, thiamiprine, thioguanine; pyrimidine analogs such as ancitabine, azacitidine, 6-azauridine, carmofur, cytarabine, dideoxyuridine, doxifluridine, enocitabine, floxuridine, 5-FU; androgens such as calusterone, dromostanolone propionate, epitiostanol, mepitiostane, testolactone; anti-adrenals such as aminoglutethimide, mitotane, trilostane; folic acid replenisher such as frolinic acid; aceglatone; aldophosphamide glycoside; aminolevulinic acid; amsacrine; bestrabucil; bisantrene; edatraxate; defofamine; demecolcine; diaziquone; elformithine; elliptinium acetate; etoglucid; gallium nitrate; hydroxyurea; lentinan; lonidamine; mitoguazone; mitoxantrone; mopidamol; nitracrine; pentostatin; phenamet; pirarubicin; podophyllinic acid; 2-ethylhydrazide; procarbazine; PSK®; razoxane; sizofuran; spirogermanium; tenuazonic acid; triaziquone; 2,2′,2″-trichlorotriethylamine; urethan; vindesine; dacarbazine; mannomustine; mitobronitol; mitolactol; pipobroman; gacytosine; arabinoside (“Ara-C”); cyclophosphamide; thiotepa; taxanes, e.g. paclitaxel (TAXOL®, Bristol-Myers Squibb Oncology, Princeton, N.J.) and docetaxel (TAXOTERE®, Aventis, Rhone-Poulenc Rorer, Antony, France); chlorambucil; gemcitabine; 6-thioguanine; mercaptopurine; methotrexate; platinum analogs such as cisplatin and carboplatin; vinblastine; platinum; etoposide (VP-16); ifosfamide; mitomycin C; mitoxantrone; vincristine; vinorelbine; navelbine; novantrone; teniposide; daunomycin; aminopterin; xeloda; ibandronate; CPT-11; topoisomerase inhibitor RFS 2000; difluoromethylornithine (DMFO); retinoic acid; esperamicins; capecitabine; and pharmaceutically acceptable salts, acids or derivatives of any of the above. Also included in this definition are anti-hormonal agents that act to regulate or inhibit hormone action on tumors such as anti-estrogens including for example tamoxifen, raloxifene, aromatase inhibiting 4(5)-imidazoles, 4-hydroxytamoxifen, trioxifene, keoxifene, LY117018, onapristone, and toremifene (Fareston); and anti-androgens such as flutamide, nilutamide, bicalutamide, leuprolide, and goserelin; and pharmaceutically acceptable salts, acids or derivatives of any of the above.
“Mammal” for purposes of treatment refers to any animal classified as a mammal, including humans, mice, SCID or nude mice or strains of mice, domestic and farm animals, and zoo, sports, or pet animals, such as sheep, dogs, horses, cats, cows, etc. Preferably, the mammal herein is human.
“Oligonucleotides” are short-length, single- or double-stranded polydeoxynucleotides that are chemically synthesized by known methods (such as phosphotriester, phosphite, or phosphoramidite chemistry, using solid phase techniques such as described in EP 266,032, published 4 May 1988, or via deoxynucleoside H-phosphonate intermediates as described by Froehler et al., Nucl. Acids Res., 14:5399-5407, 1986. They are then purified on polyacrylamide gels.
In accordance with the present invention, “humanized” and/or “chimeric” forms of non-human (e.g. murine) immunoglobulins refer to antibodies which contain specific chimeric immunoglobulins, immunoglobulin chains or fragments thereof (such as Fv, Fab, Fab′, F(ab′) 2 or other antigen-binding subsequences of antibodies) which results in the decrease of a human anti-mouse antibody (HAMA), human anti-chimeric antibody (HACA) or a human anti-human antibody (HAHA) response, compared to the original antibody, and contain the requisite portions (e.g. CDR(s), antigen binding region(s), variable domain(s) and so on) derived from said non-human immunoglobulin, necessary to reproduce the desired effect, while simultaneously retaining binding characteristics which are comparable to said non-human immunoglobulin. For the most part, humanized antibodies are human immunoglobulins (recipient antibody) in which residues from the complementarity determining regions (CDRs) of the recipient antibody are replaced by residues from the CDRs of a non-human species (donor antibody) such as mouse, rat or rabbit having the desired specificity, affinity and capacity. In some instances, Fv framework region (FR) residues of the human immunoglobulin are replaced by corresponding non-human FR residues. Furthermore, the humanized antibody may comprise residues which are found neither in the recipient antibody nor in the imported CDR or FR sequences. These modifications are made to further refine and optimize antibody performance. In general, the humanized antibody will comprise substantially all of at least one, and typically two, variable domains, in which all or substantially all of the CDR regions correspond to those of a non-human immunoglobulin and all or substantially all of the FR residues are those of a human immunoglobulin consensus sequence. The humanized antibody optimally also will comprise at least a portion of an immunoglobulin constant region (Fc), typically that of a human immunoglobulin.
“De-immunized” antibodies are immunoglobulins that are non-immunogenic, or less immunogenic, to a given species. De-immunization can be achieved through structural alterations to the antibody. Any de-immunization technique known to those skilled in the art can be employed. One suitable technique for de-immunizing antibodies is described, for example, in WO 00/34317 published Jun. 15, 2000.
An antibody which induces “apoptosis” is one which induces programmed cell death by any means, illustrated by but not limited to binding of annexin V, caspase activity, fragmentation of DNA, cell shrinkage, dilation of endoplasmic reticulum, cell fragmentation, and/or formation of membrane vesicles (called apoptotic bodies).
As used herein “antibody induced cytotoxicity” is understood to mean the cytotoxic effect derived from the hybridoma supernatant or antibody produced by the hybridoma deposited with the IDAC as accession number 180706-02 which effect is not necessarily related to the degree of binding.
Throughout the instant specification, hybridoma cell lines, as well as the isolated monoclonal antibodies which are produced therefrom, are alternatively referred to by their internal designation, AR51A165.2 or Depository Designation, IDAC 180706-02.
As used herein “antibody-ligand” includes a moiety which exhibits binding specificity for at least one epitope of the target antigen, and which may be an intact antibody molecule, antibody fragments, and any molecule having at least an antigen-binding region or portion thereof (i.e., the variable portion of an antibody molecule), e.g., an Fv molecule, Fab molecule, Fab′ molecule, F(ab′).sub.2 molecule, a bispecific antibody, a fusion protein, or any genetically engineered molecule which specifically recognizes and binds at least one epitope of the antigen bound by the isolated monoclonal antibody produced by the hybridoma cell line designated as IDAC 180706-02 (the IDAC 180706-02 antigen).
As used herein “cancerous disease modifying antibodies” (CDMAB) refers to monoclonal antibodies which modify the cancerous disease process in a manner which is beneficial to the patient, for example by reducing tumor burden or prolonging survival of tumor bearing individuals, and antibody-ligands thereof.
As used herein “antigen-binding region” means a portion of the molecule which recognizes the target antigen.
As used herein “competitively inhibits” means being able to recognize and bind a determinant site to which the monoclonal antibody produced by the hybridoma cell line designated as IDAC 180706-02, (the IDAC 180706-02 antibody) is directed using conventional reciprocal antibody competition assays. (Belanger L., Sylvestre C. and Dufour D. (1973), Enzyme linked immunoassay for alpha fetoprotein by competitive and sandwich procedures. Clinica Chimica Acta 48, 15).
As used herein “target antigen” is the IDAC 180706-02 antigen or portions thereof.
As used herein, an “immunoconjugate” means any molecule or CDMAB such as an antibody chemically or biologically linked to a cytotoxin, a radioactive agent, enzyme, toxin, an anti-tumor drug or a therapeutic agent. The antibody or CDMAB may be linked to the cytotoxin, radioactive agent, anti-tumor drug or therapeutic agent at any location along the molecule so long as it is able to bind its target. Examples of immunoconjugates include antibody toxin chemical conjugates and antibody-toxin fusion proteins.
As used herein, a “fusion protein” means any chimeric protein wherein an antigen binding region is connected to a biologically active molecule, e.g., toxin, enzyme, or protein drug.
In order that the invention herein described may be more fully understood, the following description is set forth.
The present invention provides CDMABs (i.e., IDAC 180706-02 CDMAB) which specifically recognize and bind the IDAC 180706-02 antigen.
The CDMAB of the isolated monoclonal antibody produced by the hybridoma deposited with the IDAC as accession number 180706-02 may be in any form as long as it has an antigen-binding region which competitively inhibits the immunospecific binding of the isolated monoclonal antibody produced by hybridoma IDAC 180706-02 to its target antigen. Thus, any recombinant proteins (e.g., fusion proteins wherein the antibody is combined with a second protein such as a lymphokine or a tumor inhibitory growth factor) having the same binding specificity as the IDAC 180706-02 antibody fall within the scope of this invention.
In one embodiment of the invention, the CDMAB is the IDAC 180706-02 antibody.
In other embodiments, the CDMAB is an antigen binding fragment which may be a Fv molecule (such as a single-chain Fv molecule), a Fab molecule, a Fab′ molecule, a F(ab′)2 molecule, a fusion protein, a bispecific antibody, a heteroantibody or any recombinant molecule having the antigen-binding region of the IDAC 180706-02 antibody. The CDMAB of the invention is directed to the epitope to which the IDAC 180706-02 monoclonal antibody is directed.
The CDMAB of the invention may be modified, i.e., by amino acid modifications within the molecule, so as to produce derivative molecules. Chemical modification may also be possible.
Derivative molecules would retain the functional property of the polypeptide, namely, the molecule having such substitutions will still permit the binding of the polypeptide to the IDAC 180706-02 antigen or portions thereof.
These amino acid substitutions include, but are not necessarily limited to, amino acid substitutions known in the art as “conservative”.
For example, it is a well-established principle of protein chemistry that certain amino acid substitutions, entitled “conservative amino acid substitutions,” can frequently be made in a protein without altering either the conformation or the function of the protein.
Such changes include substituting any of isoleucine (I), valine (V), and leucine (L) for any other of these hydrophobic amino acids; aspartic acid (D) for glutamic acid (E) and vice versa; glutamine (Q) for asparagine (N) and vice versa; and serine (S) for threonine (T) and vice versa. Other substitutions can also be considered conservative, depending on the environment of the particular amino acid and its role in the three-dimensional structure of the protein. For example, glycine (G) and alanine (A) can frequently be interchangeable, as can alanine and valine (V). Methionine (M), which is relatively hydrophobic, can frequently be interchanged with leucine and isoleucine, and sometimes with valine. Lysine (K) and arginine (R) are frequently interchangeable in locations in which the significant feature of the amino acid residue is its charge and the differing pK's of these two amino acid residues are not significant. Still other changes can be considered “conservative” in particular environments.
EXAMPLE 1
Hybridoma Production
Hybridoma Cell Line AR51A165.2
The hybridoma cell line AR51A165.2 was deposited, in accordance with the Budapest Treaty, with the International Depository Authority of Canada (IDAC), Bureau of Microbiology, Health Canada, 1015 Arlington Street, Winnipeg, Manitoba, Canada, R3E 3R2, on Jul. 18, 2006, under Accession Number 180706-02. In accordance with 37 CFR 1.808, the depositors assure that all restrictions imposed on the availability to the public of the deposited materials will be irrevocably removed upon the granting of a patent. The deposit will be replaced if the depository cannot dispense viable samples.
To produce the hybridoma that produces the anti-cancer antibody AR51A165.2, a single cell suspension of frozen endometroid adenocarcinoma tumor tissue (Genomics Collaborative, Cambridge, Mass.) was prepared in PBS. IMMUNEASY™ (Qiagen, Venlo, Netherlands) adjuvant was prepared for use by gentle mixing. Five to seven week old BALB/c mice were immunized by injecting subcutaneously, 2 million cells in 50 microliters of the antigen-adjuvant. Recently prepared antigen-adjuvant was used to boost the immunized mice intraperitoneally, 2 and 5 weeks after the initial immunization, with 2 million cells in 50-60 microliters. A spleen was used for fusion three days after the last immunization. The hybridomas were prepared by fusing the isolated splenocytes with NSO-1 myeloma partners. The supernatants from the fusions were tested from subclones of the hybridomas.
To determine whether the antibodies secreted by the hybridoma cells are of the IgG or IgM isotype, an ELISA assay was employed. 100 microliters/well of goat anti-mouse IgG+IgM (H+L) at a concentration of 2.4 micrograms/mL in coating buffer (0.1 M carbonate/bicarbonate buffer, pH 9.2-9.6) at 4° C. was added to the ELISA plates overnight. The plates were washed thrice in washing buffer (PBS+0.05 percent Tween). 100 microliters/well blocking buffer (5 percent milk in wash buffer) was added to the plate for 1 hour at room temperature and then washed thrice in washing buffer. 100 microliters/well of hybridoma supernatant was added and the plate incubated for 1 hour at room temperature. The plates were washed thrice with washing buffer and 1/100,000 dilution of either goat anti-mouse IgG or IgM horseradish peroxidase conjugate (diluted in PBS containing 1 percent milk), 100 microliters/well, was added. After incubating the plate for 1 hour at room temperature the plate was washed thrice with washing buffer. 100 microliters/well of TMB solution was incubated for 1-3 minutes at room temperature. The color reaction was terminated by adding 50 microliters/well 2M H 2 SO 4 and the plate was read at 450 nm with a Perkin-Elmer HTS7000 plate reader. As indicated in FIG. 1 , the AR51A165.2 hybridoma secreted primarily antibodies of the IgG isotype.
To determine the subclass of antibody secreted by the hybridoma cells, an isotyping experiment was performed using a Mouse Monoclonal Antibody Isotyping Kit (HyCult Biotechnology, Frontstraat, Netherlands). 500 microliters of buffer solution was added to the test strip containing rat anti-mouse subclass specific antibodies. 500 microliters of hybridoma supernatant was added to the test tube, and submerged by gentle agitation. Captured mouse immunoglobulins were detected directly by a second rat monoclonal antibody which is coupled to colloid particles. The combination of these two proteins creates a visual signal used to analyse the isotype. The anti-cancer antibody AR51A165.2 is of the IgG1, kappa isotype.
After one round of limiting dilution, hybridoma supernatants were tested for antibodies that bound to target cells in a cell ELISA assay. Two human ovarian cancer cell lines and 1 human normal skin cell line were tested: OCC-1, OVCAR-3 and CCD-27sk respectively. All cell lines were obtained from the American Type Tissue Collection (ATCC; Manassas, Va.). The plated cells were fixed prior to use. The plates were washed thrice with PBS containing MgCl 2 and CaCl 2 at room temperature. 100 microliters of 2 percent paraformaldehyde diluted in PBS was added to each well for 10 minutes at room temperature and then discarded. The plates were again washed with PBS containing MgCl 2 and CaCl 2 three times at room temperature. Blocking was done with 100 microliters/well of 5 percent milk in wash buffer (PBS+0.05 percent Tween) for 1 hour at room temperature. The plates were washed thrice with wash buffer and the hybridoma supernatant was added at 100 microliters/well for 1 hour at room temperature. The plates were washed 3 times with wash buffer and 100 microliters/well of 1/25,000 dilution of goat anti-mouse IgG antibody conjugated to horseradish peroxidase (diluted in PBS containing 1 percent milk) was added. After 1 hour incubation at room temperature the plates were washed 3 times with wash buffer and 100 microliter/well of TMB substrate was incubated for 1-3 minutes at room temperature. The reaction was terminated with 50 microliters/well 2M H 2 SO 4 and the plate read at 450 nm with a Perkin-Elmer HTS7000 plate reader. The results as tabulated in FIG. 1 were expressed as the number of folds above background compared to an in-house IgG isotype control that has previously been shown not to bind to the cell lines tested. The antibodies from the hybridoma AR51A165.2 showed detectable binding to the cell lines tested.
In conjunction with testing for antibody binding, the cytotoxic effect of the hybridoma supernatants (antibody induced cytotoxicity) was tested in the cell lines: OCC-1, OVCAR-3 and CCD-27sk. Calcein AM was obtained from Molecular Probes (Eugene, Oreg.) and the assay was performed as outlined below. Cells were plated before the assay at the predetermined appropriate density. After 2 days, 100 microliters of supernatant from the hybridoma microtitre plates were transferred to the cell plates and incubated in a 5 percent CO 2 incubator for 5 days. The wells that served as the positive controls were aspirated until empty and 100 microliters of sodium azide (NaN 3 , 0.01 percent, Sigma, Oakville, ON), cycloheximide (CHX, 0.5 micromolar, Sigma, Oakville, ON) or anti-EGFR antibody (c225, IgG1, kappa, 5 micrograms/mL, Cedarlane, Homby, ON) dissolved in culture medium, was added. After 5 days of treatment, the plates were then emptied by inverting and blotting dry. Room temperature DPBS (Dulbecco's phosphate buffered saline) containing MgCl 2 and CaCl 2 was dispensed into each well from a multichannel squeeze bottle, tapped 3 times, emptied by inversion and then blotted dry. 50 microliters of the fluorescent calcein dye diluted in DPBS containing MgCl 2 and CaCl 2 was added to each well and incubated at 37° C. in a 5 percent CO 2 incubator for 30 minutes. The plates were read in a Perkin-Elmer HTS7000 fluorescence plate reader and the data was analyzed in Microsoft Excel. The results are tabulated in FIG. 1 . Supernatant from the AR51A165.2 hybridoma produced specific cytotoxicity of 23 percent on the OCC-1 cells. This was 27 and 24 percent of the cytotoxicity obtained with the positive controls sodium azide and cycloheximide, respectively.
Results from FIG. 1 demonstrate that the cytotoxic effects of AR51A165.2 were not proportional to the binding levels on the cancer cell types. There was detectable binding on the three cell lines tested and cytotoxicity associated with only OCC-1. As tabulated in FIG. 1 , AR51A165.2 did not produce cytotoxicity in the CCD-27sk normal human skin cell line. The known non-specific cytotoxic agents cycloheximide and NaN 3 generally produced cytotoxicity as expected. The anti-EGFR antibody c225 produced cytotoxicity as expected on SW 1116.
EXAMPLE 2
In Vitro Binding
AR51A165.2 monoclonal antibody was produced by culturing the hybridoma in CL-1000 flasks (BD Biosciences, Oakville, ON) with collections and reseeding occurring twice/week. Standard antibody purification procedures with Protein G Sepharose 4 Fast Flow (Amersham Biosciences, Baie d'Urfé, QC) were followed. It is within the scope of this invention to utilize monoclonal antibodies that are de-immunized, humanized, chimerized or murine.
Binding of AR51A165.2 to prostate (PC-3 and DU-145), colon (DLD-1, Lovo and SW 116), pancreatic (BxPC-3, PL-45 and AsPC-1), lung (A549), ovarian (OVCAR-3, ES-2, A2780-cp, A2780-s, C-13, Hey, OV2008 and OVCA-429) and breast (MDA-MB-231 and MCF-7) cancer, and non-cancer cell lines from skin (CCD-27sk) and lung (Hs888.Lu) was assessed by flow cytometry (FACS). All cell lines, except for the majority of the ovarian cancer cell lines, were obtained from the American Type Tissue Collection (ATCC; Manassas, Va.). A2780-cp, A2780-s, C-13, OV2008, ES-2, Hey, OVCA-429 were obtained from the Ottawa Regional Cancer Center (Ottawa, ON).
Cells were prepared for FACS by initially washing the cell monolayer with DPBS (without Ca ++ and Mg ++ ). Cell dissociation buffer (Invitrogen, Burlington, ON) was then used to dislodge the cells from their cell culture plates at 37° C. After centrifugation and collection, the cells were resuspended in DPBS containing MgCl 2 , CaCl 2 and 2 percent fetal bovine serum at 4° C. (staining media) and counted, aliquoted to appropriate cell density, spun down to pellet the cells and resuspended in staining media at 4° C. in the presence of the test antibody (AR51A165.2) or control antibodies (isotype control, anti-EGFR). Isotype control and the test antibody were assessed at 20 micrograms/mL whereas anti-EGFR was assessed at 5 micrograms/mL on ice for 30 minutes. Prior to the addition of Alexa Fluor 546-conjugated secondary antibody the cells were washed once with staining media. The Alexa Fluor 546-conjugated antibody in staining media was then added for 30 minutes at 4° C. The cells were then washed for the final time and resuspended in fixing media (staining media containing 1.5 percent paraformaldehyde). Flow cytometric acquisition of the cells was assessed by running samples on a FACSarray™ using the FACSarray™ System Software (BD Biosciences, Oakville, ON). The forward (FSC) and side scatter (SSC) of the cells were set by adjusting the voltage and amplitude gains on the FSC and SSC detectors. The detectors for the fluorescence (Alexa-546) channel was adjusted by running unstained cells such that cells had a uniform peak with a median fluorescent intensity of approximately 1-5 units. For each sample, approximately 10,000 gated events (stained fixed cells) were acquired for analysis and the results are presented in FIG. 2 .
FIG. 2 presents the mean fluorescence intensity fold increase above isotype control. Representative histograms of AR51A165.2 antibodies were compiled for FIG. 3 . AR51A165.2 demonstrated binding to the many of the cell lines tested. There was very strong binding to the colon DLD-1 (168.6-fold) cancer cell line and strong binding to the ovarian ES-2 (30.9-fold), C-13 (18.0-fold) and OV2008 (22.6-fold) cancer cell lines. There was not any detectable binding to the breast cancer cell line MDA-MB-231. There was moderate binding to the rest of the cell lines. These data demonstrate that AR51A165.2 bound to several different cell lines with higher antigen expression on certain colon and ovarian cancer cell lines.
EXAMPLE 3
In Vivo Tumor Experiments with BxPC-3 Cells
Examples 1 and 2 demonstrated that AR51A165.2 had anti-cancer properties against a human cancer cell line with detectable binding across several different cancer indications. With reference to FIGS. 4 and 5 , 4 to 6 week old female SCID mice were implanted with 5 million human pancreatic cancer cells (BxPC-3) in 100 microliters saline injected subcutaneously in the scruff of the neck. The mice were randomly divided into 2 treatment groups of 5. On the day after implantation, 20 mg/kg of AR51A165.2 test antibody or buffer control was administered intraperitoneally to each cohort in a volume of 300 microliters after dilution from the stock concentration with a diluent that contained 2.7 mM KCl, 1 mM KH 2 PO 4 , 137 mM NaCl and 20 mM Na 2 HPO 4 . The antibody and control samples were then administered once per week for the duration of the study in the same fashion. Tumor growth was measured about every seventh day with calipers. The study was completed after 8 injections of antibody. Body weights of the animals were recorded once per week for the duration of the study. At the end of the study all animals were euthanized according to CCAC guidelines.
AR51A165.2 reduced tumor growth in the BxPC-3 in vivo prophylactic model of human pancreatic cancer. Treatment with ARIUS antibody AR51A165.2 reduced the growth of BxPC-3 tumors by 65 percent (p=0.035), compared to the buffer treated group, as determined on day 52, 2 days after the last dose of antibody ( FIG. 1 ). At the end of the study (Day 61), treatment with AR51A165.2 resulted in a tumor growth inhibition of 66 percent (p=0.0375; FIG. 4 ). These in vivo results, in conjunction with the results presented in Example 2, demonstrate that AR51A165.2 is able to bind to the BxPC-3 cell line, as well as induce cytotoxicity in a pancreatic cancer xenograft model.
There were no clinical signs of toxicity throughout the study. Body weight measured at weekly intervals was a surrogate for well-being and failure to thrive. The mean body weight increased in all groups over the duration of the study ( FIG. 5 ). The mean weight gain between day 1 and day 61 was 3.6 g in the control group and 3.2 g in the AR51A165.2 treated group. There were no significant differences between groups at the end of the treatment period.
In summary, AR51A165.2 was well-tolerated and decreased the tumor burden in this human pancreatic cancer xenograft model.
EXAMPLE 4
In Vivo Tumor Experiments with MDA-MB-231 Cells
Results from Example 3 were extended to a different model of human cancer. With reference to FIGS. 6 and 7 , 4 to 6 week old female SCID mice were implanted with 5 million human breast cancer cells (MDA-MB-231) in 100 microliters saline injected subcutaneously in the scruff of the neck. The mice were randomly divided into 2 treatment groups of 5. On the day after implantation, 20 mg/kg of AR51A165.2 test antibody or buffer control was administered intraperitoneally to each cohort in a volume of 300 microliters after dilution from the stock concentration with a diluent that contained 2.7 mM KCl, 1 mM KH 2 PO 4 , 137 mM NaCl and 20 mM Na 2 HPO 4 . The antibody and control samples were then administered once per week for the duration of the study in the same fashion. Tumor growth was measured about every seventh day with calipers. The study was completed after 8 injections of antibody. Body weights of the animals were recorded once per week for the duration of the study. At the end of the study all animals were euthanized according to CCAC guidelines.
AR51A165.2 reduced tumor growth in the MDA-MB-231 in vivo prophylactic model of human breast cancer. Results for the tumor growth inhibition study are shown in FIG. 6 . At day 56, the first measurement after the last treatment on day 50, AR51A165.2 decreased tumor growth by 67 percent (p=0.18) in this model of human breast cancer. This result failed to reach significance, likely due to the limited number of animals in each group in this study. From Example 2, it is evident that the binding of AR51A165.2 to the MDA-MB-231 cell line is not detectable using FACS. Nevertheless, the antibody was able to reduce the tumor growth in a MDA-MB-231 xenograft model. The efficacy may be due to either of 2 factors. It is possible that the MDA-MB-231 cell line expresses the antigen target at a level below the threshold of detection by FACS under these conditions, but that the low level of expression is sufficient to trigger an event leading to delayed tumor growth. It is also possible that antigen expression is induced when the MDA-MB-231 cells are placed into the more physiological in vivo environment. In either case, the efficacy of this antibody in a MDA-MB-231 colon cancer model is a non-obvious finding that could not have been predicted on the basis of binding.
There were no clinical signs of toxicity throughout the study. Body weight measured at weekly intervals was a surrogate for well-being and failure to thrive. There was a significant increase in body weight for both groups during the course of the study ( FIG. 7 ). At the end of the treatment period, there were no significant differences in body weights between control and antibody treated groups.
In summary, AR51A165.2 was well-tolerated and decreased the tumor burden in this human breast cancer xenograft model.
EXAMPLE 5
Isolation of Competitive Binders
Given an antibody, an individual ordinarily skilled in the art can generate a competitively inhibiting CDMAB, for example a competing antibody, which is one that recognizes the same epitope (Belanger L et al. Clinica Chimica Acta 48:15-18 (1973)). One method entails immunizing with an immunogen that expresses the antigen recognized by the antibody. The sample may include but is not limited to tissues, isolated protein(s) or cell line(s). Resulting hybridomas could be screened using a competition assay, which is one that identifies antibodies that inhibit the binding of the test antibody, such as ELISA, FACS or Western blotting. Another method could make use of phage display antibody libraries and panning for antibodies that recognize at least one epitope of said antigen (Rubinstein J L et al. Anal Biochem 314:294-300 (2003)). In either case, antibodies are selected based on their ability to displace the binding of the original labeled antibody to at least one epitope of its target antigen. Such antibodies would therefore possess the characteristic of recognizing at least one epitope of the antigen as the original antibody.
EXAMPLE 6
Cloning of the Variable Regions of the AR51A165.2 Monoclonal Antibody
The sequences of the variable regions from the heavy (V.H) and light (V.L) chains of monoclonal antibody produced by the AR51A165.2 hybridoma cell line can be determined. RNA encoding the heavy and light chains of immunoglobulin can be extracted from the subject hybridoma using standard methods involving cellular solubilization with guanidinium isothiocyanate (Chirgwin et al. Biochem. 18:5294-5299 (1979)). The mRNA can be used to prepare cDNA for subsequent isolation of V.H and V.L genes by PCR methodology known in the art (Sambrook et al., eds., Molecular Cloning, Chapter 14, Cold Spring Harbor laboratories Press, N.Y. (1989)). The N-terminal amino acid sequence of the heavy and light chains can be independently determined by automated Edman sequencing. Further stretches of the CDRs and flanking FRs can also be determined by amino acid sequencing of the V.H and V.L fragments. Synthetic primers can be then designed for isolation of the V.H and V.L genes from AR51A165.2 monoclonal antibody, and the isolated gene can be ligated into an appropriate vector for sequencing. To generate chimeric and humanized IgG, the variable light and variable heavy domains can be subcloned into an appropriate vector for expression.
(i) Monoclonal Antibody
DNA encoding the monoclonal antibody (as outlined in Example 1) is readily isolated and sequenced using conventional procedures (e.g., by using oligonucleotide probes that are capable of binding specifically to genes encoding the heavy and light chains of the monoclonal antibodies). The hybridoma cell serves as a preferred source of such DNA. Once isolated, the DNA may be placed into expression vectors, which are then transfected into host cells such as E. coli cells, simian COS cells, Chinese hamster ovary (CHO) cells, or myeloma cells that do not otherwise produce immunoglobulin protein, to obtain the synthesis of monoclonal antibodies in the recombinant host cells. The DNA also may be modified, for example, by substituting the coding sequence for human heavy and light chain constant domains in place of the homologous murine sequences. Chimeric or hybrid antibodies also may be prepared in vitro using known methods in synthetic protein chemistry, including those involving crosslinking agents. For example, immunotoxins may be constructed using a disulfide exchange reaction or by forming a thioether bond. Examples of suitable reagents for this purpose include iminothiolate and methyl-4-mercaptobutyrimidate.
(ii) Humanized Antibody
A humanized antibody has one or more amino acid residues introduced into it from a non-human source. These non-human amino acid residues are often referred to as “import” residues, which are typically taken from an “import” variable domain. Humanization can be performed the method of Winter and co-workers by substituting rodent CDRs or CDR sequences for the corresponding sequences of a human antibody (Jones et al., Nature 321:522-525 (1986); Riechmann et al., Nature 332:323-327 (1988); Verhoeyen et al., Science 239:1534-1536 (1988); reviewed in Clark, Immunol. Today 21:397-402 (2000)).
A humanized antibody can be prepared by a process of analysis of the parental sequences and various conceptual humanized products using three-dimensional models of the parental and humanized sequences. Three dimensional immunoglobulin models are commonly available and are familiar to those skilled in the art. Computer programs are available which illustrate and display probable three-dimensional conformational structures of selected candidate immunoglobulin sequences. Inspection of these displays permits analysis of the likely role of the residues in the functioning of the candidate immunoglobulin sequence, i.e. the analysis of residues that influence the ability of the candidate immunoglobulin to bind its antigen. In this way, FR residues can be selected and combined from the consensus and import sequence so that the desired antibody characteristic, such as increased affinity for the target antigen(s), is achieved. In general, the CDR residues are directly and most substantially involved in influencing antigen binding.
(iii) Antibody Fragments
Various techniques have been developed for the production of antibody fragments. These fragments can be produced by recombinant host cells (reviewed in Hudson, Curr. Opin. Immunol. 11:548-557 (1999); Little et al., Immunol. Today 21:364-370 (2000)). For example, Fab′-SH fragments can be directly recovered from E. coli and chemically coupled to form F(ab′) 2 fragments (Carter et al., Biotechnology 10:163-167 (1992)). In another embodiment, the F(ab′) 2 is formed using the leucine zipper GCN4 to promote assembly of the F(ab′) 2 molecule. According to another approach, Fv, Fab or F(ab′) 2 fragments can be isolated directly from recombinant host cell culture.
EXAMPLE 7
A Composition Comprising the Antibody of the Present Invention
The antibody of the present invention can be used as a composition for preventing/treating cancer. The composition for preventing/treating cancer, which comprises the antibody of the present invention, are low-toxic and can be administered as they are in the form of liquid preparations, or as pharmaceutical compositions of suitable preparations to human or mammals (e.g., rats, rabbits, sheep, swine, bovine, feline, canine, simian, etc.) orally or parenterally (e.g., intravascularly, intraperitoneally, subcutaneously, etc.). The antibody of the present invention may be administered in itself, or may be administered as an appropriate composition. The composition used for the administration may contain a pharmacologically acceptable carrier with the antibody of the present invention or its salt, a diluent or excipient. Such a composition is provided in the form of pharmaceutical preparations suitable for oral or parenteral administration.
Examples of the composition for parenteral administration are injectable preparations, suppositories, etc. The injectable preparations may include dosage forms such as intravenous, subcutaneous, intracutaneous and intramuscular injections, drip infusions, intraarticular injections, etc. These injectable preparations may be prepared by methods publicly known. For example, the injectable preparations may be prepared by dissolving, suspending or emulsifying the antibody of the present invention or its salt in a sterile aqueous medium or an oily medium conventionally used for injections. As the aqueous medium for injections, there are, for example, physiological saline, an isotonic solution containing glucose and other auxiliary agents, etc., which may be used in combination with an appropriate solubilizing agent such as an alcohol (e.g., ethanol), a polyalcohol (e.g., propylene glycol, polyethylene glycol), a nonionic surfactant [e.g., polysorbate 80, HCO-50 (polyoxyethylene (50 mols) adduct of hydrogenated castor oil)], etc. As the oily medium, there are employed, e.g., sesame oil, soybean oil, etc., which may be used in combination with a solubilizing agent such as benzyl benzoate, benzyl alcohol, etc. The injection thus prepared is usually filled in an appropriate ampoule. The suppository used for rectal administration may be prepared by blending the antibody of the present invention or its salt with conventional bases for suppositories. The composition for oral administration includes solid or liquid preparations, specifically, tablets (including dragees and film-coated tablets), pills, granules, powdery preparations, capsules (including soft capsules), syrup, emulsions, suspensions, etc. Such a composition is manufactured by publicly known methods and may contain a vehicle, a diluent or excipient conventionally used in the field of pharmaceutical preparations. Examples of the vehicle or excipient for tablets are lactose, starch, sucrose, magnesium stearate, etc.
Advantageously, the compositions for oral or parenteral use described above are prepared into pharmaceutical preparations with a unit dose suited to fit a dose of the active ingredients. Such unit dose preparations include, for example, tablets, pills, capsules, injections (ampoules), suppositories, etc. The amount of the aforesaid compound contained is generally 5 to 500 mg per dosage unit form; it is preferred that the antibody described above is contained in about 5 to about 100 mg especially in the form of injection, and in 10 to 250 mg for the other forms.
The dose of the aforesaid prophylactic/therapeutic agent or regulator comprising the antibody of the present invention may vary depending upon subject to be administered, target disease, conditions, route of administration, etc. For example, when used for the purpose of treating/preventing, e.g., breast cancer in an adult, it is advantageous to administer the antibody of the present invention intravenously in a dose of about 0.01 to about 20 mg/kg body weight, preferably about 0.1 to about 10 mg/kg body weight and more preferably about 0.1 to about 5 mg/kg body weight, about 1 to 5 times/day, preferably about 1 to 3 times/day. In other parenteral and oral administration, the agent can be administered in a dose corresponding to the dose given above. When the condition is especially severe, the dose may be increased according to the condition.
The antibody of the present invention may be administered as it stands or in the form of an appropriate composition. The composition used for the administration may contain a pharmacologically acceptable carrier with the aforesaid antibody or its salts, a diluent or excipient. Such a composition is provided in the form of pharmaceutical preparations suitable for oral or parenteral administration (e.g., intravascular injection, subcutaneous injection, etc.).Each composition described above may further contain other active ingredients. Furthermore, the antibody of the present invention may be used in combination with other drugs, for example, alkylating agents (e.g., cyclophosphamide, ifosfamide, etc.), metabolic antagonists (e.g., methotrexate, 5-fluorouracil, etc.), antitumor antibiotics (e.g., mitomycin, adriamycin, etc.), plant-derived antitumor agents (e.g., vincristine, vindesine, TAXOL® (paclitaxel), etc.), cisplatin, carboplatin, etoposide, irinotecan, etc. The antibody of the present invention and the drugs described above may be administered simultaneously or at staggered times to the patient.
The preponderance of evidence shows that AR51A165.2 mediates anti-cancer effects through ligation of an epitope present on cancer cell lines. Further it could be shown that the AR51A165.2 antibody could be used in detection of cells which express the epitope which specifically binds thereto; utilizing techniques illustrated by, but not limited to FACS, cell ELISA or IHC.
All patents and publications mentioned in this specification are indicative of the levels of those skilled in the art to which the invention pertains. All patents and publications are herein incorporated by reference to the same extent as if each individual publication was specifically and individually indicated to be incorporated by reference.
It is to be understood that while a certain form of the invention is illustrated, it is not to be limited to the specific form or arrangement of parts herein described and shown. It will be apparent to those skilled in the art that various changes may be made without departing from the scope of the invention and the invention is not to be considered limited to what is shown and described in the specification. One skilled in the art will readily appreciate that the present invention is well adapted to carry out the objects and obtain the ends and advantages mentioned, as well as those inherent therein. Any oligonucleotides, peptides, polypeptides, biologically related compounds, 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 a method for producing cancerous disease modifying antibodies using a novel paradigm of screening. By segregating the anti-cancer antibodies using cancer cell cytotoxicity as an end point, the process makes possible the production of anti-cancer antibodies for therapeutic and diagnostic purposes. The antibodies can be used in aid of staging and diagnosis of a cancer, and can be used to treat primary tumors and tumor metastases. The anti-cancer antibodies can be conjugated to toxins, enzymes, radioactive compounds, and hematogenous cells. | 6 |
BACKGROUND OF THE INVENTION
This invention relates to a neural network circuit for executing image recognition processing or the like.
Much interest has recently been shown in a field of neutral network in data processing. The neural network is brought up from simulation of a neuron structure of a brain of a living thing. Many neural networks are accomplished by a conventional yon Neumann sequential computer whose processing speed is extremely low. Therefore, the neural network is now tried to be structured by exclusive electric circuits. There are various kinds of neural network structured by exclusive electric circuits, such as a multi-layered neural network. FIG. 8 shows the multi-layered neural network which has neurons having branch ability and integration ability and is provided with an input layer, an output layer and an intermediate layer of multiple layers interposed therebetween.
The multi-layered neural network shown in FIG. 8 has three layers of: an input layer composed of two neuron elements 111, 112 to which input vectors i=1, i=2 are respectively inputted, an output layer composed of two neuron elements 330, 340 respectively regarding outputs o=1, o=2, and an intermediate layer composed of six neuron elements 121 and an intermediate layer composed of six neuron elements 121-124, 131, 132 Formed in two layers. The intermediate layer is disposed between the input layer and the output layer. Between neuron elements in the respective layers, synapse groups 41-43 are disposed for setting coupling load therebetween. Each coupling load of synapses of the synapse groups 41-43 is changeable by learning.
A neural network agreeing to a recognition object is structured by leaning each coupling load of synapses of the synapse groups 41-43, changing each coupling load sequentially, adequately. As a learning method of each coupling load of synapses of the synapse groups 41-43, a back propagation method (BP method) is generally known in the art, which is much time consuming for learning and additional learning and whose learning algorithm is unsuitable for constructing the hardware.
A neural network circuit shown in FIG. 9 is proposed which is capable of high speed initial learning and additional learning and whose algorithm is suitable for constructing the hardware.
The neural network circuit in FIG. 9 is a neutral network developing the network structure in FIG. 8 into a tree-like branch structure, and is a three-layered neural network provided with an input layer, an intermediate layer and an output layer. The input layer is composed of neuron elements 11--11, 12-11 for only branch operation to which input vectors i=1, i=2 are respectively inputted. The intermediate layer is composed of 24 neuron elements 11-21-11-24, 11-31-11-38, 12-21-12-24, 12-31-12-38 for only branch operation which are formed in two layers, and has networks 13-1, 13-2 in tree-like branch structure in number of input vectors i=1, i=2 of the input layer (i.e., two). The output layer is composed of two output neuron elements (output units) 310, 320 for only integration operation, which respectively regard outputs o=1, o=2, and sums outputs from the upper 16 neuron elements 11-31-11-38, 12-31-12-38 of the intermediate layer. Between the intermediate layer and the output layer a synapse group 4 is disposed for setting respective coupling loads between the neuron elements. The coupling loads of each synapse of the synapse group 4 are changeable by learning. In FIG. 9, paths through 12-11-12-22-12-34-310 corresponds to paths through 112 - 122 - 132 - 330 in FIG. 8. Wherein, each coupling load of synapse between the neuron elements 11-11-11-38 and each coupling load of synapse between the neuron elements 12-11-12-38 are not learned and are set necessarily according to a value of the input vector inputted into the respective neuron elements 11-11, 12-11 of the input layer.
As an example of network system which depends on only the value of the input vector and sets necessarily, without learning, the coupling load of synapse in three-like branch structure, such as shown in FIG. 9, there is a network system called quantizer neuron which is disclosed in "Character Recognition System Using Network Comprising Layers By Function", Preliminary Material for Image Electronic Communication Society's National Conference 1990, pages 77-80 and "Multi-Functional Layered Network using Quantizer Neurons", Computer World '90, November. In this kind of network structure, the coupling loads of synapses of a final layer is changed independent form other synapses, which leads to high speed initial learning and additional learning and makes the learning algorithm suitable for constructing the hardware.
In the recognition method in the network system shown in FIG. 9, output values of the two neuron elements 310, 320 for only integration operation which are provided at an output layer are judged as to which is the largest and the address of the neuron element whose output value is the largest is made a recognition result. In the integration method in the neuron elements 310, 320 of the final layer for integrating outputs of the neuron elements 11-31-11-38, 12-31-12-38 of the intermediate layer, the respective output values of the intermediate layer and the respective coupling loads set in the synapse group 4 are multiplied and summed for integration.
The integration method in neuron elements are explained, with reference to FIG. 10.
In FIG. 10, the output neuron elements 310, 320 and the synapse group 4 are identical with those in FIG. 9. References f1 and f2 denote intermediate output values of the neuron elements 11-31, 11-32 in FIG. 9 respectively. In accordance with the above-mentioned references, the neuron elements 11-31-12-38 are branch points of an input signal, so that an output value from the neuron element 11-31 to the output neuron element 310 and an output value from the neuron element 11-31 to the output neuron element 320 are equal to each other and are indicated by f1. Respective coupling load calculations of synapses to the output neuron elements are executed by respective coupling calculation executing parts 4-11-4-22. The coupling load calculation executing part 4-11 is composed of a multiplier 112 and a coupling load coefficient W11 which is multiplied with the output value f1 corresponding to the intermediate layer to output a multiplied result. The coupling load calculation executing parts 4-12-4-22 have the same function as the coupling load calculation executing part 4-11, and have a different coupling load coefficient from one another. The integration calculations in the output neuron elements 310, 320 are expressed in following respective equations. The thus integrated output values of the neuron elements 310, 320 are judged as to which is the largest, and an address of the neuron element whose output value is the largest is made a recognition result.
output of output neuron element 310=W11×f1+W12×f2+ . . .
output of output neuron element 320=W21×f1+W22×f2+ . . .
The learning algorithm in network system shown in FIG. 9 uses the learning rule of Hebb, in which if the recognition result is false, the coupling load of the synapse group 4 to an output neuron element to be true is fortified until the value of the output neuron element to be true is the largest output value by a supervisor input in FIG. 9. As to the fortifying method, the coupling load coefficient is added according to the output value of the neuron elements 11-31-11-38, 12-31-12-38.
The fortifying method of coupling load of the synapse is explained, with reference to FIG. 11.
FIG.11 shows the coupling load W11 of FIG. 10 in enlarged scale. The intermediate layer output f1 is added to the present coupling load W11 according to a learning signal. The change in coupling load by learning is expressed as follows:
W11=W11+f1
In the multi-layered neural network structure which has the intermediate layer of tree-like branch structure, executes integration of synapses by output neuron elements of the final layer and executes learning by changing the coupling loads of the synapses of the final layer, the coupling load change is executed independent from the other synapses, which leads to high speed initial learning and additional learning and makes the learning algorithm suitable for constructing the hardware.
Recognition accuracy in the above multi-layered neural network of tree-like brunch structure is, however, low in case where a new unlearned data is recognized after an initial learning. The inventors have studied the reasons and consider the following is one of the reasons: in case where some kinds of input data are all identified by learning in the above neural network and variance of one kind of input data is small, a coupling load of the synapse group to the output neuron elements for recognizing a data similar to the input data is inflated at learning of the similar data so as to clarify a difference between the similar data and the one-kind input data, with a result that the similar data is misrecognized as an output result of output neuron element having as an input the inflated coupling load at next recognition of an unlearned data different from the similar data under such a condition since the inflated coupling load is extremely large compared with the other coupling loads of the unlearned data when the synapse group of the inflated coupling load is included in the synapse group to the output neuron element for the unlearned data recognition.
At the initial learning, the coupling load of synapse to the output neuron element is gradually increased according to the number of times at learning, which requires bit accuracy (bit word length) of coupling load and increases hardware in size which is required for coupling load memory. The above-mentioned references disclose that the coupling load memory of about 16 bits is required for 13-font learning of 62 kinds of character data according to a data group to be recognized. This means a large-sized hardware required for the coupling load memory.
SUMMARY OF THE INVENTION
This invention has its objects of providing a neural network circuit capable of solving the problems in the neural network of tree-like branch structure, of improving a recognition accuracy for unlearned data and of reducing hardware size required for coupling load memory.
To attain the above object, in the present invention, connection of the synapses to the output neuron elements is controlled by learning, different from the conventional one that the synapses are connected to the output neuron elements by weight of coupling load.
In detail, in the present invention, a multi-layered neural network circuit provided with an input layer having one or plural input vectors, an intermediate layer having networks in tree-like structure whose outputs are necessarily determined by values of the input vectors and whose number corresponds to the number of the input vectors of the input layer, and an output layer having one or plural output units for integrating all outputs of the intermediate layer, comprises: learning-time memories for respectively memorizing a number of times at learning in paths between the intermediate layer and the respective output units; threshold processing circuits for respectively threshold-processing an output of the respective leaning-time memories; and connection control circuits for respectively controlling connection and disconnection of the paths between the intermediate layer and the respective output units according to an output of the respective threshold processing circuits, wherein the respective output units sum the outputs of the intermediate layer connected by the respective connection control circuits.
The neural network circuit further comprises upper limit clipping means for respectively clipping the number of times at learning stored in the respective learning-time memories to a set upper limit.
The neural network circuit further comprises: learning-time updaters for respectively subtracting a set value from the number of times at learning stored in the respective learning-time memories; and lower limit clipping means for respectively clipping an updated result of the number of times at learning which is less than 0 to 0.
In the present invention, another multi-layered neural network circuit provided with an input layer having one or plural input vectors, an intermediate layer having networks in tree-like structure whose outputs are necessarily determined by values of the input vectors and whose number corresponds to the number of the input vectors of the input layer, and an output layer having one or plural output units for integrating all outputs of the intermediate layer, comprises: flag memories for respectively memorizing whether paths between the intermediate layer and the respective output units are learned in a past learning; and connection control circuits for respectively controlling connection and disconnection of the paths between the intermediate layer and the respective output units according to an output of the respective flag memories, wherein the respective output units sum the outputs of the intermediate layer connected by the respective connection control circuits.
In the neural network circuit, each output of the intermediate layer has two kinds of values of "HIGH" and "LOW", and the respective output units count the number of "HIGH"s among the outputs of the intermediate layer connected by the respective connection control circuits.
According to the neural network circuit with the above construction, the number of times at learning of synapses to the output neuron elements is memorized in the learning-time memory, and only paths between the outputs whose numbers of times at learning (number of times that non-zero values are outputted or number of times that each of the outputs exceeds the set value in each output of the intermediate layer of network in tree-like branch structure) exceed the set threshold among outputs of the networks and the respective output units are connected by the connection control circuit only when the number of times at learning exceeds the set threshold. As a result, each output unit executes summation of all outputs of the connected intermediated layer to recognize the input data. The input data recognition depends on the path connection between the outputs whose numbers of times at learning exceed the set threshold among the outputs of the intermediate layer and the respective output units. Since there presents no weight in the connected paths, the local inflation in coupling load of synapse as the conventional one does not occur, thus enhancing the recognition accuracy for unlearned data.
By clipping the number of times at learning in the learning-time memory to the upper limit value, the hardware size required for memorizing the number of times at learning is reduced.
Many paths among paths between outputs of the intermediate layer and the output units are connected unnecessarily owing to excessive learning. However, the unnecessary paths are disconnected so as to connect only the necessary paths by subtracting the set value from each number of times at learning in all learning-time memory or by increasing the threshold of the threshold processing circuit by the set value. Thus, noise component of data to be recognized at excessive learning is reduced, while further enhancing the recognition accuracy for unlearned data.
Moreover, in the present invention, instead of learning-time memory, the flag memory is provided for memorizing the presence of learning history of synapse to the output neuron element, which further reduces the hardware in size.
Instead of summation of output values of the intermediate layer by the respective output units of the output layer, the number of times that outputs of non-zero value among outputs of the intermediate layer are outputted are counted, which further reduces the hardware size of the integration circuit including the output layer.
Other and further object and novel features of the present invention will appear more fully from the following description with accompanying drawings.
BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS
Accompanying drawings show preferable embodiments of the present invention, in which:
FIG. 1 is a diagram showing a construction of a neural network circuit in a first embodiment;
FIG. 2 is a diagram of a learning calculation circuit of a learning-time memory;
FIG. 3 is a diagram of a leaning calculation circuit showing a first modified example of learning-time memory;
FIG. 4 is a diagram of a learning calculation circuit showing a second modified example of learning-time memory;
FIG. 5 is a diagram showing a construction of a neural network circuit in a second embodiment;
FIG. 6 is a diagram showing a construction of a neural network circuit in a third embodiment;
FIG. 7 is a diagram showing a construction of a neural network circuit in a fourth embodiment;
FIG. 8 is a diagram showing a construction of a conventional multi-layered network circuit;
FIG. 9 is a diagram showing a construction of a conventional multi-layered network circuit in tree-like branch structure;
FIG. 10 is a diagram for explaining an integration method of integral neuron elements in the conventional multi-layered neural network circuit in tree-like branch structure; and
FIG. 11 is a diagram of a conventional coupling load calculation circuit of a coupling load memory.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
Description is made below about preferred embodiments of the present invention, with reference to accompanying drawings.
FIG. 1 shows a construction of a neural network circuit, and corresponds to the conventional example in FIG. 10. As far as is possible the same reference numerals have been used as in FIG. 10.
In FIG. 1, reference numerals 310 and 320 are output neuron elements of a final layer for integrating intermediate layer outputs of neuron elements 11-31-11-38, 12-31-12-38 in FIG. 9. References f1 and f2 are, as mentioned in the conventional example, intermediate layer output values of neuron elements 11-31 and 11-32 in FIG. 9 respectively. In accordance with the above mentioned references, the neuron elements 11-31-12-38 are branch points of an input signal, so that an output value from the neuron element 11-31 to the output neuron element 310 and an output value from the neuron element 11-31 to the output neuron element 320 are equal to each other and are indicated by f1. The calculation of connection of synapse to the output neuron elements is executed by connection calculation executing parts 4-11-4-22.
The connection calculation executing part 4-11 is composed of a learning-time memory 113, a threshold processing circuit 114 for threshold-processing the learning-time memory 113, namely for comparing the number of times at learning stored in the corresponding learning-time memory 113 with a set threshold and for outputting a set value when the number of times at learning of the corresponding learning-time memory is equal to or more than the threshold and outputting another set value when the number of times at learning of the corresponding learning-time memory is less than the threshold, and a connection control circuit 115 controlled by two kinds of control signals from the threshold processing circuit 114. The connection control circuit 115 controls connection of synapse between the intermediate layer and the output neuron elements. The connection calculation executing parts 4-12-4-22 have the same function as of the connection calculation executing part 4-11, and have a different number of times at learning from one another. If the threshold of the threshold processing circuit 114 is 1, the intermediate layer output f1 is outputted when the learning-time value R11 (the number of times at learning) of the learning-time memory 113 in the connection calculation executing part 4-11 is 1 or more and 0 is outputted without connection of the intermediate layer output f1 when the learning-time value R11 of the learning-time memory 113 is 0. In the output neuron elements 310, 320, only the intermediate layer outputs of connected synapses are added for integration among the intermediate layer outputs.
The thus integrated output values of the output neuron elements 310, 320 are judged as to which is the largest so as to make an address of the output neuron element whose output value is the largest a recognition result.
Learning algorithm in the network system shown in FIG. 1 is discussed next.
First, all learning-time memories of synapses continuing to the output neuron elements are set 0. Then, an initial learning is executed only one time to all data to be initial-learned. The learning method is that: the values in all learning-time memories of synapses whose intermediate layer outputs are not 0 are incremented by a supervisor input in FIG. 1 among the synapses connected to the output neuron elements corresponding to the input data. It may be possible to increment the values in the learning-time memories of synapses whose intermediate layer outputs are equal to or more than a threshold.
FIG. 2 shows an example of an updater of the learning-time memory 113 in FIG. 1 in enlarged scale. The present learning-time value R11 is incremented by 1 according to a learning signal. Change in number of times at learning by learning is expressed in a following equation:
R11=R11+1
As described above, in this embodiment, the number of times at learning of synapse to the output neuron elements is memorized, and only the intermediate layer outputs from synapses whose numbers of times at learning exceed the threshold are summed. Thus, the local inflation in coupling load of synapse due to small variance of one kind input data in addition to similar data is prevented and the recognition accuracy for unlearned data is enhanced.
FIG. 3 shows a modified example of a learning calculation circuit of the learning-time memory 113. As shown in FIG. 3, an upper limiter 113 as upper limit clipping means is provided on the input side of the learning-time memory 113. This reduces a memory capacity of the learning-time memory 113. Different from the conventional construction that the synapse to the output neuron elements is connected by weight of coupling load, in the present invention, the connection of synapse to the output neuron elements is controlled according to the number of times at learning.
When a limit value (upper limit of the number of times at learning) of the upper limiter 113a shown in FIG. 3 is set to 3, only two bits are required for memorizing the number of times at learning, which is one eighth of 16-bit coupling load memory in the conventional one. Further, the recognition accuracy is increased to about 86% (63% in the conventional one) in a recognition test for unlearned data after the initial learning according to the present invention with the neural network construction in the above mentioned references. In the recognition test, 62 kinds of 13-font character data are learned at the initial learning and the recognition accuracy for 62 kinds of 10-font unlearned character data is calculated.
According to the present invention, the recognition accuracy for unlearned data is excellent even with less memory capacity required for learning.
According to the neural network circuit with the above construction, one-time learning to one input data makes the value of the corresponding output neuron element the largest for the same input data without exception, thus enabling the initial learning without recognition result with no conditions. Accordingly, the convergence time at the initial learning in the neural network construction in the present invention is about one sixtieth to one thousandth of that in the conventional one.
While the learning-time memory 113 in FIG. 3 has excellent feature, a problem arises that the recognition accuracy for unlearned data is lowered owing to excessive learning. Because, the synapses to the output neuron elements are unnecessarily connected, receiving many noise components by excessive learning. However, the lowering of the recognition accuracy for unlearned data due to excessive learning is prevented by regarding the synapses which are not so learned in past learning as noise components and ignoring the learning history.
FIG. 4 shows an example of an updater of the learning-time memory which solves the problem which is another modification of the learning-time memory 113 in FIG. 1. The learning-time memory in FIG. 4 includes a selector 113b as a learning-time updater having a function of decrementing by one the present learning-time value R11 according to a learning signal, in addition to the incrementing function shown in FIG. 2. The selector 113b receives a control signal for subtraction. When the control signal for subtraction is inputted, the selector 113b outputs -1 to an adder 113c, halting the incrementing function, to decrement by 1 the present learning-time value R11. Further, the learning-time memory includes a lower limiter 113d as lower limit clipping means which has a function of limiting a value less than 0 to 0.
When the recognition accuracy for unlearned data is lowered due to excessive learning, 1 is subtracted from all learning-time values stored in the learning-time memories of the synapses to the output neuron elements according to the control signal for subtraction. Wherein, the learning-time value R11 less than 0 is limited to 0 by the lower limiter 113d. With the above function added, the lowering of the recognition accuracy for unlearned data due to excessive learning is prevented.
As to means for preventing the lowering of the recognition accuracy for unlearned data due to excessive learning, the same effect can be obtained by adding 1 to the threshold of the threshold processing circuit 114 in FIG. 1, besides the method showing in FIG. 4.
The updater of the learning-time memory subtracts 1 in this embodiment, but may execute division if it has the function of decreasing the number of times at learning.
FIG. 5 shows a construction of a neural network circuit in a second embodiment, and corresponds to FIG. 10 of the conventional example, so the same reference numerals as in FIG. 10 have been used for the same elements in FIG. 5.
In FIG. 5, reference numerals 310 and 320 are output neuron elements of the final layer for integrating intermediate layer outputs of the neuron elements 11-31-11-38, 12-31-12-38. References f1 and f2 are, as mentioned in the conventional example, the intermediate layer output values of the neuron elements 11-31 and 11-32 in FIG. 9 respectively. In accordance with the above mentioned references, the neuron elements 11-31-12-38 are branch points of an input signal, so that an output value from the neuron element 11-31 to the output neuron element 310 and an output value from the neuron element 11-31 to the output neuron element 320 are equal to each other and are indicated by f1. The calculation of connection of synapse to the respective output neuron elements is executed by the connection calculation executing parts 4-11-4-22.
The connection calculation executing part 4-11 is composed of a flag memory 116 and a connection control circuit 115 to be controlled by the flag memory 116 for controlling connection of synapse between the intermediate layer and the output neuron elements. The connection calculation executing parts 4-12-4-22 have the same function as that of the connection calculation executing part 4-11, and have a different flag value from one another. The intermediate layer output f1 is outputted when a value Q11 of the flag memory 116 in the connection calculation executing part 4-11 is 1 and 0 is outputted without connection of the intermediate layer output f1 when the value Q11 of flag memory 116 is 0. In the output neuron elements 310, 320, only the intermediate layer outputs of connected synapses are added for integration among the intermediate layer outputs. The thus integrated output values of the neuron elements 310, 320 are judged as to which is the largest so as to make an address of the output neuron element whose output value is the largest a recognition result.
The learning algorithm in the network system shown in FIG. 5 is discussed next.
First, all flag memories of synapses continuing to the output neuron elements are set to 0. Suppose that the intermediate layer output is not connected to the output neuron elements when the flag memory is 0 and is connected thereto when the flag memory is 1. Then, at the initial learning, learning is executed only one time to all of the data to be initial-learned. The learning method is that: 1 is set by a supervisor input in FIG. 5 to all values in the flag memories of synapses whose intermediate layer outputs are not 0 among the synapses connected to the output neuron elements corresponding to the input data. Setting to 1 may be conducted to the flag memories whose intermediate layer output is equal to or more than a set threshold, instead of non-zero intermediate layer value.
As described above, in this embodiment, the flag memory requires only one-bit memory capacity for one synapse, which means further reduction of memory capacity than in the first embodiment. Since the threshold processing circuit for the learning-time memory is unnecessary, the size of the hardware is expected to reduce. As to the recognition accuracy for unlearned data, the equivalent performance is obtained as in the neural network circuit in the first embodiment.
According to the present invention, the recognition accuracy for unlearned data is excellent even with less memory capacity of the flag memory which is required for learning.
Further, in the neural network circuit with the above construction, one-time learning to one input data makes the value of the corresponding output neuron element the largest for the same input data without exception, which enables the initial learning without recognition result with no conditions. Accordingly, the convergence time at the initial learning in the neural network construction in the present invention is about one sixtieth to one thousandth of that in the conventional one.
In the neural network circuit in this embodiment, the recognition accuracy for unlearned data is lowered because of excessive learning. However, such the low recognition accuracy can be ignored in cases of initial learning not to be excessive learning, of learning of data with less noise component or of use of the flag memory in ROM construction as recognition device.
FIG. 6 shows a neural network circuit according to a third embedment, and corresponds to FIG. 5 of the conventional example, so the same reference numerals as in FIG. 5 have been used for the same elements in FIG. 6.
In FIG. 6, reference numerals 310 and 320 are the output neuron elements of the final layer for integrating intermediate layer outputs of the neuron elements 11-31-11-38, 12-31-12-38. References f1 and f2 are, as described in the conventional example, the intermediate layer output values of the neuron elements 11-31 and 11-32 in FIG. 9 respectively. In accordance with the above mentioned references, the neuron elements 11-31-12-38 are the branch points of an input signal, so that an the output value from the neuron element 11-31 to the output neuron element 310 and an output value from the neuron element 11-31 to the output neuron element 320 are equal to each other and are indicated by f1. Wherein, in FIG. 6, there are two kinds, i.e. 1 and 0, of intermediate layer output values f1, f2. The calculation of connection of synapse to the respective output neuron elements is executed by the connection calculation executing parts 4-11-4-22.
The connection calculation executing part 4-11 is composed of the flag memory 116 and a connection control circuit 117 to be controlled by the flag memory 116 for controlling the connection of synapse between the intermediate layer and the output neuron elements. The connection calculation executing parts 4-12-4-22 have the same function as the connection calculation executing part 4-11, and have a different flag value from one another. Since the connection control circuit 117 receives two kinds of input values from the intermediate layer, a logical product circuit, instead of the selector shown in FIG. 5, can serve as the connection control circuit 117. In the output neuron elements 310, 320, the number of ones of output intermediate layer outputs of connected synapses among the intermediate layer outputs are counted for integration.
The thus integrated output values of the output neuron elements 310, 320 are judged as to which is the largest so as to make an address of the output neuron element whose output value is the largest a recognition result.
The learning algorithm in the network system shown in FIG. 6 is discussed next.
First, all flag memories of synapses continuing to the output neuron elements are set to 0. Suppose that the intermediate layer output is not connected to the output neuron elements when the flag memory is 0 and is connected thereto when the flag memory is 1. Then, at the initial learning, learning is executed only one time to all of the data to be initial-learned. The learning method is that: 1 is set by a supervisor input in FIG. 6 to all values in the flag memories of synapses whose intermediate layer outputs are 1 among the synapses connected to the output neuron elements corresponding to the input data.
By employing the invention in the second embodiment and this embodiment, the connection control circuit 117 of the synapse to the output neuron elements is simplified and the integration processing which is executed in the output neuron elements 310, 320 is executed by counting the number of inputted values of 1, thus reducing the hardware size, compared with the circuit shown in FIG. 5.
Upon a test of recognition accuracy for unlearned data, about 2-3% lowering of recognition accuracy is caused compared with the circuits in first and second embodiments. However, the recognition accuracy is much higher than that in the conventional learning method, which means applicable into practice depending on a kind of data to be recognized.
FIG. 7 shows a neural network circuit according to a fourth embodiment of the present invention and corresponds to FIG. 1, so the same reference numerals as in FIG. 1 have been used for the same elements in FIG. 7.
In FIG. 7, reference numerals 310 and 320 are output neuron elements of the final layer for integrating the intermediate layer outputs of the neuron elements 11-31-11-38, 12-31-12-38 shown in FIG. 9. References f1 and f2 are, as mentioned in the conventional example, the intermediate layer output values of the neuron elements 11-31 and 11-32 in FIG. 9 respectively. In accordance with the above mentioned references, the neuron elements 11-31-12-38 are the branch points of an input signal, so that an output value from the neuron element 11-32 to the output neuron element 310 and an output value from the neuron element 11-32 to the output neuron element 320 are equal to each other and are indicated by f1. Wherein, in FIG. 7, the intermediate layer output values f1, f2 have two kinds of outputs, i.e. 1 and 0. The calculation of connection of the synapse to the output neuron elements is executed by the connection calculation executing parts 4-11-4-22.
The connection calculation executing part 4-11 is composed of the learning-time memory 113, the threshold processing part 114 for threshold-processing the learning-time memory 113 and the connection control circuit 117 to be controlled by the control signal of two kinds of values by the threshold processing circuit 114 for controlling the connection of synapse between the intermediate layer and the output neuron elements. The connection calculation executing parts 4-12-4-22 have the same function as that of the connection calculation executing part 4-11, and have a different learning-time value from one another. Since the connection control circuit 117 receives two kinds of values from the intermediate layer, a logical product circuit, instead of the selector shown in FIG. 1, can serve as the connection control circuit 117. In the output neuron elements 310, 320, the number of intermediate layer outputs of 1 of the connected for integration synapses is counted for integration among the intermediate layer outputs.
The thus integrated output values of the neuron elements 310, 320 are judged as to which is the largest so as to make an address of the output neuron element whose output value is the largest a recognition result.
According to the circuit shown in FIG. 6, the connection control circuit 117 of the synapse to the output neuron elements is simplified and the integration processing executed in the output neuron elements 310, 320 is executed by counting the number of input values of 1, thus reducing the hardware size, compared with the circuit shown in FIG. 1.
Similar to the circuit shown in FIG. 6, the recognition result for the unlearned data is about 2-3% lower than that in the first embodiment shown in FIG. 1 and that in the second embodiment shown in FIG. 5. However, the recognition accuracy thereof is much higher than that in the conventional learning method and the circuit is applicable into practice depending on a kind of data to be recognized. The circuit shown in FIG. 7 can prevent the lowering of the recognition accuracy for unlearned data due to excessive learning, as well as the circuit in FIG. 1.
In the above embodiments, each connection calculation executing part 4-11-4-22 requires a memory for memorizing a different learning value. However, the processing in each connection calculation executing part and the integration processing in the output neuron elements can be executed by using one or plural processing devices, sequentially exchanging the learning memories. Moreover, as described in this embodiment, the connection calculation executing parts may be provided at all synapses to the respective output neuron elements to execute parallel processing.
The two output neuron elements are discussed for the sake of simplicity, but the present invention is not limited to this example, and may have another number of outputs. | In a multi-layered neural network circuit provided with an input layer having input vectors, an intermediate layer having networks in tree-like structure whose outputs are necessarily determined by the values of the input vectors and whose number corresponds to the number of the input vectors of the input layer, and an output layer having plural output units for integrating all outputs of the intermediate layer, provided are learning-time memories for memorizing the numbers of times at learning in paths between the intermediate layer and the respective output units, threshold processing circuits for threshold-processing the outputs of the leaning-time memories, and connection control circuits to be controlled by the outputs of the threshold processing circuits for controlling connection of paths between the intermediate layer and the output units. The outputs of the intermediate layer connected by the connection control circuits are summed in each output unit. Thus, the neural network circuit for recognizing an image or the like can execute recognition and learning of data to be recognized at high speed with small circuit size, and the recognition accuracy for unlearned data is high. | 6 |
BACKGROUND OF THE INVENTION
Rotary electric machines including electric motors, generators, and the like have employed various types of stator windings. The most common stator winding type is a distributed winding. One type of which is an integer-slot winding wherein the number of slots per pole per phase is an integer. An example of this is a 4 pole 12 slot, 3 phase motor. The number of slots per pole per phase is 1 and therefore an integer. These windings typically require some relatively complex end turns to wire them properly.
Another type of distributed winding is a fractional-slot winding. When the number of slots per pole per phase is a fraction greater than one, this is called a fractional-slot winding. This also has complicated end turns and has the disadvantage of being less efficient. It is sometimes used to smooth out torque ripple or for other specific applications.
Another type of winding is a concentrated winding when the number of slots per pole per phase is a fraction less than one. These can also be called a non-overlapping concentrated winding. They have the disadvantage of decreasing the inherent efficiency of the device, but make the end turns very simple and can facilitate other advantages. An example of a concentrated winding would be an 8 pole, 9 slot, 3 phase machine. The number of slots per pole per phase is 0.375 in this case. The fundamental power from this configuration is reduced by 5.5%. Concentrated windings can be single layer or double layer designs. Single layer designs have windings that are wound only on alternating stator teeth and only apply where there is an even number of stator slots/teeth. Double layer designs have coils wound on every stator tooth. In this configuration, there is a coil that surrounds each of the teeth on the stator and there are the same number of coils as slots. Further, each slot has half of one coil and half of another coil going through the slot and the end turns are very short. Ideally, the end turns can be as short as the width of the stator tooth.
Double layer concentrated windings have the advantage of being a simple coil wrapped around each tooth. For an external rotor configuration, and using relatively open slots, this allows simple assembly of coils. For the more typical internal rotor configuration, assembly is a bit trickier because even with relatively open slots, the opening is smaller than the slot. This is further complicated if the slot opening is made smaller for motor performance reasons. A typical method of mitigating this issue is to make the teeth separate to either be able to 1) wind the wire directly on the tooth or 2) slide the winding on from the outside. The first method is shown in U.S. Pat. No. 5,583,387 entitled STATOR OF DYNAMOELECTRIC MACHINE incorporated herein by reference. The second method is shown in U.S. Pat. No. 4,712,035 entitled SALIENT POLE CORE AND SALIENT POLE ELECTRONICALLY COMMUTATED MOTOR also incorporated herein by reference although it is shown as an external rotor configuration. Both methods are shown as conventional in U.S. Pat. No. 8,129,880 entitled CONCENTRATED WINDING MACHINE WITH MAGNETIC SLOT WEDGES, incorporated herein by reference. The challenge with any stator lamination design that has separate teeth is to secure the teeth structurally so they do not move or break. Even small movements of the teeth can cause acoustic noise. A second challenge is to configure the joint in such a way to not significantly disturb the magnetic flux traveling through the laminations. If the joint could be made with zero clearance this would not be a problem, but with real manufacturing tolerances and features required for attachment, this is a major consideration.
Rotary electric machines including electric motors, generators, and the like have employed various methods of constructing stator windings. Some methods are applicable to only certain types of stator windings.
One common method is random winding. This method can use rectangular or round wire, but typically uses round wire. Here the windings are placed by the winding machine with the only requirement that they be located in the correct slot. This is the easiest method of stator winding, but results in the lowest amount of conductor in the slot and therefore the lowest efficiency. This type method can be used with any type of stator winding including concentrated windings.
Another common method is traditional form winding. This method typically uses rectangular wire with mica tape located between conductors to separate any conductors that are significantly different in voltage. This insures a robust winding for higher voltage machines or machines that are prone to partial discharge. This is the most labor-intensive type of winding and is typically used in machines that are less cost sensitive. This type method can be used with any type of stator winding but is typically used for distributed windings.
One winding type that is not typical in motors, is used in certain types of transformers, chokes, and inductors is bobbin layer winding. This type of winding places conductors in exact locations for very accurate stacking of wires. This can achieve a high amount of conductors in a small area for high efficiency. This is not typically used for distributed windings because you are not able to bobbin wind a coil and then insert it into a stator assembly. This is possible with concentrated windings that have removable teeth. The most common wire to use is round wire but it is possible to use square or rectangular wire. Layer winding with rectangular wire is typically laid flat and wound the easy way. This facilitates simpler winding, but one disadvantage of this is the eddy current losses due to slot leakage can be significantly higher. Also, orientation of the rectangular wire can have an impact on thermal performance and depends on the overall heat removal scheme.
Layer winding with rectangular wire can be done edge wound (wound the hard way.) This is shown in U.S. Pat. No. 4,446,393 entitled DYNAMOELECTRIC FIELD ASSEMBLY AND WINDING THEREFOR incorporated herein by reference. In this patent a single layer of rectangular wire is used in each slot and is edge wound. This patent used removable teeth and an internal rotor. U.S. patent application serial number 2010/0066198 filed Mar. 18, 2010 entitled INSERTION OF PRE-FABRICATED CONCENTRATED WINDINGS INTO STATOR SLOTS incorporated herein by reference also shows a single layer of rectangular wire but does not use removable teeth. Edge wound coils can have significantly lower eddy current losses in the wires. The cooling may be better or worse depending on the overall cooling scheme.
Rotary electric machines including electric motors, generators, and the like have employed various cooling methods including air cooling and liquid cooling. Liquid cooling is used to help make motors smaller and to remove the heat more efficiently.
The most common liquid cooling design uses a cooling jacket wrapped around the outside of the stator assembly. This can be seen in U.S. Pat. No. 5,448,118 entitled LIQUID COOLED MOTOR AND ITS JACKET, included herein by reference. In this design there is an aluminum extrusion that surrounds the outside of the stator and has passages for cooling fluid to pass through. This design cools the stator better than air, but is limited by i) the conductivity between the jacket and the stator, ii) the poor conductivity of the stator laminations, iii) the conductivity of the slot liners, and iv) the poor conductivity between the winding and the slot liners.
Another method that is commonly used is passing cooling through the stator laminations or into slots cut into the stator laminations. Either of these has similar disadvantages to the cooling jacket design.
Further, some techniques involve spraying fluid directly on the stator or submerging the stator. These have the disadvantage of either being overly complex or having the fluid cause drag between the rotor and the stator.
There are at least two techniques placing the cooling jacket through the winding slot. One of these is forcing fluid down the center of a conductor. Typically the fluid in this case is a non-conductive oil. This has the disadvantage of requiring a special fluid and some complex manufacturing methods to provide the fluid channel. Other techniques place a pipe or vessel down through the slot with cooling fluid in it. These typically also use non-conductive oil and have non-conductive connections to a manifold at their end. An example of this can be found in U.S. Pat. No. 3,112,415 entitled CONTROL OF WINDING TEMPERATURES OF LIQUID COOLED GENERATORS, incorporated herein by reference.
Novel methods of cooling are also shown in other applications filed by Marvin et al U.S. patent application Ser. No. 13/548,199 entitled LIQUID COOLED HIGH EFFICIENCY PERMANENT MAGNET MACHINE WITH GLYCOL COOLING, Ser. No. 13/548,203 entitled LIQUID COOLED HIGH EFFICIENCY PERMANENT MAGNET MACHINE WITH IN SLOT GLYCOL COOLING, Ser. No. 13/548,207 entitled HIGH EFFICIENCY PERMANENT MAGNET MACHINE WITH CONCENTRATED WINDING AND DOUBLE COILS, and Ser. No. 13/548,208 entitled HIGH EFFICIENCY PERMANENT MAGNET MACHINE WITH LAYER FORM WINDING all filed Jul. 13, 2012, all incorporated herein by reference.
SUMMARY OF THE INVENTION
The machine described herein incorporates several novel construction methods in its stator. It uses a concentrated winding with a novel approach to secure its removable teeth. This method insures metal on metal contact with real manufacturing tolerances. The preload caused by deflected steel insures that this metal on metal contact maintains itself in all loading conditions.
This design also uses Edge Form Wound windings which minimize eddy current losses in the windings. Further, the use of pre-insulated wire, novel cooling manifold location, and assembly loading insures a very good thermal solution that allows much higher current density in the slot. This higher current density in the slot allows significantly higher overall power density of the rotating machine particularly in larger machines and higher speed machines.
This edge winding solution needs a very sophisticated winding method to achieve accurate coils that can achieve high packing density and work reliably in demanding applications. The incorporation of a controlled winding approach using pre-insulated wire is unique. Pre-insulated wire has been used with simple pin-bending solutions, but this would not achieve the higher packing density or high yields in manufacturing. Further, in real applications, the wire size may need to get quite large to accommodate the correct number of turns. This wire may get larger than commonly available for pre-insulated wire and this larger wire will have more eddy current losses in the wire due to slot leakage magnetic flux. This design uses multiple in hand winding to solve these issues.
The machine described herein also includes novel in slot liquid cooling in a configuration that allows the use of conductive fluid such as ethylene glycol. This configuration places the cooling manifold between the winding and the stator laminations to give ideal cooling for the winding as well as the stator laminations.
Further, this design uses metallic vessels that contain the liquid cooling medium for high reliability. These metallic vessels are brazed together into manifolds to efficiently direct the liquid to where the heat is generated.
The combination of these approaches leads to a very reliable, small, efficient, and low cost design.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a three dimensional view of the stator assembly,
FIG. 2 is a cross sectional view of the stator assembly of FIG. 1 ,
FIG. 3 is an enlarged detail sectional view of the stator assembly shown in FIG. 2 ,
FIG. 4 is cross sectional view of the stator assembly,
FIG. 5 is a detail view of the stator assembly shown in FIG. 4 ,
FIG. 6 is a detail view of the stator assembly shown in FIG. 5 ,
FIG. 7 is a cross sectional view showing motor/generator assembly,
FIG. 8 is two detail views of the motor/generator assembly shown in FIG. 7 ,
FIG. 9 is a view of the inner coil from the stator assembly of FIG. 1 and also shows a cross section of the rectangular wire and the rectangular wire that has been shaped into a keystone shape,
FIG. 10 is a detail view of the stator assembly shown in FIG. 4 ,
FIG. 11 is a three dimensional view of an assembly with 4 coils and the insulator of the stator assembly of FIG. 1 ,
FIG. 12 is a top view of the inner coil of FIG. 9 ,
FIG. 13 is a three dimensional view of the coils and insulator of FIG. 11 with an added slot liner,
FIG. 14 is a three dimensional view of an edge winding machine before wire is bent,
FIG. 15 is the edge winding machine of FIG. 14 after the wire is bent 90 degrees,
FIG. 16 is a cross sectional view of the edge winding machine of FIG. 15 ,
FIG. 17 is a three dimensional view of an edge winding machine winding 2 wires in hand, and
FIG. 18 is a cross section view of the edge winding machine of FIG. 17 .
DESCRIPTION OF PREFERRED EMBODIMENT
Referring particularly to FIG. 1 , a stator assembly 1 is shown containing stator coils 2 and stator lamination teeth 3 . Also shown is a fluid manifold 4 for supplying coolant to the motor or generator.
FIG. 2 shows more detail on the stator assembly showing outer tube 6 , outer laminations 5 , and stator teeth 3 . The stator shown in FIG. 2 has a double layer concentrated winding since there is a winding around every stator tooth. In addition, the stator winding is comprised of four portions: innermost layer 8 , second layer 9 , third layer 10 , and fourth layer 11 as shown in FIG. 3 . The four portions are separate and distinct from this being a double layer winding which refers to there being a winding around every stator tooth.
Each winding surrounds a cooling manifold with the upper portion 7 shown in FIG. 3 and the in slot portion 12 shown in FIG. 5 . The cooling manifold is shown with 8 holes in each side. Since this is an even number it facilitates a single sided manifold where in slot cooling vessels are connected only on one end of the machine. Since the number of holes is divisible by four, it also facilitates making redundant cooling loops and a single sided manifold (two up and two down for each of the two redundant loops.) These coolant loops can be connected to their own pump and designed such that only one loop is necessary to keep the machine cool.
This flow path is desirable since there are no electrically conductive loops around stator teeth that are formed with the coolant. This is important because it allows the use of conductive fluids such as a water and ethylene glycol mixture without sacrificing any performance. Further, it allows the use of metals to hold cooling fluid with brazed or soldered joints without causing any shorting paths. While using soldering or brazing, a preferable method of adding filler material is either by using stamped foils inserted between components or by applying paste on one of the surfaces.
Having a soldered or brazed joint is important for the overall reliability of the system and is preferable to O-rings, hoses or other insulation systems. Fluid can pass through this passage in either direction but preferably is in a cross flow configuration. These can be manifolded from a single end and can be connected in parallel or in series. A parallel configuration is the preferred method due to reduced fluid pressure drop with smaller passages.
The in-slot cooling manifold 12 as shown in FIG. 5 can be configured with a step 17 to facilitate better cooling with edge wound coils. It is typical that the available space in the slot is not rectangular and has a more unique shape. By putting this step in the cooling manifold and making the height of the step equal to the thickness of the first layer, it allows a larger cooling surface without taking away from room for copper wire in the slot. The tooth 3 as best shown in FIG. 5 is designed as a separate piece from the rest of the stator lamination. This is done to allow the cooling manifolds and windings to be installed on the tooth before insertion into the stator. This is desirable in many concentrated winding designs but is particularly important on this design because the teeth 3 are designed to have a very small gap from each other. Further when using edge wound coils it is much easier to install with a straight in insertion that does not require deformation.
The tooth is preferably built with a bonded stack configuration where all of the laminations are glued together. The tooth 3 mates with the outer lamination 5 along angled surfaces 19 a and 19 b as shown in FIG. 5 . The goal is to preload the tooth on these two angled surfaces such that the forces of the motor do not separate these surfaces. To accomplish this, a retention feature 20 is included to preload these surfaces. This retention feature 20 is shown in more detail in FIG. 6 where there are two tabs 21 a and 21 b that are built as part of this feature. Wedges 22 a , 22 b , 23 a , and 23 b are driven in from the end to deform tabs 21 a and 21 b and preload surfaces 19 a and 19 b . Wedges are preferably made of non-magnetic material to reduce eddy current losses. The best material choice would be an austenitic stainless steel, 300 series stainless steel for example. To manufacture wedges easily and to fit the feature in the limited space available, wedges can be made out of sheet metal. This means that the width of the wedge pair 22 a and 23 a for instance would be small compared to the combined thickness of the wedges as best shown in FIG. 6 . The wedges in FIG. 6 show an example where the combined thickness is approximately 3.7 times the width.
The location of this retention feature is important for magnetic flux reasons. Teeth dimensions are preferably designed in such a way to not unacceptably saturate the iron but keep the tooth width as small as possible. The magnetic flux travels from the tooth across surfaces 19 a and 19 b into the outer lamination portion 5 . It is important to design this retention feature out of the flux path which limits its location to outside of the two cylinders shown by the two circles 18 a and 18 b in FIG. 5 . All the cutouts in the outer lamination 5 to accommodate retention feature 20 are located outside of these two cylinders. These cylindrical exclusion volumes have a diameter equal to the width of the tooth and their axes are at the junction of the tooth side 3 a and 3 b and the inside diameter of the outer lamination 5 a and 5 b . The angled surfaces 19 a and 19 b are angled to accommodate this flux plus mechanically center the tooth when preload is applied through tabs 21 a and 21 b . Ideally the surfaces 19 a and 19 b have an angle between them of 100-170 degrees.
There are other features that may want to fall in the good sector outside circles 18 a and 18 b as shown in FIG. 5 . These could be notches 13 a and 13 b on the exterior of outer lamination 5 . These notches could function as a space for a recessed weld or space for cooling air to recirculate inside the machine.
FIG. 7 shows an entire motor assembly that includes the stator assembly shown in FIG. 1 . The rotor configuration is showing magnets 25 and tab pole plates 26 and 27 . This rotor configuration is the same as shown in the two U.S. patent application Ser. No. 13/438,792 entitled HIGH EFFICIENCY PERMANENT MAGNET MACHINE WITH SEPARATED TAB POLE ROTOR AND STACKED CERAMIC MAGNET SECTIONS and Ser. No. 13/438,803 entitled SHAFT ATTACHMENT MEANS FOR HIGH EFFICIENCY PERMANENT MAGNET MACHINE WITH SEPARATED TAB POLE ROTOR both filed on Apr. 3, 2012, and each incorporated herein by reference. Outer tube 6 is preferably shrunk fit onto outer lamination 5 to mechanically align as well as transmit torque. The outer tube is compressed between drive side endplate 28 and non-drive side endplate 29 using threaded tie bars 30 . The friction between outer tube and endplates transmits the torque to the machine mounting features. Alignment of shaft 24 is controlled through outer tube 6 , endplates 28 and 29 and through bearings on each end. Sealing of the system can be accomplished by adding an O-ring seal 31 and 32 as shown in FIG. 8 .
The inner coil 8 is shown in detail in FIG. 9 . This coil is edge wound because the width of the wire is narrower than the thickness in the direction the wire is bent around the stator tooth. When wire is bent it tends to form a keystone shape in the corner areas. As shown in FIG. 9 , when wire is in shape of a rectangle 35 with the mandrel side 37 and the outside edge 36 , it forms a keystone shape 38 and the mandrel side 40 grows in width and the outside edge 39 contracts in width. The fact that wires always want to keystone when bent is why the coils bulge out in the corners as shown by 34 . Limiting the amount of the keystone is important for overall packaging and can be controlled in the manufacturing process if the right process is used. The coil shown is two in hand wound (two wires wound simultaneously) with wires side by side 33 . Depending on the specific design it may make sense to have single wire, two in hand or more than two in hand.
It is important for to have the wire thermally connected to the cooling manifold 12 as shown in FIG. 10 . The cooling manifold is electrically isolated from the windings 8 , 9 , 10 , 11 , and by plastic insulator layer 41 that functions as ground insulation. Each of the winding layers is compressed towards cooling manifold 12 . This is accomplished by wedge assemblies 14 a , 14 b , 14 c ; 15 a , 15 b , 15 c ; and wedge block 14 d which push the windings up against each other through insulators 16 a , 16 b , 16 c ; against the insulation layer 41 ; and ultimately against cooling manifold 12 . The first wedge assembly functions by driving tapered wedge 14 a and 14 b against each other in the cutout of 14 c . The second wedge assembly functions by driving tapered wedge 15 a and 15 b against each other in the cutout of 15 c against the wedge block 14 d . There is a slot liner insulation 42 that acts as ground insulation between the wires and the outer lamination 5 . This insulation is not directly in the path so thermal conductivity is not critical.
Insulators 41 , 16 a , 16 b , and 16 c are directly in the path of heat transfer so thermal conductivity is critical. Further, due to the higher heat fluxes generated with more compact machines of this type, the thermal conductivity is even more critical. This can be accomplished by some combination of making it thin and using high thermal conductivity material. It is desired to have at least a thermal conductivity of 1 W/mK and preferably a conductivity of 3 W/mK and ideally a conductivity of 10 W/mK. Since this material also needs to be an electrical insulator to act as primary insulation, metals typically do not work. To function as primary insulation, electrical resistivity needs to be greater than 1000 Ohm cm and preferably greater than 10^15 Ohm cm. Plastics typically have thermal conductivities less than 1 W/mK, but there are some plastics such as those made by Coolpoly in Rhode Island USA that achieve this combination of properties. Materials such as Liquid Crystal Polymer (LCP) and Polyphenylene Sulfide (PPS) make good choices due to their heat stability, but need to have special fillers to achieve high thermal conductivity.
The wire layers are preferably pre-insulated to minimize the thermal insulation with maximum electrical insulation. Wire is available with many grades of insulation with one or multiple coated layers. Polyamide-imide and Polyester are common material used for some of these layers with the Polyamide-imide typically as the outer layer to have good abrasion resistance.
The coils are preferably individually wound and then connected together after assembly. An assembly of the 4 coils and the plastic insulator is shown in FIG. 11 . The inner coil 8 is electrically connected to the 2 nd coil 9 at location 45 a and 45 b . This joint can be soldered, brazed or mechanically connected. The 2 nd coil 9 is electrically connected to the 3 rd coil 10 at location 44 a and 44 b . The 3 rd coil 10 is electrically connected to the 4 th coil 11 at location 43 a and 43 b . All 4 coils are therefore connected in series with the functional entire coil starting at location 46 on the first coil and ending at location 47 on the 4 th coil. It is important to note that each of the strands of the wire is individually connected for reducing eddy current losses. Also, the configuration shown causes the furthest radial member of one coil to be connected to the closest radial member of the next coil. This is also done for eddy current reasons. This should be done for at least one of the coil connections, but here is shown at all 3 coil connections.
It is possible to do similar connections with more or less than 4 layers. In an alternative configuration, the coils can be connected electrically in parallel to reduce the size of wire required. If this is done, it is important to match the impedance of the parallel coils.
Particular geometry of the winding is important to maximize the amount of wire that can fit in the slot and maximize the thermal conductivity between the wire and cooling manifold. To have the coils sit flat it is important to keep a configuration as shown in FIG. 12 . The first wrap 48 and 49 is planar with the other side of the first wrap 50 and 51 . This wrap then crosses over 54 and 55 to the second wrap 52 and 53 on only one edge of the coil. The first side of the second wrap 52 and 53 is planar with the other side of the second wrap 56 and 57 . Ideally this crossover 54 and 55 is done on the same end of the coil as the terminations 63 and 64 are done. The keystoning of the bends causes the coil to have bulges on the corners 58 , 59 , 60 , 61 , and 62 . These bulges can be accommodated since they are located axially beyond the stator laminations. Bumps 65 can be added to the slot liner insulation 42 and Bumps 66 can be added to insulation 41 on other side as shown in FIG. 13 .
The winding process to edge wind pre-insulated wire and minimize keystoning in the corners is critical. As shown in FIG. 14 a rectangular wire 69 is clamped by clamp 71 to spindle 67 against mandrel 68 . Width is constrained by edge guide 70 . Spindle 67 , clamp 71 , and edge guide 70 are all fixed with respect to each other and rotate together. The spindle is rotated in a clockwise direction as viewed from above to form wire around the mandrel. Preferably there would be controlled tension on wire end 72 during the bend as shown in FIGS. 14 and 15 . This controlled tension allows the neutral bending plane location to be controlled. More tension moves the neutral bending plane toward the mandrel 68 . While the wire is being bent the wire is controlled between surfaces 74 and 75 as shown in FIG. 16 . Fairly tight clearance should be maintained between the wire and these surfaces to minimize keystoning. Note the edge guide 70 that controls the wire along surface 75 extends at least past the neutral bending surface, approximately half way up the wire thickness. This bending is preferably done with pre-insulated wire to optimize the process. Additional bends can be made up unclamping the wire, rotating the spindle back to the previous position, extending the wire the correct amount, and then re-clamping the wire and repeating the process. When completing more than 360 degrees of bends, the wire can be guided up to sit on top of (vertically up along axis of spindle) the wire being bent. End termination, special features, and truing up the stack can be completed once the winding is complete.
A very similar winding process can be used to edge wind multiple in hand wires that are pre-insulated with minimizing keystoning in the corners. As shown in FIG. 17 , two in hand rectangular wire 78 is clamped by clamp 80 to spindle 76 against mandrel 77 . Width is constrained by edge guide 79 . Spindle 76 , clamp 80 , and edge guide 79 are all fixed with respect to each other and rotate together. Spindle 76 is rotated in a clockwise direction as viewed from above to form wire around mandrel. After it is bent 90 degrees the wire 69 would now be bent as shown in FIG. 15 . Preferably there would be controlled tension on wire end 81 during the bend as shown in FIG. 17 . This controlled tension allows the neutral bending plane location to be controlled. More tension moves the neutral bending plane toward the mandrel 77 . While the wire is being bent the wire is controlled between surfaces 83 and 84 as shown in FIG. 18 . Fairly tight clearance should be maintained between the wire and these surfaces to minimize keystoning. Note the edge guide 79 that controls the wire along surface 84 extends at least past the neutral bending surface, approximately half way up the wire thickness.
The overall process of building this stator assembly consists of
1) Creating the edge wound coil as described above, 2) Assembling the tooth assembly that consists of multiple edge wound coils, cooling manifolds, laminated teeth, and electrical insulation in various locations, 3) Compressing the wires together and against the cooling manifolds and holding them together in a fixture, 4) Inserting this assembly into the lamination stack including driving wedges to lock teeth into the stator lamination and driving wedges to push wire tight against cooling manifolds, 5) Any required fluid or electrical interconnections that are completed prior to Vacuum Pressure Impregnation (VPI), 6) Vacuum Pressure Impregnation (VPI) of the stator assembly. | A permanent magnet motor, generator or the like that is constructed with a concentrated winding using a separate tooth. This tooth is preloaded in such a way to achieve high structural rigidity and good magnetic performance. | 7 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to supporting elements for lattice structures of the type comprising securement means adapted to receive spaced elongated components of the structure to be supported. Such lattice structures are of all types, such as welded or otherwise assembled elongated elements of the wire or rod type for use as cable trays and industrial equipment, in partitions, for the building industry, inter alia.
Depending on the use, the carrier surfaces of such lattice structures can have various orientations and require suitable securement means adapted for more or less complicated constructions and/or uses; it may also involve securement, on wall brackets, hangers, suspensions, members and the like.
2. Summary of the Invention
The present invention provides in this context a supporting element adapted to the most diverse uses and configurations with great facility of use.
According to one aspect of the invention, there is provided a section in the form of a channel with notches for securement with cut outs on opposite sides along the edges of the end wall thereof, tongues from end wall overlying the notches and extending along a fraction of the length thereof.
The notches thus defined and surmounted by the tongues cut out from the end wall surface of the profile, constitute recesses suitable, owing to their dimensions and their spacing, for receiving longitudinally-extending components, wires or rods, of the lattice structure to be supported.
For vertical orientation the lattice structure, it can simply bear under the force of gravity in the recesses of the supporting element. In any event, the securement of the lattice structure in the notches can be ensured by merely bending the tongues against the components received in the recesses.
According to a preferred arrangement of the invention, the channel-shaped profiles are arranged in pairs along the wings of a generally omega shape.
There is thus provided a structural element offering remarkable performance as regards mechanical strength in beams.
The structural section or profile can preferably be bent once or twice for the formation a bracket or of a suspension element, securement perforations being provided for the mounting on a vertical or horizontal wall, the arrangement of the supporting notches being in this case provided in a portion or portions of the structural section or profile.
According to another aspect of the invention, there is provided a pair of two structural sections or profiles of omega shape, assembled back-to-back thereby to form a structural element which is even stronger, for use as a beam or a post with the possibility of access on four sides. In this case the structural section or profile need not comprise notches and tongues over its entire extent and may in fact be eliminated.
BRIEF DESCRIPTION OF THE DRAWINGS
The characteristics and advantages of the invention will be further apparent form the description which follows, by way of example, with reference to the accompanying schematic drawings, in which:
FIG. 1 is a perspective view of a structural section or profile embodying the invention;
FIG. 2 is a cross-sectional view on the line II--II of FIG. 1;
FIG. 3 is a perspective view of an arrangement of a support bracket for a cable tray or trough;
FIG. 4 is a cross-sectional view on the line IV--IV of FIG. 3;
FIG. 5 is a perspective view of an arrangement of double bracket;
FIG. 6 is a perspective view of an assembly of two structural sections or profiles back-to-back;
FIG. 7 is a cross-sectional view on the line VII--VII of FIG. 6;
FIG. 8 is a perspective view of a modification of the double structure shown in FIG. 6;
FIG. 9 is a cross-sectional view of the double structure of FIG. 8;
FIG. 10 is a schematic view of a step in the production by profiling of a section of profile according to FIG. 1;
FIG. 11 is a perspective view of a length of a single channel structural section of profile;
FIG. 12 shows a similar section provided with a securement tongue;
FIG. 13 shows in perspective an arrangement forming a hanger;
FIG. 14 shows details of a securement member incorporated in the arrangement of FIG. 13;
FIG. 15 shows an embodiment with a double bracket similar to that of FIG. 5 for mounting on a post constituted by the carrying element of FIG. 8.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
According to the preferred embodiment shown in FIGS. 1 and 2, a support element according to the invention is constituted by a profile or structural section 10 of generally inverted omega shape 52 with a flat bottom base wall between two lateral flaring oblique surfaces or wings 11, 12, each of the flaring surfaces is connected to a respective end wall 13, 14 which is connected to a turned-down flange edge or wing 15, 16, whereby channel sections are spaced above the base wall 10 and open downwardly in the direction of the base wall to each side thereof.
FIG. 10 shows how such a profile is formed by profiling from a strip 1 of sheet metal of corresponding width, the broken lines indicated by 0-1, 0-2, 1-3, 2-4, 3-5, and 4-6 indicating the bend lines between adjacent regions. Prior to forming a series of aligned perforations 2 will be cut out from base wall section 10 and, on either side of the base wall section, along bend lines 1-3, 3-5, and the bend lines 2-4, 4-6, rectangular regions indicated at 3 and 4, of a certain length L will be cut out, the cut out portions are adapted to be detached during bending and to define in each of the channel profiles to corresponding notches 3, 4, as shown in FIG. 1, spaced at predetermined distances or intervals P.
After bending, cut outs in the end walls 13 and 14 of rectangular sections 5, 6 and a length L1 are made so as to provide corresponding flat tongues 7, 8 extending along a part of the length L designated L3 of each notch.
It will therefore be seen that the supporting element thus has in the end walls of each of the channels base, a series of notches 3, 4 of length L, spaced a distance interval P from one another. Each of the notches has an overlying tongue 7, 9 cut out from 13, 14 of the channels.
In the embodiment shown in FIGS. 3 and 4, such a supporting element is defined on only one of the branches of a profile or structural member having two branches 21, 22 at right angles on opposite sides of an elbowed region 23, only branch 31 being notched. In this embodiment, in each of the end walls 13, 14 of the channels, there is a series of three notches to receive respectively the three "warp" or longitudinal wires 31, 32, 33 of a section of cable tray 30 of lattice construction in which said warp or longitudinal wires are in the usual way welded to the "weft" or transverse wires 34, 35 and bear the warp wires 36, 37 defining the free edges of the sides of the cable tray.
As is seen in FIG. 4, each associated warp wire such as 32 is disposed in a corresponding notch, such as notch 4, and the corresponding tongue 8 can be bent down if desired against the wire thus received to ensure its securement. Each of the notches 3, 4 comprises a pair of lateral edges in the respective wings 11, 15, 12, 16. One of the lateral edges 3B, 3C, 4B, 4C is located at the junction between the associated tongue 7, 8 and the adjacent land 7A, 8A of the end wall 13, 14. The other lateral edge 3C 4C is in alignment with the edge 3D, 4D, defining the edge of the next adjacent land remote from the tongue. A longitudinal edge 3A, 4A extending longitudinally in the wings between the spaced lateral edges 3B, 3C, 4B, 4C. The edge of the tongue 3E, 4E extends transversely between longitudinal edges 3F, 4F of the tongue and is parallel and spaced from the edge 3D, 4D, defining the edge of the next adjacent land.
Locking by means of tongues permits immobilization of any wire or rod components, whether square or other cross section provided that their transverse dimension does not exceed the depth of the notch. Locking is effected by bending or deformation of the tongue inwardly into the notch so that it mates along a generatrix of the elongated wire or rod like component or wire by blocking the same against the longitudinal edges 3A, 4A.
In this embodiment of FIG. 3, the bracket 20 is adapted to be secured e.g. by bolting, its unnotched leg 22 against a vertical support wall.
FIG. 5 shows an embodiment of double bracket structure with three legs 41, 42, 43 interconnected by right angled bend areas 44, 45. Here again, only a leg, namely leg 41 is notched, the securement of the leg 43 to any horizontal support surface, ceiling or the like is possible.
However, the example of use for a cable trough is in no way limiting, as the support element according to the invention is adapted for mounting all types of lattice structures, with openings comprising longitudinal elements of the wire or rod type whether cylindrical or of any cross section. The longitudinal elongated components or elements, and the transverse components or elements fixed to each other at crossing points by welding or other means. It is particularly suitable for structures, decorations, partitioning, false ceilings, and the like with suitable adaptations of the parameters of the system according to the invention, namely the access passages L1 provided between the free transverse edges 3E 4E of the tongues and the opposed edge 3D, 4D of the adjoining land (which will correspond substantially to the longitudinal dimensions of the notches), the total length L of the access passages L1 and the tongue length L3 and the pitch or spacing P of the notches and tongues.
The perforations 2 provided in the base walls 10 of the omega shaped profile permit securement on any support: walls, ceilings, beams, floors, but are also suitable for the assembly of two profiles 10, 10' according to the embodiment of FIGS. 6 and 7, by bolting, electric spot welding or rowelling. The assembly thus constituted thus forms an X-shaped beam or structural element which has particularly preferred characteristics from the point of view of mechanical strength, but also from the point of view of functional possibilities.
The X-shaped structural section as illustrated particularly in FIG. 7 offers the possibility of securement on four sides and can preferably be used as a beam in a structural assembly; and particularly as a support in a cable trough installation of the "suspended" type.
A development of the X-shaped structural section is shown in FIGS. 8 and 9, where will be seen wings 11, 15 and 12, 16, in turned flanges 17, 18 constituting a four-sided structure of the "caisson" type with shaped section on pairs of opposite surfaces anchoring rail. This arrangement opens the possibilities of providing supporting structures or suspension units for the securement of "heeled" brackets.
The invention thus opens great possibilities for developments and uses in various fields, as will be pointed out hereinafter with reference to FIGS. 11 to 15.
First will be considered a simplified embodiment of the supporting element according to the invention as illustrated in FIGS. 11 and 12.
In the preceding embodiments the supporting elements had an omega shaped profile structural section. In FIGS. 11-12, the supporting element is in the form of a single channel with two wings 11, 15 symmetrically arranged on opposite sides of the flat end wall 13. The two wings of the profile can be of equal length or of different lengths as in the preceding embodiments. These two wings are not necessarily symmetrical, neither in lengths nor in shape nor as to angle. The channel section could also form a part of a structural profile of generally tubular shape. But in all cases, as the tongues 7 cut out from the end wall are deformed inwardly, they will never project and will never therefore snag or harm objects such as cables or the like which slide in contact with the inner surface of the supporting element.
Such a supporting element can be supported and secured by any means known per se in any spacial position, horizontally, vertically or otherwise, with the lattice structure, being self-supporting or suspended. Thus, by way only of example, the supporting element of the FIG. 12 embodiment is provided at one extremity with a securement tongue 51 formed as an extension of the outermost band of the end wall 13, which may be ben if desired, and pierced with at least one hole for securement on any associated support in vertical, horizontal, or inverted position or even in some other position.
FIG. 13 shows a hanger type support comprising a section 60 of double omega section of the type illustrated in FIG. 8 descending vertically from a suspension member 61 of stirrup shape comprising a base wall 62 pierced by holes for securement by bolts or long screws for example to a ceiling structure or to a post or the like (not shown), and two flanks 63, 64 receiving suspension pins 65, 66 coacting with perforations (not illustrated) in the flat base walls of the omega shaped sections 60. As is shown in the cross-sectional view of FIG. 9, on opposite sides of omega-shaped section base walls and at the end of the wings 11 and 12 a four-sided caisson structure forming two pairs of opposed anchoring rails. In this case the section 60 has no notches or tongues.
In the embodiment illustrated in FIGS. 13 and 14, these anchoring rails are used in pairs for fixing an angle member 70 on each side by means of securement tabs 67 provided with grooves 68, and optionally with notches (shown here). The grooves come into bearing relation against retaining surfaces such as defined by wings 15 of the caissons by means of in-turned flanges such as 17 and securement nuts 69. The two angle members thus secured spatially are suitable for example for mounting by means of bolts 71 on a post 72 also of double omega shape, but of the type shown in FIG. 7, with the formation at the edge of only the lower wings of the omega-shaped section of supporting elements 73, 74 with notches and tongues such as described above, for a lattice structure 75 schematically shown in broken lines and which can be part of a ceiling unit for example.
FIG. 15 shows an embodiment with an X-shaped beam section 80 as illustrated in FIGS. 8 and 9. Thus, there is provided on opposite sides of the double base wall 81 resulting from back-to-back securement of the omega shaped recesses, two opposed recesses 82, 83 of flared channel section shape and, on either side of these recesses, two pairs of caissons 84 and 85 adapted to form anchoring or sliding rails for sliding members of corresponding shape having securement tabs 67 as described above.
In the embodiment of FIG. 15, only one lateral recess 82 is used for receiving and securement by bolting (not shown) of U-shaped bracket 90 similar to that of the FIG. 5 embodiment with an X-shaped structural section 92 similar to that of the post 80 but in horizontal position and mounted on the upper branch or leg of the U-shaped bracket.
Thus, the double omega profile according to the invention provides mounting means for members to be supported in four different directions. There is thus available, first, a pair of flaring channels with joined base walls, as in the case of the channels indicated at 82 and 83 in the FIG. 15 embodiment. Second, there is another pair of channels perpendicular to one of flaring channels 82, 83 which form anchoring rails 84, 85 as shown.
Of course the invention is not limited to the details of construction described above simply by way of illustration. It is particularly to be noted that the supporting element and the beam structures can be of metallic or non-metallic material, for example a deformable plastic material, or any other material having sufficient mechanical strength to be deformed and to retain its shape after deformation. | A supporting element for lattice structures comprises at least one channel shaped structural section including an endwall flanked by obliquely oriented adjoining wings. Regularly longitudinally spaced securement notches are provided for securing lattice or wire cable trays the supporting element. The notches comprise longitudinally extending cutouts in each of the wings. The cutouts are defined by longitudinal and lateral edges in the wings. Regularly spaced lands extend between successive notches. Tongues longitudinally extend from the lands and partly overlying the notches. Gaps are defined between free edges of the tongues and adjacent lands. The tongues are bendable from a position generally in alignment with associated lands to a deformed position extending into the notches for restraining a section of the components between an underface of the tongues and the edges in the wings. According to a preferred embodiment two such channels shaped structural sections are joined by a common basewall to define a one-piece omega-shaped section. An X-shaped beam is also provided comprising omega-shaped sections fixed together at their basewalls. | 4 |
This invention relates to systems for, and methods of, providing energy from a battery to obtain controlled movements of a toy vehicle under a variety of different operating parameters.
BACKGROUND OF THE INVENTION
Toy vehicles are subjected to different types of movement. For example, toy vehicles may be (a) subjected to accelerations in forward and rearward directions, (b) spin-turning (spinning in revolutions in a substantially stationary position), (c) turning while moving horizontally in the forward or rearward directions and (d) movements in the forward or rearward direction at a substantially constant speed.
Each toy vehicle is generally powered by a battery which has a limited life and which has a limited voltage. Some of the movements specified in the previous paragraph require considerably more power from the battery than others of such specified movements. The toy vehicles may be subjected to the individual types of movements in accordance with controls provided by a microprocessor. The operation of the microprocessor may be provided by power from the battery. However, the drain of energy from the battery may sometimes become so great, such as during periods of starting and/or acceleration of the toy vehicle at high rates, that the microprocessor does not receive sufficient energy from the battery to operate properly in controlling the movements of the toy vehicle. This results, from increased current flows through a resistance in the battery during the times that the vehicle is being started or is being accelerated. Such a resistance particularly occurs in alkaline batteries.
Attempts have been made in the prior art to assure that the microprocessor will receive sufficient energy to provide for proper movements of the toy vehicle even when the vehicle is being started or is being accelerated at high rates. For example, an energy storage member such as a capacitor has been connected across the battery to receive and store energy from the battery. Such energy has been introduced to the microprocessor so that the microprocessor will provide for the desired movements of the toy vehicle even when the toy vehicle is being started or being accelerated at high rates. However, even when the energy storage member has been connected across the microprocessor, the microprocessor has sometimes not received a sufficient voltage from the energy storage member to obtain and/or maintain the desired movements of the toy vehicle.
BRIEF DESCRIPTION OF THE INVENTION
This invention provides a system for controlling the operation of motors for moving a toy vehicle in accordance with controls provided by a microprocessor. The system of this invention assures that, regardless of the drain imposed on a battery by the motors in moving the toy vehicle, the microprocessor will receive a voltage of sufficient magnitude to obtain a proper operation of the microprocessor in controlling the movements of the toy vehicle.
In one embodiment of the invention, a vehicle may have a chassis, wheels rotatably mounted on the chassis and motors disposed on the vehicle for selectively rotating the wheels to (a) accelerate the vehicle forwardly and rearwardly, (b) spin-turn the vehicle (turn the vehicle on a substantially stationary position), (c) turn the vehicle to the right or left during the vehicle movement forwardly or rearwardly, and (d) move the vehicle forwardly or rearwardly at a substantially constant speed.
Energy is introduced from a battery in the vehicle to an energy storage member (e.g. capacitor) in the vehicle and from the capacitor to a microprocessor in the vehicle. The microprocessor controls the operation of the vehicle motors in performing individual ones of the movements specified in (a) to (d) above. In accordance with the microprocessor operation, energy is introduced to the vehicle motors on a pulse width modulation basis where the pulse width in each modulation at each instant is dependent upon the operations of the motors in performing individual ones of the vehicle movements specified in (a) to (d) above.
For each vehicular speed of movement, the pulse widths of the energy modulations introduced to the motor are greater for the movement (a) than for the movement (b), greater for the movement (b) than the movement (c) and greater for the movement (c) than for the movement (d). Energy is introduced from the battery to the capacitor but is prevented from passing from passing from the capacitor to the battery.
In this way, operative voltage levels are maintained.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an electrical diagram, partially in block form, of a system of the prior art for providing movements of a toy vehicle;
FIG. 2 illustrates voltage wave forms at strategic terminals in the system shown in FIG. 1;
FIG. 3 is an electrical diagram, partly in block form, of a system constituting one embodiment of the invention for providing movements of a toy vehicle;
FIG. 4 illustrates voltage wave forms at strategic terminals in the system shown in FIG. 3; and
FIG. 5 is a schematic representation of a toy system, including toy vehicles, in which the electrical system shown in FIG. 3 can be used.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 illustrates an electrical system, generally indicated at 10, of the prior art for providing movements of a toy vehicle such as that generally indicated at 12 in FIG. 5. The system 10 is disposed in the toy vehicle 12. The system 10 includes a portable source of voltage such as a battery 14, a motor 16, a microprocessor 18, an energy storage member such as a capacitor 20 and a switch 21.
The battery 14 has two (2) terminals, one for providing a suitable voltage such as five (5) volts and the other for providing a reference voltage such as ground. The ungrounded terminal of the battery 14 is schematically shown as being connected to one terminal of the switch 21. The other terminal of the switch 21 is connected an ungrounded terminal of the motor 16 having a second terminal which provides a reference potential such as ground. Although only one motor 16 is shown in FIG. 1, two (2) motors, may be provided for the toy vehicle 12 in FIG. 5, one for the left wheels and the other for the right wheels.
The ungrounded terminal of the battery 14 is common with one terminal of the microprocessor 18. The microprocessor 18 controls the opening and closing of the switch 21. This is indicated by a broken line 24 extending between the microprocessor 18 and the movable arm of the switch 21. The undergrounded terminal of the battery 14 is also connected to the ungrounded terminal of the capacitor 20.
The vehicle 12 may have a number of individual movements at different times. These include the following: (a) acceleration in forward or rearward directions, (b) spin-turning (turning the vehicle without moving the vehicle forwardly or rearwardly), (c) turning the vehicle during the movement of the vehicle forwardly or rearwardly or (d) moving the vehicle forwardly or rearwardly at a substantially constant speed. As will be appreciated, each of such movements requires a different amount of power than the other movements. For example, starting the vehicle or accelerating the vehicle forwardly or rearwardly requires considerably more power than moving the vehicle forwardly or rearwardly at a substantially constant speed.
The microprocessor 18 determines at each instant which one of the different modes of vehicle movement is to be provided at that instant. The microprocessor 18 provides this determination at each instant to control the operation of the motor. For example, the microprocessor 18 may determine that the vehicle is to be started or to be accelerated forwardly. The microprocessor 18 communicates this determination to the switch 21 to close the switch so that the motor will operate to accelerate the vehicle forwardly.
When the vehicle 12 is started or accelerated forwardly or rearwardly, so much energy is drained from the battery 14 that the voltage from the battery drops below a level such as approximately three and one half volts (3.5V.). This results from the current flowing through the internal resistance in the battery 14. The voltage of approximately three and one half volts (3.5V.) is indicated at 22 in FIG. 2. This voltage is not sufficient to obtain a proper operation of the microprocessor 18. Although the capacitor 20 is connected across the battery 14 to provide stored energy to the microprocessor 18, the capacitor 20 does not provide an operative voltage to the microprocessor 18 since the voltage across the capacitor is also below three and a half volts (3.5 V.) This is indicated at 24 in FIG. 2.
FIG. 3 illustrates a system, generally indicated at 30, for overcoming the disadvantages of the prior art system shown in FIG. 1. The system 30 includes a battery 34, a motor (or motors) 36, a microprocessor 38 and a capacitor 40 respectively corresponding to the battery 14, the motor 16, the microprocessor 18 and the capacitor 20 in FIG. 1. The system 30 in FIG. 3 corresponds to the system 10 in FIG. 1 except that a diode 42 and a switch 44 are included in the system 30.
The anode of the diode 42 is common with the ungrounded terminal of the battery 34 and the cathode of the diode has a common connection with the ungrounded terminal of the capacitor 40. The switch 44 is in a series circuit with the battery 34 and the motor 36. The opening and closure of the switch 44 is controlled by the operation of the microprocessor 38 as indicated schematically by broken lines 46 extending between the switch and the microprocessor. Although the switch 44 is shown as a mechanical switch, it will be appreciated that it may constitute other types of switches such as a transistor switch.
In each successive period of time, current passes through the diode 42 for obtaining a charging of the capacitor 40. At the same time, the microprocessor 38 opens the switch 44 to prevent the battery 34 from introducing energy to the motor 36. The percentage of time for passing current through the diode 42 and opening the switch 44 in each time period at each instant is dependent upon the mode of movement of the vehicle at that instant. As will be seen, the passage of current through the diode 42 and the closure of the switch 44 are operated on a pulse width modulation basis.
When the vehicle 12 is being started or accelerated forwardly or rearwardly, the switch 44 may be closed for a suitable period of time such as approximately ninety three percent (93%) of the time in each successive time period. Each successive time period is indicated at 48 in FIG. 4. During this time, the voltage on the anode of the diode 42 has a waveform indicated at 50 in FIG. 4. The percentage of ninety-three percent (93%) of the time in each time period 48 for the operation of the motor 36 may be considered as a portion of a duty cycle, as may be the percentage of seven percent (7%) for the charging of the capacitor 40 in each time period 48 when the switch 44 is open. During the other seven percent (7%) of the time, the voltage on the anode of the diode 42 reaches a value approaching five volts (5V.). This is indicated at 52 in FIG. 4.
The voltage on the cathode of the diode 42 is indicated at 54 in FIG. 4 during the time that the switch 44 is closed. The voltage at the cathode of the diode 42 rises to a voltage approaching five volts (5v.) during the relatively short period of time that the switch 44 is opened in each successive time period. This is indicated at 56 in FIG. 4. Because of this rapid rise in voltage and the corresponding slow fall in voltage across the capacitor 40, the voltage across the capacitor 40 never falls below three and a half volts (3.5 V.). As a result, the magnitude of the voltage across the microprocessor 38 is always sufficient to provide the desired control over the operation of the motor 36.
In one embodiment of the invention, the vehicle 12 can have two (2) different speeds. For example, one speed can be approximately one half that of the other speed. The motor 36 is preferably energized for a suitable period such as approximately ninety three percent (93%) of the time when the vehicle 12 is moving at the fast speed. This occurs whether the vehicle 12 is moving forwardly or rearwardly at the fast speed, whether the vehicle is spin turning at the fast speed or whether the vehicle is turning at the fast speed while moving forwardly or rearwardly.
The motor 36 may be energized at different percentages of the time in each time period at the slow speed depending upon the type of movement of the vehicle. For example, the motor 36 may be energized for a suitable period such as approximately fifty percent (50%) of the time in each time period 48 at the slow speed when the vehicle 12 is moving forwardly or rearwardly, for a suitable period such as approximately seventy five percent (75%) of the time in each time period when the vehicle is turning while moving forwardly or rearwardly and for a suitable period such as approximately eighty five percent (85%) of the time in each time period when the vehicle is spin turning at slow speeds.
As will be seen, the pulse width modulation for the closure of the switch 44 increases as the motor 36 is subjected to increased loads. For example, the pulse width modulation for the closure of the switch 44 is as high as approximately ninety three percent (93%) when the vehicle 12 is being started, is being accelerated forwardly or rearwardly or is being moved at the fast speed. However, even when the capacitor 40 is charged only approximately seven percent (7%) of the time in each successive time period 48, the capacitor 40 becomes charged to a magnitude significantly above three and a half volts (3.5V.). This is indicated at 56 in FIG. 4. This assures that the microprocessor 38 provides proper controls over the operation of the motor 36. Furthermore, although the motor 36 does not receive energy for some of the time in each successive time period, thereby causing the motor to coast during this time, this is not noticeable to the operator of the vehicle. This results from the fact that the torque output to the motor 36 is not reduced significantly during the time in each time period 48 that the motor is not being energized and the capacitor 40 is being charged.
The advantages in the operation of the system shown in FIG. 3 may be seen from the differences in the voltage drops shown in FIG. 4. The initial voltage drop at the anode of the diode 42 is indicated at 60 in FIG. 4. As will be seen, this voltage drop is quite [steep] large. In contrast, the voltage drop at the cathode of the diode 42 is relatively small. This relatively small voltage drop is indicated at 62 in FIG. 4. Because of the relatively small voltage drop 62 at the cathode of the diode 42, the microprocessor 38 is able to control the operation of the motor 36.
The system 30 shown in FIG. 3 and described above is adapted to be used in a system disclosed and claimed in co-pending application Ser. No. 08/763,675 filed by William M. Barton, Jr., Paul Eichen and Peter C. DeAngelis on Dec. 11, 1996, for a "System For, and Method Of, Selectively Providing the Operation of Toy Vehicles" and assigned of record to the assignee of record of this application. The system disclosed and claimed in co-pending application Ser. No. 08/763,678 is shown on a simplified basis in FIG. 5 and this simplified basis is described below. Reference should be made to co-pending application Ser. No. 08/763,678 to complete the disclosure in this application with respect to the showing in FIG. 5 if it is believed that details necessary or desirable to complete the disclosure in this application with respect to FIG. 5 are missing from FIG. 5.
The system shown in FIG. 5 includes a central station generally indicated on a simplified basis at 60, a pair of hand held pads generally indicated on a simplified basis respectively at 62 and 64 and a pair of vehicles generally indicated on a simplified basis respectively at 12 and 68. The central station 60 communicates with the pads 62 and 64 by wires 70 and 72 respectively connected between the central station and the pads. The central station 60 has an antenna 74 which transmits address and control signals to antennas 75 and 76 respectively on the vehicles 12 and 68. The central station 60 has a plug 78 which is disposed in a wall socket (not shown) to apply a voltage to the central station and the pads 62 and 64.
The central station 60 interrogates the pads 62 and 64 on a cyclic basis to determine if each of the pads has addressed one of the vehicles 12 and 68. Each of the pads 62 and 64 has a switch 80 which is manually activated. A single activation of the switch 80 on one of the pads 62 and 64 causes the vehicle 12 to be addressed by that pad. Two (2) activations of the switch 80 on one of the pads 62 and 64 within a particular period of time causes the vehicle 68 to be addressed by that pad. For example, a user may activate the switch 80 in the pad 62 twice within the particular period of time to address the vehicle 68 for operation by that pad. When the user of the pad 62 addresses the vehicle 68, the user of the pad 62 continues to operate the vehicle until such time as the user of the pad no longer wishes to operate the vehicle. The user of the pad 62 also operates a plurality of switches 82, 84, 86 and 88 on the pad 62 to control the movements of the addressed vehicle 68.
The vehicles 12 and 68 are provided with sockets to receive a key such as indicated at 90 and 92. Each of the keys 90 and 92 is constructed to close switches in a vehicle in a pattern individual to that key. In this way, each of the keys provides a vehicle with an address individual to that key when the key is inserted in a socket in the vehicle. For example, the key 90 may close the second and fourth of four (4) switches in the vehicle 12 when the key is inserted into the socket in the vehicle. These switch closures provide a distinctive address to the vehicle 12. Similarly, the key 92 may close the second and third switches in one of the vehicles 12 and 68 when inserted into the socket in the vehicle.
Each of the vehicles 12 and 68 has at least a pair of front wheels 94 mounted on a first axle and at least a pair of rear wheels 95 mounted on a second axle displaced from the first axle. The closure of the switch 82 in the pad addressing one of the vehicles causes a motor 96 in the vehicle to rotate the left wheels on the chassis in the vehicle in a direction providing for a forward movement of the vehicle. The closure of the switch 84 in the pad addressing the vehicle causes the motor 96 in the vehicle to rotate the left wheels on the chassis in the vehicle in a direction providing for a rearward movement of the vehicle. In like manner, the closure of respective ones of the switches 86 and 88 in the pad addressing the vehicle causes a motor 98 in the vehicle to rotate in directions respectively providing for a forward or rearward movement of the vehicle. The motors 96 and 98 are considered the equivalent of the motor 36 in FIG. 3.
When the switches 82 and 86 in the pad addressing a vehicle are simultaneously closed, the motors 96 and 98 will provide an acceleration of the vehicle in the forward direction if the vehicle is stationary or is traveling at a reduced rate of speed. The motors 96 and 98 will maintain the vehicle at a constant speed in the forward direction if the vehicle is already traveling at the maximum speed in the forward direction. In like manner, the simultaneous closure of the switches 84 and 88 will cause the motors 96 and 98 to rotate the wheels for providing a movement of the vehicle in the rearward direction.
When it is desired to turn the vehicle while the vehicle is moving forwardly, only one of the motors 96 and 98 is operated. For example, when it is desired to turn the vehicle to the left, only the motor 98 is operated. Similarly, only the motor 96 is operated when it is desired to turn the vehicle to the right. For a spin-turning operation, the motor 96 is operated to move the left wheels on the vehicle in one direction and the motor 98 is operated to move the right wheels on the vehicle in the opposite direction. For example, the vehicle spin-turns to the right when the motor 96 rotates the left wheels for movement of the vehicle in the forward direction and the motor 98 rotates the right wheels for movement of the vehicle in the rearward direction.
As previously described, the microprocessor 38 determines, in accordance with the signals from the central station 60 indicating the closure of the switches 82,84,86 and 88, whether the vehicle is to move forwardly or rearwardly, turn to the right or the left or spin-turn to the right or the left. The microprocessor 38 then produces a closure of the switch 44 at each instant in relative percentages of time in each successive time period 48, these relative percentages being dependent upon the type of movement to be imparted to the vehicle at such instant.
Applicants have used the word "vehicle" in the specification and claims in this application in a broad sense consistent with the definition of the word "vehicle" in various dictionaries. For example, Webster's New Collegiate Dictionary copyrighted in 1976 defines "vehicle" as a "means of carrying or transporting something" and also as "an agent of transmission". Webster's Third New International Dictionary copyrighted in 1993 also defines a "vehicle" as "a means of carrying or transporting something" and additionally defines "vehicle" as "a container in which something is conveyed" and as "a carrier of goods and passengers".
Although this invention has been disclosed and illustrated with reference to particular embodiments, the principles involved are susceptible for use in numerous other embodiments which will be obvious to persons of ordinary skill in the art. The invention is, therefore, to be limited only as indicated only by the scope of the appended claims. | A vehicle may have a chassis, wheels rotatably mounted on the chassis and motors disposed on the vehicle for selectively rotating the wheels to (a) accelerate the vehicle forwardly and rearwardly, (b) spin-turn the vehicle (turn the vehicle on a substantially stationary position), (c) turn the vehicle to the right or left during the vehicle movement forwardly or rearwardly, and (d) move the vehicle forwardly or rearwardly at a substantially constant speed. Energy is introduced from a battery in the vehicle to an energy storage member (e.g. capacitor) in the vehicle and from the capacitor to a microprocessor in the vehicle. The microprocessor controls the operation of the vehicle motor(s) in performing individual ones of the movements specified in (a) to (d) above. In accordance with the microprocessor operation, energy is introduced to the vehicle motors on a pulse width modulation basis where the pulse width in each modulation at each instant is dependent upon the operations of the motor(s) in performing individual ones of the motor movements specified in (a) to (d) above. For each vehicular speed of movement, the pulse widths of the energy modulations introduced to the motor(s) are greater for the movement (a) than for the movement (b), greater for the movement (b) than for the movement (c) and greater for the movement (c) than for the movement (d). In this way, the operative voltage levels are maintained. | 0 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to a method and apparatus for coordinating the pacing of a heart and more particularly, to a method and apparatus for ventricular pacing that is triggered upon sensing an early ventricular event.
2. Description of the Related Art
Cardiac muscle needs to be electrically excited to depolarize causing a contraction. To depolarize, the muscle must reach a threshold voltage. Intrinsically, the threshold voltage is initiated by a nerve impulse. Once initiated, the depolarization wave propagates through the muscle causing the contraction. The depolarization can be recorded intracardially and/or extracardially. The recorded depolarization events are typically referred to as an electrocardiogram or ECG. An ECG recorded intracardially is more appropriately referred to as an electrogram. Typically, electrograms are recorded by electrodes placed endocardially in or epicardially on an atrium or ventricle. An ECG recorded extracardially is more appropriately referred to as a surface ECG. Surface ECGs are typically recorded from two or more electrodes placed at predetermined locations on a patient's skin. A complete surface ECG recording typically utilizes a conventional twelve lead configuration.
The features in a surface ECG are typically labeled according to the electrical activity's origin. The signal corresponding to the depolarization of the atria is called the P-wave. The signal corresponding to the depolarization of the ventricles is the QRS complex. The QRS complex can be described using three waves: the Q-wave; the R-wave; and the S-wave. The time interval from the P-wave to the R-wave is the PR interval. Thus, the PR interval is a measure of the delay between the electrical excitation in the atria and the ventricles.
Unlike surface ECG, electrograms mainly reflect local electrical depolarization. For example, an atrial electrogram mainly reflects the atrial depolarization. Therefore, an atrial electrogram corresponds to the P-wave in the surface ECG. Similarly, a ventricular electrogram mainly reflects ventricular depolarization, and thus, corresponds to a QRS complex of the surface ECG. However, it is quite often that the morphology of an electrogram may differ from its counterpart in a surface ECG, depending on the configuration of the recording electrode(s).
Currently, no consensus terminology describes the features of a ventricular electrogram. Borrowing terminology from surface ECGs, the largest peak in a ventricular electrogram is referred to as the R-wave, and the onset of the ventricular electrogram is referred to as the Q* point in the present disclosure. Physiologically, the Q* is considered the time of first or earliest detectable ventricular depolarization. Defined as the time of first detectable ventricular depolarization, the Q* concept can be applied to surface ECGs. Thus, the onset of the Q-wave in a surface ECG may be the first detectable ventricular depolarization coinciding with the Q* point of a ventricular electrogram. Thus, Q* may be measured from an electrogram or from a surface ECG.
Cardiac pacing has been used primarily to treat patients with bradycardia. A variety of pacing modes are used for the different syndromes of bradycardia. For example, for patients with normal atrial rhythm but slow ventricular rhythm due to 3 rd degree AV node block, VDD mode is often the choice of therapy. In the VDD pacing mode, ventricular pacing is triggered, after an AV delay, by a sensed electrical event in the atrium. Thus, the heart rate is increased and the ventricular rate is maintained at the atrial rate.
Recently, there has been increasing interest in using electrical stimulation as an alternative therapy to treat congestive heart failure (CHF) patients who are refractory to conventional drug therapy. For example, VDD pacing has been applied to CHF patients with normal heart rate, but with abnormal ventricular conduction system. In these patients, electrical stimulation has been used to correct the electric activation pattern of the ventricle(s) rather than to maintain the heart rate as it does for bradycardia patients. In theory, stimulating at an otherwise delayed portion of the ventricle restores synchronous ventricular contraction and thus, improves hemodynamic performance. Therefore, VDD stimulation for CHF is frequently referred to as cardiac resynchronization therapy (CRT). Currently, CRT is mainly applied to the left ventricle (LV) or both ventricles (biventricular or BV) for CHF patients with bundle branch block (BBB).
However, a large number of CHF patients also have chronic atrial fibrillation (AF). For those patients, VDD mode cannot be applied because of unavailable and/or unreliable atrial sensing to trigger ventricular stimulation. Biventricular triggering (BVT) has been developed to allow treatment of patients suffering from AF. In BVT, bi-ventricular stimulation is triggered upon sensing a ventricular event in either ventricle. In theory, BVT may still provide some degree of coordinated ventricular contraction. However, BVT mode is less likely than other methods to provide highly synchronous ventricular contraction because of a time delay between ventricular depolarization and triggering. That is, by the time current methods sense a ventricular event, usually from a R-wave as seen in a ventricular electrogram, a large portion of the ventricle may have already been intrinsically excited through asynchronous slow muscle propagation due to the block of the fast conduction system. Thus, a need exists for an alternative triggering event that is early enough to trigger ventricular stimulation and allows for more reliable sensing in the AF patients.
SUMMARY OF THE INVENTION
The method and apparatus of present invention meet the above described needs and provide additional advantages and improvements that will be recognized by those skilled in the art upon review of this disclosure. The present invention provides an apparatus and method for ventricular pacing triggered by an early ventricular sensed event. This early event occurs earlier than the R-wave and exists whenever there is intrinsic ventricular depolarization regardless of atrial conduction. The pacing pulse is delivered immediately or following a short delay to either or both ventricles upon detection of such an early event.
In its broadest aspects, the present invention comprises an apparatus including a sensor that is configured to sense the depolarizations of the heart, the sensor feeding data to a processor that is programmed to identify an early ventricular electrical event and a pulse generator controlled by the processor and configured to provide a pacing stimulus to at least one ventricle of the heart based upon the occurrence of the event. Possible early ventricular electrical events include the onset (Q*) of ventricular depolarizations which can be detected from QRS complex, and the onset of HIS bundle depolarization, which can be detected from a HIS bundle electrogram.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram of a pacing apparatus in accordance with the present invention;
FIG. 2 is an electrogram illustrating one embodiment for detecting a Q* event;
FIG. 3 is an embodiment apparatus in accordance with the present invention for detecting the onset of depolarization from the HIS bundle; and
FIG. 4 is a graph showing a comparison of Q* triggered and BVT pacing.
DETAILED DESCRIPTION OF THE INVENTION
The present invention provides an apparatus and method for ventricular pacing triggered by an early ventricular sensed event, such as the onset (Q*) of ventricular depolarization or the onset of HIS bundle depolarization. The apparatus and method provide a pacing pulse or series of pulses to one or both ventricles upon sensing this early event. For the purpose of the present invention, the Q* is defined as the first detectable onset of the QRS complex. The Q* point is typically obtained from an electrogram or a surface ECG. The onset of HIS bundle depolarization can be obtained from a HIS bundle electrogram.
The pacing method of the present invention may be carried out by any of a variety of pacing/defibrillation devices that can be either internal or external to the patient. A typical apparatus 10 in accordance with the present invention is shown in FIG. 1 . Apparatus 10 includes a processor 12 , at least one sensor 14 , and a pulse generator 16 . Processor 12 may be a microprocessor or a circuit configured to detect the Q* point of a QRS complex. Processor 12 may also include a memory 17 for storing data. Sensor 14 is configured to sense an electrogram or a surface ECG and condition the signal by amplification and filtering the record of Q* component of a QRS complex. Processor 12 receives data from sensor 14 and determines the time of occurrence of the Q* event. The processor then immediately or after a short period of time responds by sending a controlling signal to pulse generator 16 which directs at least one pacing stimulus pulse to one or both ventricles.
When an electrogram is utilized, the electrogram is typically sensed using a unipolar sensing lead. The lead may be placed endocardially or epicardially. The use of a unipolar lead may provide a waveform more representative of a global depolarization event as shown in FIG. 2. A waveform representative of the global depolarization event simplifies the detection of the Q* event. However, a multipolar sensing lead may also be used with minor modifications to the below described detection methods, as will be recognized by those skilled in the art.
The processor may carry out any number of methods capable of establishing the Q* point in the cardiac cycle. For example, the Q* may be detected in real time based on a pre-established template. In one method, to detect the Q* based on a template, an ensemble-average is first calculated from digitized electrogram waveforms. The Q* is then established from the ensemble average. A template is established from the original ensemble-averaged waveform and a real time Q* is identified. Finally, ventricular pacing is triggered based on the identified real time Q* point.
The ensemble average may be performed by aligning a number (K) of normal QRS complexes having similar morphology at the peak of the R-wave. Typically, K is an integer between 20 and 50. The selection of normal QRS complexes can be done automatically by a device or manually by visual inspection. Typically, all the normal QRS complexes have regular R-to-R intervals, with differences among the intervals less than 10%. Therefore, the time relationship between the intervals of the R-waves may be used for automatic selection.
The Q* is then established from the ensemble-averaged waveform in accordance with several algorithms.
One such suitable algorithm may first calculate the absolute derivative of the ensemble-averaged waveform, and the results normalized by the maximum derivative. The algorithm would then mark the location of the R-wave of the ensemble-averaged waveform by searching for a largest peak.
Second, the algorithm may search for a flattest segment of the normalized derivative prior to the R-wave. This is typically done by calculating the mean and standard deviation (STD) of data points within a fixed-length window that moves away from the location of R-wave to the left (i.e. earlier than R-wave). The data related to the flattest segment of the normalized derivative has the minimum standard deviation over all the data within the window. The window length can be programmed to values between 20 to 100 ms. In one embodiment, the window length is set to 50 ms with satisfactory results. The algorithm may then set a threshold as the mean+STD of the flattest segment. The algorithm would then start from the flattest segment, examine each data point in the normalized derivative and compare it with the threshold. The Q* point is established as the first point after which there are no more than M consecutive data points whose values fall below the threshold. Typically, M is set to be a number that spans 2 to 5 ms in time. In one embodiment, the M value has been set to be equivalent to 4 ms. The location of Q* is then marked in the original ensemble-averaged waveform.
Third, the algorithm determines the template, the template being a segment of data from the original ensemble-averaged waveform. The template extends for a time, T 1 , leftwards and for a time, T 2 , rightwards from the Q* point (see FIG. 2 ). T 1 and T 2 can be programmed to fall in a range from 10 to 100 ms. In a typical embodiment, T 1 may be 30 ms and T 2 may be 20 ms. The corresponding number of data points in the template is N.
Fourth, the algorithm identifies the Q* in real time. Typically, a search for a Q* point begins about 200 ms after the R-wave of the previous beat (intrinsic) or 300 ms after the pacing pulse of the previous (stimulated) beat. Each incoming data point in the electrogram and all the past data points within a window (length=T 1 +T 2 ) are cross-correlated with the template using the following equation: corr ( t ) = ∑ k = 1 n [ Tmp ( k ) × Egm ( t - n + k ) ] ∑ k = 1 n ( Tmp ( k ) ) 2 × ∑ k = 1 n ( Egm ( t - n + k ) ) 2
Where t is the current time, which is referenced to the R-wave (if intrinsic) or the pacing spike (if stimulated) of the previous beat; Egm(t) is the incoming electrogram data for the current beat; and Tmp(k) is the k-th point in the template, k=1, 2, . . . n. The triggering point is found at time t Q , when the following criteria are met:
i). corr(t Q )>C T ; and
ii). Corr(t Q )≦Corr(t), where t is any data point within a small period of time, T 3 , prior to t Q (i.e. t Q −T 3 <t<t Q ). T 3 is set to be between 5-10 ms, C T is a programmable threshold.
C T can typically be set between 0.75 and 0.9, depending on the noise level of the data. The t Q point may be later than the Q* point by an amount of about the value of T 2 .
Fifth, the identification of the Q* triggers ventricular stimulation: One or more stimulation pulses are delivered to one or both ventricles at the time of t Q . Typically, the delivery of the stimulation pulses is premised on the time difference between t Q and the reference point being between an upper rate pacing interval and a lower rate pacing interval. The reference point being either the peak of the R-wave from a previous intrinsic beat or the pacing spike from a previous paced beat.
Alternatively, the triggering point may be identified by an apparatus that includes an electrode which is placed in proximity to the HIS bundle to enable sensing of the HIS bundle electrical activity, as exemplified in FIG. 3 . The sensor detects and records the signals being propagated by the HIS bundle. Typically, the output is called a HIS electrogram. Physiologically, the HIS bundle is depolarized prior to the major ventricular depolarization, thus, the HIS electrical event is earlier than the Q* as measured from a ventricular electrogram. However, triggering ventricular stimulation directly upon a HIS bundle event may produce even better ventricular coordination than triggering using Q*.
Due to different spectrums between HIS electrograms and ventricular electrograms, a special sensing amplifier may be used in the sensor 14 for detecting the HIS bundle activities. The characteristics of such amplifiers and the threshold crossing detection algorithms applicable to the present invention will be recognized by those skilled in the art upon review of this disclosure and literature. The following method relates only to the triggering of ventricular stimulation upon detection of a HIS bundle depolarization.
For each current beat, the detection for a HIS event starts about 200 ms after the R-wave of the previous beat (intrinsic) or 300 ms after the pacing spike of the previous beat (stimulated). In one embodiment, the HIS event is detected by the processor by electrogram signal threshold crossing. In another embodiment, the HIS event is detected by the processor using the template matching algorithm described for detecting Q*. Once a HIS event is detected, a triggering delay (T H ) is started. The value of T H can be programmed from 0 to 50 ms. The T H may typically be set to 0.0 ms. At the end of T H , one or more stimulation pulses are delivered to one or both ventricles. Typically the delivery of stimulation pulses is premised on the time difference between the current delivery of stimulation and the reference point being between an upper rate pacing interval and a lower rate pacing interval. Again, the reference point is either the peak of the R-wave from a previous intrinsic beat or the pacing spike from a previous paced beat.
Some potential benefits of Q* triggered pacing over BVT have been retrospectively simulated through a study of 30 patients shown in FIG. 5 . The data from the 30 patients under the PATH-CHF study were evaluated from the Q* triggered pacing's effectiveness relative to BVT pacing. In the study, all the patients were stimulated biventricularly with five AV delays during acute test.
Peak positive rate of change of left ventricular pressure during systole (abbreviated as LV+dp/dt) is a hemodynamic parameter that reflects left ventricular contractility (pumping power). Increases in LV contractility are observed in measurements as increases in LV+dp/dt. In this analysis, selected PATH-CHF patients responded to the biventricular stimulation therapy with an increase in LV+dP/dt of at least 5% over the sinus baseline. For each patient, a response curve was constructed which is the change in LV+dP/dt plotted against AV delays. To compensate for a discrete number (5) of paced AV delays in the actual trials, each response curve was interpolated by fitting through with a 4 th order polynomial. Then the timing for a Q* triggered stimulus or a BVT stimulus was converted into a corresponding AV delay, from which the outcome of the Q* triggered pacing or BVT pacing was obtained retrospectively from the response curve at the BV pacing mode. FIG. 5 illustrates the mean changes in LV+dP/dt that would be obtained from the Q* triggered pacing and the BVT pacing in the patients. These results demonstrate a greater increase in LV+dP/dt for the Q* triggered mode.
This invention has been described herein in considerable detail in order to comply with the patent statutes and to provide those skilled in the art with the information needed to apply the novel principles and to construct and use such specialized components as are required. However, it is to be understood that the invention can be carried out by specifically different equipment and devices, and that various modifications, both as to the equipment and operating procedures, can be accomplished without departing from the scope of the invention itself. | A pacing apparatus and method for providing optimum timing for ventricular pacing without referencing atrial activities. The pacing apparatus includes a processor, at least one sensor and a pulse generator. The pacing method includes the sensing of ventricular depolarization and the identification of an early electrical event, such as a depolarization of the HIS bundle or an onset of a ventricular depolarization (Q*). The system derives the proper timing using this early electrical event which provides a predictable relationship with an optimal ventricular pacing signal. | 0 |
BACKGROUND OF THE INVENTION
The present invention relates generally to integrated circuit devices such as the microprocessors of computers and more particularly to the cooling of such devices to below ambient temperatures for improved efficiency and enhanced speed of operation.
It is well known in the electronics industry that cooling integrated circuit devices to below ambient temperatures substantially improves the efficiency and speed at which such devices can operate. Such cooling is particularly beneficial in microprocessors that form the heart of modern day computers. For example, it has been found that the performance of a desktop computer can be significantly improved by cooling the microprocessor to temperatures of −40 degrees Centigrade or below.
Various methods and apparatus are known in the art for removing the thermal heat generated by integrated circuit devices. For example, KryoTech, Inc., the assignee of the present invention, has previously developed a refrigeration system for cooling an integrated circuit device in a desktop computer. This refrigeration system operates by circulating refrigerant fluid to a thermal head engaging the microprocessor.
The thermal head defined a flow channel through which the refrigerant fluid would pass as it circulated around the closed loop of the refrigeration system. Due to its design, the thermal head functioned as an evaporator where the refrigerant fluid was converted from liquid to gaseous form. In accordance with known thermodynamic principles, thermal energy was thus removed from the location of the microprocessor. The gaseous refrigerant drawn from the evaporator by a compressor was then fed back to a condenser where the thermal energy was removed.
As one skilled in the art will appreciate, size limitations require the refrigeration system to be relatively small with a relatively low volume of refrigerant. As a result, slight changes in ambient air temperature directly affect the system's performance. For example, a decrease in ambient temperature causes the continuous operation fan to remove more heat from the gaseous refrigerant in the condenser. This results in liquid refrigerant exiting the condenser at a lower temperature and pressure. Given the small volume of refrigerant available, even a slight decrease in ambient temperature can reduce liquid refrigerant pressure excessively and significantly reduce the cooling capacity of the refrigeration system.
SUMMARY OF THE INVENTION
In one aspect, the present invention provides an integrated circuit device cooled by a refrigeration system. In this embodiment, the refrigeration system comprises a coolant loop containing a refrigerant, an evaporator, a compressor, and a condenser.
The evaporator is in thermal contact with the integrated circuit device and defines a flow channel for passage of the refrigerant to remove thermal energy from the integrated circuit device. The compressor increases the pressure of the refrigerant exiting the evaporator. The condenser is located between the compressor and the evaporator and includes a variable speed fan to force air across the condenser. A temperature sensor in thermal contact with the refrigerant provides a signal to a controller for varying the speed of the fan to maintain the refrigerant at a predetermined temperature.
Other aspects of the present invention provide a refrigerant system for cooling an integrated circuit device. The refrigerant system comprises a coolant loop containing refrigerant, an evaporator, a compressor, and a condenser.
The evaporator is in thermal contact with the integrated circuit device and has an inlet plenum and an exhaust plenum. The evaporator further defines a flow channel between the inlet plenum and exhaust plenum, and the refrigerant passes through the flow channel to absorb thermal energy from the integrated circuit device, changing the refrigerant to a gaseous state. The compressor has a suction and a discharge, and the coolant loop connects the evaporator exhaust plenum to the compressor suction. The gaseous refrigerant passes through the compressor and is discharged at a higher pressure. The condenser connects between the compressor discharge and the evaporator inlet plenum. The condenser includes a variable speed fan to remove thermal energy from the gaseous refrigerant passing through the condenser, changing the gaseous refrigerant to a liquid state. A temperature sensor in thermal contact with the refrigerant provides a signal to a controller for varying the speed of the fan to maintain the refrigerant at a predetermined temperature.
In some exemplary embodiments, the temperature sensor measures the temperature of the refrigerant between the condenser and the evaporator. In other exemplary embodiments, the coolant loop includes a capillary tube between the condenser and the evaporator for restricting flow of the refrigerant from the condenser to the evaporator. It will often be desirable that the capillary tube produces a refrigerant pressure entering the capillary tube of more than 225 pounds per square inch.
Still further aspects of the present invention are provided by a method used to cool an integrated circuit device. The method uses a refrigeration system to circulate a refrigerant throughout a coolant loop including a compressor, a condenser, and an evaporator. The method controls refrigerant pressure by providing a variable speed fan operational across the condenser for removing thermal energy from the refrigerant. The method detects a temperature of the refrigerant at a predetermined location and compares the temperature to a predetermined value. If the temperature exceeds the predetermined value, indicating that the refrigerant pressure is too high, the method increases the variable speed of the fan to reduce the temperature.
If the predetermined value exceeds the temperature, indicating that the refrigerant pressure is too low, the method decreases the variable speed of the fan to increase the temperature. In an exemplary embodiment, the predetermined location is between the condenser and the evaporator.
Other objects, features and aspects of the present invention are discussed in greater detail below.
BRIEF DESCRIPTION OF THE DRAWINGS
A full and enabling disclosure of the present invention, including the best mode thereof, to one of ordinary skill in the art, is set forth more particularly in the remainder of the specification, including reference to the accompanying drawings, in which:
FIG. 1 is a perspective view of a computer having a refrigeration system constructed in accordance with the present invention;
FIG. 2 is a diagrammatic representation of the refrigeration system that is installed in the computer of FIG. 1; and
FIG. 3 is a schematic diagram of preferred controller circuitry for use in the refrigeration system of FIG. 2 .
Repeat use of reference characters in the present specification and drawings is intended to represent same or analogous features or elements of the invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
Reference will now be made in detail to presently preferred embodiments of the invention, one or more examples of which are illustrated in the accompanying drawings. Each example is provided by way of explanation of the invention, not limitation of the invention. In fact, it will be apparent to those skilled in the art that modifications and variations can be made in the present invention without departing from the scope or spirit thereof. For instance, features illustrated or described as part of one embodiment may be used on another embodiment to yield a still further embodiment. Thus, it is intended that the present invention covers such modifications and variations as come within the scope of the appended claims and their equivalents.
FIG. 1 illustrates a computer 10 including a refrigeration system 20 constructed in accordance with the present invention. The refrigeration system 20 operates to cool an integrated circuit device, such as the computer's microprocessor 12 (FIG. 2 ). It should be understood, however, that the present invention is not limited to cooling a microprocessor 12 but is equally applicable to cooling any integrated circuit device that can benefit from lower operating temperatures.
As shown, the computer 10 generally includes a mother board 14 , various other devices, a power supply 16 , and a housing 18 . The mother board 14 provides a centralized platform for locating various electronic components, including the microprocessor 12 .
Referring to FIGS. 1 and 2, the general components of the refrigeration system 20 include a coolant loop 30 , an evaporator 40 , a compressor 60 , and a condenser 70 .
The coolant loop 30 comprises flexible tubing 32 made from copper, stainless steel, or a synthetic material to connect the various components of the refrigeration system 20 in series. The flexible tubing 32 contains a refrigerant 34 , such as R404a, R507a, R134a, or other suitable substitute, for circulation throughout the refrigeration system 20 . During circulation, the refrigerant 34 changes between gaseous and liquid states to alternately absorb and release thermal energy. Insulation material 36 surrounds the flexible tubing over portions of the coolant loop 30 that contain refrigerant 34 below the local ambient dew point to prevent condensation from forming.
The length and inner diameter of the coolant loop 30 depends on the location in the refrigeration system 20 . For example, between the condenser 70 and the evaporator 40 , the coolant loop 30 necks down to form a capillary tube 38 . In presently preferred embodiments, the capillary tube 38 may be approximately ten feet long and have an inner diameter of approximately 0.026 inches. In this configuration, the capillary tube 38 ensures refrigerant pressure at its inlet will be greater than 110 pounds per square inch, preferably between 225 and 250 pounds per square inch. It should be understood by one of ordinary skill in the art that integrated circuit devices having different thermal demands may require variations in the length and inner diameter of the flexible tubing 32 , and these variations are within the scope of the present invention.
The evaporator 40 mounts directly on the integrated circuit device, in this illustration a microprocessor 12 of a computer 10 . The evaporator 40 is formed from a highly thermally conductive material, such as brass or copper, to maximize heat transfer from the microprocessor 12 . The evaporator 40 includes an inlet plenum 42 for receiving the refrigerant 34 . The inlet plenum 42 opens to a flow channel 44 which traverses the interior of the evaporator 40 and provides maximum surface area for the refrigerant 34 . The flow channel 44 terminates at an exhaust plenum 46 for exhausting the refrigerant 34 from the evaporator 40 .
A mounting assembly 50 fixedly attaches the evaporator 40 to the microprocessor 12 . In general, the mounting assembly 50 includes an upper section 52 and a lower section 53 which attach by way of fasteners 54 , such as bolts that extend through mating flanges. Other methods of fastening are known in the art and within the scope of the present invention. In this manner, the mounting assembly 50 defines an airtight chamber 56 around the evaporator 40 and the microprocessor 12 to isolate the cooled components from ambient air. Heating elements 58 imbedded in the upper 52 and lower 53 sections maintain the exterior surface of the mounting assembly 50 above the local ambient dew point, thus preventing g condensation from forming.
The preceding description of the evaporator 40 and mounting assembly 50 is by way of example only and is not intended to limit the scope of the present invention. A more detailed description of a preferred construction of an evaporator and mounting assembly is described in pending patent application Ser. No. 09/911,865, filed by Lewis S. Wayburn, Derek E. Gage, Andrew M. Hayes, R. Walton Barker and David W. Niles on Jul. 24, 2001, titled “Integrated Circuit Cooling Apparatus”, assigned to Kryotech, Inc., the assignee of the present invention, and incorporated here by reference.
The compressor 60 includes a suction 62 and a discharge 64 and connects downstream of the evaporator exhaust plenum 46 . As is understood by one of ordinary skill in the art, the compressor 60 functions to increase the pressure of the gaseous refrigerant 34 . The compressor 60 operates at a constant rate from a constant voltage power supply (not shown), although a variable rate compressor may also be used in some embodiments.
The condenser 70 connects in series between the compressor 60 and the evaporator 40 . The condenser 70 includes cooling coils 72 , a temperature sensor 74 , a controller 76 , and a variable speed fan 78 . The cooling coils 72 are formed from a highly thermally conductive material, such as brass, aluminum, stainless steel, or copper, to maximize heat transfer from the condenser 70 to the environment. The temperature sensor 74 may be a thermocouple or other suitable substitute for measuring refrigerant temperature at a predetermined location. In one embodiment, the temperature sensor 74 is in thermal contact with the coolant loop 30 between the condenser 70 and the evaporator 40 . Insulation 75 around the temperature sensor 74 enables the temperature sensor 74 to accurately measure the refrigerant temperature inside the coolant loop 30 without penetrating the coolant loop 30 . The temperature sensor 74 provides an electrical signal 82 (shown in FIG. 3) to the controller 76 responsive to the temperature of the refrigerant leaving the condenser 70 .
In one embodiment, the controller includes a pulse width modulator circuit 80 (FIG. 3) to proportionally control the operating speed of fan 78 based on the electrical signal 82 from the temperature sensor 74 . The variable speed fan 78 forces ambient air across the cooling coils 72 to transfer thermal energy from the condenser 70 to the environment.
The refrigeration system 20 can be an after market component capable of installation with minimal modification to the integrated circuit device. For example, referring again to FIG. 1, the refrigeration system 20 can mount adjacent to the computer housing 18 . The coolant loop 30 can supply and return the refrigerant 34 to the microprocessor 12 through a thermal bus 92 extending through a cutout 94 in the computer housing 18 . The mounting assembly 50 then attaches over the microprocessor 12 to secure the evaporator 40 in position to cool the microprocessor 12 .
Referring now to FIGS. 2 and 3, the operation of the refrigeration system 20 will be described in more detail. Starting at the evaporator 40 , the liquid refrigerant 34 enters the evaporator 40 through the inlet plenum 42 where it expands into the flow channel 44 . The expansion of the liquid refrigerant 34 reduces the pressure of the refrigerant, causing the liquid refrigerant 34 to change to a gaseous state. The gaseous refrigerant 34 traverses through the flow channel 44 to quickly cool the evaporator 40 , to approximately −40 degrees Centigrade in one embodiment. The thermally conductive surface of the evaporator 40 transfers thermal energy from the microprocessor 12 to the gaseous refrigerant 34 . Simultaneously, the heating elements 58 embedded on the exterior surface of the mounting assembly 50 ensure that the exterior of the mounting assembly 50 remains above the local dew point to prevent condensation from forming.
The gaseous refrigerant 34 exits the flow channel 44 at the exhaust plenum 46 and passes through the coolant loop 30 to the compressor 60 . The compressor 60 increases the pressure of the gaseous refrigerant 34 , and the gaseous refrigerant 34 exits the compressor discharge 64 at a much higher temperature and pressure.
The pressurized and heated gaseous refrigerant 34 passes through the coolant loop 30 to the cooling coils 72 (shown in FIG. 1) in the condenser 70 . As the heated gaseous refrigerant 34 passes through the cooling coils 72 , the variable speed fan 78 forces ambient air across the cooling coils 72 , and the ambient air removes thermal heat from the gaseous refrigerant 34 to the environment. As the gaseous refrigerant 34 cools, the refrigerant 34 condenses into a liquid state.
The liquid refrigerant 34 exits the condenser 70 and passes through the coolant loop 30 . The insulated temperature sensor 74 measures the coolant loop temperature, and thus the liquid refrigerant temperature, and provides an electrical signal 82 to the controller 76 indicative of the temperature of the liquid refrigerant 34 leaving the condenser 70 .
Referring now to FIG. 3, the controller circuitry 80 compares the electrical signal 82 from the temperature sensor 74 to a predetermined temperature selected by the user to vary the speed of the variable speed fan 78 . An operational amplifier 84 amplifies the electrical signal 82 from the temperature sensor and passes the amplified signal to the input of a pulse width modulator 86 . In presently preferred embodiments, the operational amplifier 84 produces a proportional signal between about 0 and 5 volts. The pulse width modulator 86 receives the output from the operational amplifier 84 and produces a square wave having a duty cycle which is directly proportional to the magnitude of the input.
The output of the pulse width modulator 86 passes to the gate of a field effect transistor 88 which is rendered conductive when the duty cycle is “on.” By adjusting the speed of the fan 78 , the controller 76 regulates the amount of ambient air that the fan forces over the cooling coils 72 , thus controlling the temperature and pressure of the liquid refrigerant 34 leaving the condenser 70 .
Referring again to FIG. 2, the liquid refrigerant 34 passes through the coolant loop 30 and into the capillary tube 38 . The relatively long length and reduced inner diameter of the capillary tube 38 restrict the flow of the liquid refrigerant 34 , producing a desired higher pressure at the inlet of the capillary tube 38 through which the refrigerant passes to the evaporator 40 where the refrigeration cycle repeats.
It can thus be seen that the preceding description provides one or more preferred embodiments of the present invention. It should be understood that any and all equivalent realizations of the present invention are included within the scope and spirit thereof. The embodiments depicted are presented by way of example only and are not intended as limitations upon the present invention. Thus, it should be understood by those of ordinary skill in this art that the present invention is not limited to these embodiments since modifications can be made. Therefore, it is contemplated that any and all such embodiments are included in the present invention as may fall within the literal and equivalent scope of the appended claims. | An apparatus and method for controlling the temperature of an integrated circuit device includes a refrigerant system having a coolant loop containing refrigerant, an evaporator, a compressor, and a condenser. The condenser has a variable speed fan controlled to maintain the temperature of the refrigerant at a predetermined value. In a refrigeration system used to cool an integrated circuit device, a method for controlling refrigerant pressure by comparing the refrigerant temperature at a predetermined location to a predetermined value and varying the cooling applied to the condenser. | 8 |
CROSS-REFERENCE TO RELATED APPLICATION
This application is a continuation of U.S. patent application Ser. No. 12/857,766, filed on Aug. 17, 2010, which claims the benefit of U.S. Provisional Patent Application No. 61/234,583, titled “Advanced Loyalty Applications For Powered Cards and Devices,” filed Aug. 17, 2009, each of which is hereby incorporated by reference herein in its their entirety.
BACKGROUND OF THE INVENTION
This invention relates to magnetic cards and devices and associated payment systems.
SUMMARY OF THE INVENTION
A card may include a dynamic magnetic communications device. Such a dynamic magnetic communications device may take the form of a magnetic encoder or a magnetic emulator. A magnetic encoder may change the information located on a magnetic medium such that a magnetic stripe reader may read changed magnetic information from the magnetic medium. A magnetic emulator may generate electromagnetic fields that directly communicate data to a magnetic stripe reader. Such a magnetic emulator may communicate data serially to a read-head of the magnetic stripe reader.
All, or substantially all, of the front as well as the back of a card may be a display (e.g., bi-stable, non bi-stable, LCD, LED, or electrochromic display). Electrodes of a display may be coupled to one or more capacitive touch sensors such that a display may be provided as a touch-screen display. Any type of touch-screen display may be utilized. Such touch-screen displays may be operable of determining multiple points of touch. Accordingly, a barcode may be displayed across all, or substantially all, of a surface of a card. In doing so, computer vision equipment such as barcode readers may be less susceptible to errors in reading a displayed barcode.
A card may include a number of output devices to output dynamic information. For example, a card may include one or more RFIDs or IC chips to communicate to one or more RFID readers or IC chip readers, respectively. A card may include devices to receive information. For example, an RFID and IC chip may both receive information and communicate information to an RFID and IC chip reader, respectively. A device for receiving wireless information signals may be provided. A light sensing device or sound sensing device may be utilized to receive information wirelessly. A card may include a central processor that communicates data through one or more output devices simultaneously (e.g., an RFID, IC chip, and a dynamic magnetic stripe communications device). The central processor may receive information from one or more input devices simultaneously (e.g., an RFID, IC chip, dynamic magnetic stripe devices, light sensing device, and a sound sensing device). A processor may be coupled to surface contacts such that the processor may perform the processing capabilities of, for example, an EMV chip. The processor may be laminated over and not exposed such that such a processor is not exposed on the surface of the card.
Advanced loyalty features are provided on cards and devices such as payment cards. Such cards and devices may, for example, allow a user to purchase a product not sold by a merchant when the card is used at that merchant. For example, a card or device may include a user interface able to receive manual input to indicate that a user desires to purchase a product not sold by a merchant (or a particular merchant product). Such a card or device may send information indicative of such a user desire during a payment transaction at the merchant. For example, information may be communicated in a discretionary data field of one or more tracks of magnetic stripe data (e.g., via a dynamic magnetic stripe communications device). As per another example, information may be communicated via RFID communications to an RFID reader or IC chip (e.g., EMV chip) communications to an IC chip reader. The value of such a product chosen by a user may be subtracted from a user's cash account, available line of credit, or available point balance. A display may be included to display information indicative of a user's selection (e.g., to purchase a non-merchant product) such that a user may enter this information into a data entry field of an online store. Such products may include, for example, damage insurance and/or theft insurance. Multiple user payment accounts may be linked. For example, if a user desires to pay for an additional product with points and that user's point balance does not have enough points to cover the purchase price of the product, then a user's credit or debit account may be utilized to pay for the entire price of the product or the outstanding balance needed to purchase the product. An LED may indicate a particular user selection (e.g., via different colors). A display may be provided next to a button such that a user can see information representative of the product being purchased. The product displayed may be toggled from a list of products by, for example, pressing a button additional times. A confirmation button may also be provided such that a user presses a button first to activate a display and display a product name and then presses the confirmation button to confirm. A card may include a default method of payment (e.g., credit, debit, gift balance, or points) associated with a particular button (e.g., a button for purchasing a particular product). Limitations with such a default (e.g., a minimum point balance needed to utilize a product purchase with points) may be communicated to a user at card issue (e.g., via physical mail, email, or posting on a user's account page of a card issuer's website).
A user interface is provided on a card or device that allows a user to indicate a desire to top-up a purchase to the nearest dollar (or other monetary unit) and use the excess to purchase additional points. For example, a user may press a button on a card associated with $5 such that every purchase is rounded up to the nearest $5. In doing so, any excess amount between the price of a purchase and the round-up interval may be utilized to purchase points at a particular conversion rate. The conversion rate to buy points in this manner may be different (e.g., more points may be purchased for a particular monetary unit) than the conversion rate to buy points outside of a purchase transaction.
All or a portion of the purchase price of merchant items may be paid for at the merchant using points. A card or device may include buttons associated with monetary amounts (e.g., $1, $5, and $10). A user may press a button associated with the desired amount of money a user desires to pay for an item with points. A user may select an amount greater than the purchase price and the difference may be added to a user's credit balance or debit account at a point-to-cash conversion rate. Such a conversion rate may be different (e.g., more points needed for a monetary unit) than if a user selects a monetary amount that only pays for a portion of a purchase.
A user may earn points for different point accounts by providing different manual input for the different point accounts. Different buttons may be provided on a card or device. One, more than one, or all point accounts may be point pools. A point pool may be connected to different accounts—such as different cards. Such different accounts may be owned by different users (e.g., a husband and a wife). Accordingly, for example, points may be shared between multiple users. For example, a card may have a vacation pool. Every member of the family may have a card linked to such a vacation pool. In order to redeem points in a pool, for example, a particular user (e.g., a father), multiple users (e.g., a father and a mother), or all users (e.g., all members of a family) may need to agree to redeem the points for a particular award (e.g., a free vacation). Such users can do so, for example, on each user's account webpage of a main account. Multiple people may also share the same account (e.g., a husband and a wife) such that two cards are issued with the same account number and share the same point account. A cardholder may elect to contribute some or all of the points earned with a purchase to the account of a beneficiary (e.g., a child).
A card is provided that includes a user interface for receiving manual input indicative of a user's desire to forego earning points with a purchase in order to obtain an entry into a lottery. Alternatively, for example, an entry into a lottery may cost a particular number of points (e.g., over 1 point such as 50 points). Additionally, for example, an entry may only be able to be purchased while a user is purchasing an item or an entry may be able to be purchased at any time. Such a lottery may be held at least, for example, once a day, once a month, once a quarter, once every six months, or once a year. Multiple prizes and multiple winners may be included in each lottery. A winner of a lottery may win, for example, points (e.g., 1 million points), cash, and/or products. Non-point awards (e.g., plane tickets) may also be awarded in such a lottery.
A user interface may be provided on a card or button operable to receive manual input indicative of a user's desire to not earn points at a purchase from a merchant in order to obtain the ability to receive a particular point multiplier at the user's next purchase at that merchant so long as the purchase is transacted within a particular period of time (e.g., within a week or within a month). For example, a user may press a button on a card and associated information may be communicated in the discretionary data field of magnetic stripe data. Such a user may, for example, not earn any points with that purchase but may earn three times as many points with the next purchase at that merchant if the two purchases are made within a week of one another. The triple points may be, for example, limited to overlapping purchase value such that if the first purchase is $50 and the second purchase is $75 only $50 worth of purchase value obtains triple points. The remaining $25 of value may obtain no points or single points (regardless of the order of the $50 and $75 purchases). As per another example, the remaining $25 in value may receive double or triple points. Such a point bonus may be limited by a minimum purchase threshold for either a first or subsequent purchase (e.g., for qualifying purchases).
A card may be provided with an option (e.g., a manual user interface) for a user to select an opt-in marketing feature. Such a feature may send information to a merchant through, for example, magnetic stripe data communicated through a dynamic magnetic communications device. Such information may include, for example, demographic information or contact information (e.g., a user's email address). In turn, the merchant may fund a discount or additional points (e.g., a point multiplier such as double points) for the purchase. If a user has already used the opt-in feature at the merchant, the user may or may not be awarded the benefit associated with the user using the opt-in feature for the first time at a merchant. A merchant may send a user a communication (e.g., an email) as a result of receiving the user's email address in a communication to a payment card reader. The user may receive points from filling out such a survey.
Points may be utilized, for example, to purchase discounts for purchases. For example, a particular number of points may provide a 5%, 10%, 15%, or 20% discount on a purchase. A purchase limit for the discount may be provided (e.g., $100) or no purchase limit for the discount may be provided. If a limit is provided and the purchase is over the limit, the discount may only be applied to the limited amount (e.g., $100). Points may be utilized to purchase rebates (e.g., $5, $10, or $20) for a purchase. Such rebates or discounts may be, for example, open to all merchants or limited to qualifying purchases at participating merchants). Discounts and rebates may be processed by a card issuer by placing a credit on a credit statement having the value of the discount or rebate. In doing so, for example, rebates and discounts may be provided at any merchant without the knowledge of the merchant. Point levels required for purchase of a particular rebate or discount (or any other offering such as purchase insurance) may be communicated to a user via email, physical mail, or a user's account page on a card issuer's website. A product purchased with points via a button on a card may be, for example, an extended warranty associated with the products of a purchase as well as defect, damage, and/or theft protection. Other products purchased for points (or from other sources of payment) include, for example, product registration, expedited delivery, and ombudsman service.
Combinations of features may be provided on a card. For example, a card may be provided with a button associated with a feature that allows a user to earn a point multiplier at a second transaction within a period of time at a particular merchant. Another button may be provided on that card associated with a lottery feature. Yet another button may be provided on that card that allows a user to purchase a product at a purchase. Such a product may be associated with the purchase (e.g., purchase insurance for that product).
BRIEF DESCRIPTION OF THE DRAWINGS
The principles and advantages of the present invention can be more clearly understood from the following detailed description considered in conjunction with the following drawings, in which the same reference numerals denote the same structural elements throughout, and in which:
FIG. 1 is an illustration of cards constructed in accordance with the principles of the present invention;
FIG. 2 is an illustration of a card constructed in accordance with the principles of the present invention;
FIG. 3 is an illustration of a card constructed in accordance with the principles of the present invention;
FIG. 4 is an illustration of a card constructed in accordance with the principles of the present invention; and
FIG. 5 is an illustration of a mobile device constructed in accordance with the principles of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 shows card 100 that may include, for example, a dynamic number that may be entirely, or partially, displayed via display 112 . A dynamic number may include a permanent portion such as, for example, permanent portion 111 . Permanent portion 111 may be printed as well as embossed or laser etched on card 100 . Multiple displays may be provided on a card. For example, display 113 may be utilized to display a dynamic code such as a dynamic security code. Display 125 may also be provided to display logos, barcodes, as well as multiple lines of information. A display may be a bi-stable display or non bi-stable display. Permanent information 120 may also be included and may include information such as information specific to a user (e.g., a user's name or username) or information specific to a card (e.g., a card issue date and/or a card expiration date). Card 100 may include one or more buttons such as buttons 130 - 134 . Such buttons may be mechanical buttons, capacitive buttons, or a combination or mechanical and capacitive buttons. Card 100 may include button 199 . Button 199 may be used, for example, to communicate information through dynamic magnetic stripe communications device 101 indicative of a user's intent to purchase a particular product with a purchase for points.
Architecture 150 may be utilized with any card. Architecture 150 may include processor 120 . Processor 120 may have on-board memory for storing information (e.g., application code). Any number of components may communicate to processor 120 and/or receive communications from processor 120 . For example, one or more displays (e.g., display 140 ) may be coupled to processor 120 . Persons skilled in the art will appreciate that components may be placed between particular components and processor 120 . For example, a display driver circuit may be coupled between display 140 and processor 120 . Memory 142 may be coupled to processor 120 . Memory 142 may include data that is unique to a particular card. For example, memory 142 may store discretionary data codes associated with buttons of card 150 . Such codes may be recognized by remote servers to effect particular actions. For example, a code may be stored on memory 142 that causes a non-merchant product to be purchased with points during a merchant transaction. Memory 142 may store loyalty information such as identifying information for a points account (e.g., a points account number) and associated information (e.g., a default preference on how points are earned during a purchase, such as 50% of a purchase's points is given to the user and 50% of a purchaser's points is used to purchase lottery entries for a lottery that has at least one award of a particular number of points).
Any number of reader communication devices may be included in architecture 150 . For example, IC chip 152 may be included to communicate information to an IC chip reader. IC chip 152 may be, for example, an EMV chip. As per another example, RFID 151 may be included to communicate information to an RFID reader. A magnetic stripe communications device may also be included to communicate information to a magnetic stripe reader. Such a magnetic stripe communications device may provide electromagnetic signals to a magnetic stripe reader. Different electromagnetic signals may be communicated to a magnetic stripe reader to provide different tracks of data. For example, electromagnetic field generators 170 , 180 , and 185 may be included to communicate separate tracks of information to a magnetic stripe reader. Such electromagnetic field generators may include a coil wrapped around one or more materials (e.g., a soft-magnetic material and a non-magnetic material). Each electromagnetic field generator may communicate information serially to a receiver of a magnetic stripe reader for particular magnetic stripe track. Read-head detectors 171 and 172 may be utilized to sense the presence of a magnetic stripe reader (e.g., a read-head housing of a magnetic stripe reader). This sensed information may be communicated to processor 120 to cause processor 120 to communicate information serially from electromagnetic generators 170 , 180 , and 185 to magnetic stripe track receivers in a read-head housing of a magnetic stripe reader. Accordingly, a magnetic stripe communications device may change the information communicated to a magnetic stripe reader at any time. Processor 120 may, for example, communicate user-specific and card-specific information through RFID 151 , IC chip 152 , and electromagnetic generators 170 , 180 , and 185 to card readers coupled to remote information processing servers (e.g., purchase authorization servers). Driving circuitry 141 may be utilized by processor 120 , for example, to control electromagnetic generators 170 , 180 , and 185 .
FIG. 2 shows card 200 that includes button 211 associated with display 215 , button 212 associated with display 216 , and button 213 associated with display 217 . Each button may be associated with a feature displayed in display 210 . A user may press a button in order to communicate data representative of the feature through a magnetic stripe communications device or other communications device (e.g., RFID or IC chip). A light emitting diode (or other source of light) may be associated with each button to indicate to a user what feature was selected by a user. A user may be able to select multiple features such that multiple feature codes are communicated in tracks of magnetic stripe data communicated by a magnetic stripe communications device. Such codes may be provided in discretionary data fields. Such codes may be repeated on each track of communicated magnetic stripe data (e.g., repeated on tracks 1 and 2 or repeated on tracks 1, 2, and 3). In doing so, a user may associate multiple features to a purchase. A user may purchase a financial service by, for example, pressing button 211 for a purchase transaction. A user may press button 212 to enter into a lottery. The cost of the entry may be that no points are earned during the transaction. Button 213 may allow a user to earn multiple points if a purchase is made at the same merchant within a particular time period (e.g., over a day such as within a week) for a cost. The cost may be that a user does not earn any points with the initial purchase or earns a reduced amount of points (e.g., 50% point reduction). Persons skilled in the art will appreciate that one or more remote servers may manage a point balance as well as authorize and settle transactions.
The features associated with each card may be pre-determined by a user. For example, a user may select features to place on a card when ordering a card. Additionally, a user may go to a card issuer's website and select attributes of features. For example, a user may visit a card issuer's website and select the particular offering that is to be purchased whenever a user selects the feature associated with button 211 and displayed on display 215 . Information associated with a button may be displayed via a display or permanently printed, embossed, or laser engraved on a card. Card 200 may include a light sensing device to receive information via light pulses from a display (e.g., a television, mobile phone, or laptop display). A user may select to change the features or attributes of features from a card issuer's websites and may reconfigure a card accordingly. Alternatively, a card may be provided with buttons and no descriptive information. A user may change the features or attributes of features associated with one or more buttons via a card issuer's website and remote processing may perform the associated processing as a result of on-card button selections. Different codes may be communicated depending on the feature or attributes of features on a card. Such codes may be changed via a wireless communications signal (e.g., a light-based communications signal). In doing so, processing may occur off-card at a remote server without the need to determine what feature a user associated with a code. Persons skilled in the art will appreciate that a card issuer may monitor the frequency and number of times that a user utilizes a particular feature. A card issuer may cross-sell new products based on this information. For example, suppose a user's card allows a user to purchase insurance for that purchase with a particular number of points. If the user utilizes this option at a particular frequency or a particular number of times, then the user may be sent an offer to purchase the product on a periodic subscription basis (e.g., monthly) instead of an individual purchase. The offer may be communicated, for example, via physical mail, email, or a card issuer's website. In doing so, a card issuer may convert cardholders to subscription-based products the cardholder has tested in a per-purchase environment. If a user purchases a subscription for a product that was associated with a button on a card, the card issuer may change the product associated with that button and notify the user of the change (e.g., via email or a card issuer's website). Persons skilled in the art will appreciate that various types of insurance may be provided. For example, insurance may be associated with a purchase such that if a merchant fails to deliver a product, the insurance covers the incident. Insurance may also be provided, for example, for damage to a product during shipping. Insurance may cover multiple types of incidents. A card issuer may add or modify the attributes of a feature. For example, a card issuer may modify or add products in a list of products associated with a buy product for points feature. The addition or modification may be communicated via light information pulses. Additionally, a user may be provided with a code to enter into buttons on a card where the code represents the modifications or additions. Additionally, the card may receive wireless communications signals (e.g., WiFi signals) associated with the modifications and additions). In this manner, a merchant may change the information on a display associated with a lottery feature to read “win 1 M points” during a first period of time and “win Olympic tickets” during a second period of time.
A card issuer may provide a reward network of participating merchants. Accordingly, merchant specific promotions may be provided and paid for with points. For example, a particular merchant may allow for free overnight shipping for a particular number of points while another merchant may allow for an extended warranty for a particular number of points. All such promotions may be associated to a single button (or more than one button). Permanent indicia associated to the single button may generically describe all such merchant-specific promotions (e.g., “merchant promotion”). A different point conversion rate (e.g., a discounted lower point conversion rate) may be provided when items are purchased at a merchant inside of the rewards network versus merchants outside of the rewards network. Such products may be merchant products or non-merchant products. For example, a user may purchase any merchant items using points (e.g., any DVD at a Best Buy) but may receive different conversion rates for the points depending on whether the merchant is within a card issuer's reward network as well as the level of membership within that issuer's reward network. Merchants (e.g., merchants that are part of a particular rewards network) may be provided with devices that offer on-the-spot promotions. Such devices may emit light pulses or other communication signals that are received and stored on a card or other device. A card may prompt a user to interact with a card (e.g., press a button) to confirm acceptance and desire to use a communicated promotion. A promotion may be paper based, but may interact with payment process that includes a card or other device. For example, a user may pick up a coupon that states “give this coupon to a friend and if that friend makes a purchase within 10 days, you will get double points.” The cashier may then scan the barcode of the coupon and a user may press a MERCHANT OFFER button on a card. The merchant system may similarly send the coupon code to a remote system. An associated code may be communicated with payment information (e.g., magnetic stripe data) to the remote system. The remote system may then associate the purchase with the coupon code. Upon a friend redeeming the coupon, the user associated with the original payment information may be provided with additional points (e.g., double points). As per another example, a merchant may pre-register with a card issuer the merchant's promotion. The promotion may be, for example, a cross-merchant promotion where a user that purchases an item at one merchant may receive double points and a 10% discount if a paper coupon is used within a particular number of days at a different merchant. To qualify, a user may be required to press a MERCHANT OFFER button. A card issuer may then retrieve the promotion for the merchant from a database to learn that the user has opted in for the cross-merchant promotion. Accordingly, the card issuer's processing system may periodically check during the promotional window (or at the end of the promotion) whether the user has made a purchase at the second merchant to receive the double points. The coupon may be utilized at the second merchant to receive the 10% discount. Alternatively, for example, the coupon may also be needed to obtain the double points in addition to the 10%.
FIG. 3 shows card 300 that may include dynamic magnetic stripe communications device 310 , buttons 311 - 315 , permanent information 320 , display 350 , data receiving device 370 , and buttons 331 - 333 . Button 331 may be associated with a first line of displayed information on display 350 . Button 332 may be associated with a second line of displayed information on display 350 . Button 333 may be associated with a third line of displayed information on display 350 . Persons skilled in the art will appreciate that buttons 331 - 333 may actually be virtual buttons on display 350 and display 350 may be a capacitive touch screen. Data receiving device 370 may be a light or sound sensor for receiving information through received light or sound.
FIG. 4 shows card 400 that may include signature line 410 and display 420 . Persons skilled in the art will appreciate that card 300 of FIG. 3 may depict the obverse side of a card and card 400 of FIG. 4 may depict the reverse side of a card. Individual components of card 300 of FIG. 3 or card 400 of FIG. 4 may be provided on either side of a card or both sides of a card. More than one instance of a component may be provided on any side of a card (e.g., the same side as a component or a different side as a component). Persons skilled in the art will appreciate that a user may communicate feature codes representative of a user's on-card selection via codes that may be displayed visually and entered into a webpage as part of an online payment. A display may display not only a code for an online payment, but also indicia representative of the feature. In doing so, the user can confirm that the right feature was selected. Persons skilled in the art will appreciate that different codes for the same feature may be displayed and communicated via a dynamic magnetic communications device. In doing so, the security of the card may be increased. Additionally, the same or different codes may be communicated on different tracks of data to represent the selection of a particular feature.
FIG. 5 shows mobile device 500 , which may be a mobile telephonic device. Device 500 may include one or more physical buttons (e.g., button 540 ). Device 500 may include one or more display screens 510 . Such a display screen may be touch sensitive such that virtual buttons (e.g., button 530 may be provided) on virtual card 520 . Virtual card 520 may appear similar to a physical card described herein. A user may select different virtual cards by, for example, swiping his/her finger across a touch-sensitive display to scroll to the next virtual card. Mobile phone 502 may include a communications device operable to communicate data to a card reader. For example, mobile phone 502 may include an RFID antenna to communicate to an RFID reader, a pop-out IC chip panel operable to be fed into an IC chip reader, or a magnetic communications device having a magnetic emulator operable to communicate magnetic stripe data wirelessly to a read-head of a magnetic stripe reader.
Persons skilled in the art will also appreciate that the present invention is not limited to only the embodiments described. Instead, the present invention more generally involves dynamic information. Persons skilled in the art will also appreciate that the apparatus of the present invention may be implemented in other ways than those described herein. All such modifications are within the scope of the present invention, which is limited only by the claims that follow. | Advanced loyalty applications are provided to improve the functionality of cards and devices. For example, a user interface may be placed on a card (e.g., a physical button) or a telephonic device (e.g., a virtual button on a capacitive touch screen). Manual input provided to this user interface may, for example, cause a non-merchant product (e.g., insurance) to be purchased with a merchant purchase. The product can be paid for with debit, credit, gift card balance, or points. A code indicative of a user's desire to purchase the product may be communicated to a payment card reader (e.g., to a magnetic stripe reader via a magnetic stripe communications device). A display may be provided next to a button to allow a user to scroll, or toggle by pressing the button repeatedly, through different products (which may be merchant or non-merchant products). | 6 |
FIELD OF THE INVENTION
The present invention relates to a process for simultaneous and selective preparation of single walled and multi-walled carbon nanotubes.
Carbon nanotubes (also referred to as carbon fibrils) are seamless tubes of graphite sheets with full fullerene caps which were first discovered as multilayer concentric tubes or multi-walled carbon nanotubes and subsequently as single-walled carbon nanotubes in the presence of transition metal catalysts. Carbon nanotubes are fascinating structures for fundamental science and technological applications e.g. super strong composites, field emission display devices, hydrogen storage, AFM tips, and drug delivery systems etc.
Generally, single-walled carbon nanotubes are preferred over multi-walled carbon nanotubes for use in these applications because they have fewer defects and are therefore stronger and more conductive than multi-walled carbon nanotubes of similar diameter. Defects are less likely to occur in single-walled carbon nanotubes than in multi-walled carbon nanotubes because multi-walled carbon nanotubes can survive occasional defects by forming bridges between unsaturated carbon valances, while single-walled carbon nanotubes have no neighboring walls to compensate for defects.
However, the availability of these new single-walled carbon nanotubes in quantities necessary for practical technology is still problematic. Large scale processes for the production of high quality single-walled carbon nanotubes are still needed. Presently, there are three main approaches for synthesis of carbon nanotubes. These include the laser ablation of carbon (Thess, A. et al., Science, 273:483, 1996), the electric arc discharge of graphite rod (Journet, C. et al., Nature, 388:756, 1997), and the chemical vapor deposition of hydrocarbons (Ivanov, V. et al., Chem. Phys. Lett, 223:329, 1994; Li A. et al., Science, 274:1701, 1996). The production of multi-walled carbon nanotubes by catalytic hydrocarbon cracking is now on a commercial scale (U.S. Pat. No. 5,578,543) while the production of single-walled carbon nanotubes is still in a gram scale by laser (Rinzler, A. G. et al., Appl. Phys. A., 67:29, 1998) and arc (Journet, C. et al., Nature, 388:756, 1997) techniques.
The synthesis of nanotubes in experimental quantities using a standard carbon arc method has been accomplished for several years. Production of nanotubes typically consists of placing water-cooled carbon electrodes of amorphous carbon or graphite rods approximately one millimeter apart within a vacuum chamber, evacuating the chamber to a pressure of approximately 10.sup.−7 torr, backfilling the chamber with an inert gas such as helium, nitrogen, argon or hydrogen to pressures ranging from approximately 50 to 500 torr, striking a high current electrical arc between the electrodes while continually adjusting them to maintain the one millimeter electrode gap. In this process, the ability to create an inert gas atmosphere is essential. The result is a growth of carbon nanotubes and other small carbon particles on the negative electrode. The quantity of nanotubes produced in the electrode deposits depends on how long optimum growth conditions can be maintained.
In such experimental setups, a DC voltage of about 18V is applied between two carbon electrodes in a chamber under about 500 torr of helium. A plasma forms between the closely-spaced electrodes. Carbon accumulates on the negative electrode and grows as the positive electrode is consumed. When the correct electrode spacing is maintained, the deposit grows into a cylindrical structure with an outer hard shell and an inner soft fibrous core. The gray outer shell is composed of carbon nanotubes and other carbon nanoparticles fused into a hard mass, probably due to excessive current passing through it. The soft black inner core contains free nanotubes and nanoparticles in the form of fibers where the fibers are aligned with the direction of current flow between the electrodes.
In order to produce any substantial number of carbon nanotubes, it is a typical practice to employ a larger diameter graphite rod as the cathode and a relatively smaller diameter graphite rod as the anode. Initially, at least, the electrodes have flat and parallel opposing faces. Since the anode rod is consumed as the arc discharge proceeds, one of the electrodes must be moved to displace a constant gap. Furthermore, it is desirable to move the anode with respect to the cathode so as to expose a fresh surface for deposition of the nanosize particle products. U.S. Pat. No. 5,482,601 to Oshima et al, for example, describes a mechanism for the production of carbon nanotubes in an inert gas-containing chamber. The complicated mechanism is required to position the two electrodes in the chamber and move them with respect to each other as the DC arc causes the production of the carbon nanotubes. As disclosed, it is also desirable to provide a scraper to shear the deposited nanotubes and other nanoparticles from the surface of the cathode. All of this is to be accomplished without altering the pressure of the inert gas in the chamber and while maintaining a suitable gap between the electrodes for the production of the plasma and the deposition of the carbon nanotubes.
There are several efforts reported in the open literature/patents wherein carbon nanotubes have been synthesized by dc-arc discharge technique. The biggest challenge comes from obtaining large quantities of pure nanotubes free from, catalyst, amorphous carbons, carbon nanoshells etc. The carbon Nanotubes prepared by the technology can be extended to various applications.
Reference may be made to Iijima's work [S. Iijima, Nature, 354, 1991, 56] who first discovered carbon nanotubes in the carbon soot obtained from carbon arc-discharge process. These nanotubes were multiwalled only, with diameter ranging from 10 to 25 nm. In their later experiments, Iijima [S. Iijima et. al. Nature, 363, 1993, 603] produced single walled carbon nanotubes by using transition metal catalyst. They however, did not report the existence of MWNTs. Ebbesen et. al [T. W. Ebbesen and P. M. Ajayan, Nature 358, 1992, 220] produced Multi walled carbon nanotubes as cathode deposit in gram quantity by applying potential of ˜18V between two graphite rods inside a reaction vessel with flowing He or Ar atmosphere. Using almost similar set-up Bethune et. al [D. S. Bethune, Nature, 363, 1993, 605] and Journet [C. Journet, Nature, 388, 1997, 756] produced SWNTs in the form of spider webs or ropes inside the reactor by drilling a hole in the anode and filling it up with catalyst powder comprising of Ni, Co, Fe or combinations of Ni—Y, Co—Y in different atomic percents. A He atmosphere of 660 mbar and voltage of ˜30V was used to strike the arc. In the dc-arc discharge setup the cooling was provided to the whole chamber by water circulation. Saito et. al. [Y. Saito, Chem. Phys. Lett. 294, 1998, 593] used Rh—Pt as mixed catalyst to produce carbon nanotubes by dc-Arc discharge technique. The purity of the graphite rods was 99.998% and that of metal powder higher than 99.9%. This caused the process to be much costlier. The TEM micrographs showed the presence of SWNTs predominantly in the cathode deposit and almost no trace in chamber soot was available. Similar observation was made with Fe—Ni system. In a relatively recent study Gavillet et. al. [J. Gaviillet et. al. Carbon 40, 2002, 1649] produced good yield of carbon nanotubes containing soot in the dc-arc discharge reactor by using combinations of Ni/Y: 100/0, 80/20, 50/50, 20/80, 0/100. The tubes found on the cathode contained small amount of Y catalyst as well. The studies helped in understanding the growth mechanism of carbon nanotubes. Cui et. al [S. Cui, Carbon 42, 2004, 931] reported investigation on preparation of multiwalled CNT by dc arc discharge under N 2 atmosphere. U.S. Pat. No. 7,008,605 describes a process where CNTs have been produced non-catalytically by creating an electric arc between carbon anode and carbon cathode in the open atmosphere. U.S. Pat. No. 7,011,884 describes a process of manufacturing CNTs with an integrally attached outer graphitic layer on CNTs. U.S. Pat. No. 4,663,230 describes a process of producing multi-walled carbon nanotubes using catalysts containing iron, cobalt or nickel at temperatures between 850° C. to 1200° C. Recently, rope-like bundles of single-walled carbon nanotubes were generated from the thermal cracking of benzene with iron catalyst and sulfur additive at temperatures between 1100-1200° C. (Cheng, H. M. et al., Appl. Phys. Lett., 72:3282, 1998; Cheng, H. M. et al., Chem. Phys. Lett., 289:602, 1998). U.S. Pat. No. 6,955,800 describes a process of producing CNTs where catalytic particles are exposed to different process conditions at successive stages wherein the catalytic particles do not come in contact with reactive (catalytic) gases until preferred process conditions have been attained, thereby controlling the quantity and form of carbon nanotubes produced. Ryzhkov et. al [Ryzhkov, Vladislav Andeevitch, US pat. 20020122754, Sep. 5, 2002] describes a process in which fullerene/nanotubes mixture is produced during a periodical pulsed auto-regulated action of the electric current arc-discharge in the multi component hydrocarbon medium. Kazunori Anazawa et. al. [K. Anazawaa et. al. U.S. patent No. 20040168904, Sep. 2, 2004] describes a process to produce carbon nanotubes by striking arc between two electrodes, using a porous carbonaceous material for at least one of the two electrodes.
OBJECTIVES OF THE INVENTION
The main object of the present invention is to provide a process for the simultaneous and selective growth of single walled and multi-walled carbon nanotubes in the single experiment on the arc-discharge setup which obviates the drawbacks as detailed above.
Another object of the present invention is to increase the yield of carbon nanotubes per run by using a specially prepared carbon composite electrode.
Yet another object of the present invention is to create a suitable temperature gradient around the cathode by using an ingenious device.
Yet another object of the present invention is to produce catalyst free MWNTs at the cathode.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 represents the dc-arc discharge set-up.
FIG. 2 represents Ingenious-cooling device.
FIG. 3 represents SEM micrograph of Chamber deposit showing nanotubes webs.
FIG. 4 represents SEM micrograph of cathode deposit showing straight nanotubes.
FIG. 5( a ) represents Raman micrograph of the Chamber soot showing presence of SWNTs.
FIG. 5( b ) represents Raman micrograph of the cathode deposit soot showing presence of MWNTS.
FIG. 6 TEM micrograph of the chamber deposit showing presence of SWNTs.
FIG. 7 TEM micrograph of the cathode deposit showing presence of MWNTs.
SUMMARY OF THE INVENTION
Accordingly the present invention provides a process for the simultaneous and selective growth of single walled and multiwalled carbon nanotubes which comprises preparing a graphite electrode rod containing catalyst selected from Fe, Co, Ni and a mixture thereof, acting as an anode and another graphite electrode rod acting as a cathode each electrode having a distal and a proximal end, placing the above said two electrodes parallel to each other and their axis being substantially aligned such that their distal ends are at least 1 mm apart, in a closed and evacuated arc discharge chamber, creating a DC-arc discharge inside the above said chamber by applying a DC-current voltage in the range of 10-50 V, at an arc current of 50-200 amp, under inert gas pressure of 120-500 torr followed by cooling the system by maintaining a temperature gradient by using a cooling coil around the arching electrodes, to obtain simultaneously the desired deposition of multiwalled carbon nanotubes at the cathode and the single walled carbon nanotubes in the chamber.
In an embodiment of the present invention the anode electrode is made by filling the catalyst in a hole drilled in the graphite electrode or is a composite graphite electrode containing uniformly distributed catalyst.
In yet another embodiment the anode electrode or composite graphite electrode used comprises coke, binder pitcher and uniformly distributed catalyst.
In yet another embodiment the electrodes used are in the form of rods of diameter in the range of 8-20 mm.
In yet another embodiment the cooling coil used for maintaining the temperature gradient is made of Copper.
In yet another embodiment the multiwalled carbon nanotubes deposited at the cathode are free from catalyst impurities.
In yet another embodiment the DC-current voltage used is preferably in the range of 20-25 V.
In still another embodiment the DC-current used is preferably in the range of 50-150 amp.
In still another embodiment the inert gas used is selected from Nitrogen, Argon and Helium.
DETAILED DESCRIPTION OF THE INVENTION
The present process of synthesizing single walled and multi walled carbon nanotubes simultaneously in the same experiment by Dc-arc discharge technique employs a self synthesized carbon anode electrode having uniformly distributed catalyst. The process also employs an ingenious device inside the arc chamber to produce desired temperature gradient around the arcing electrodes. The process ensures the synthesis of single walled and almost catalyst free multi walled carbon nanotubes simultaneously in the same experiment.
The present invention provides a process for the simultaneous growth of single walled and multiwalled carbon nanotubes in the same set of experiment, which comprises:
An airtight chamber in which an arc discharge is to be carried out. An axially extending rod-like anode 5 having a distal and a proximal end is horizontally disposed within the chamber 10 . The anode 5 is formed of a carbonaceous material such as carbon, graphite or metal-containing graphite. The metal of the metal-containing graphite may be, for example, copper, iron or cobalt or nickel. The diameter of the anode is generally 5-30 mm, preferably 6-15 mm. The anode is supported by a holder having a hole to fix the anode electrode. The holder is electrically connected to a positive pole of a direct current source. A cathode 6 is also disposed within the chamber 10 such that the cathode surface is oriented parallel to the axis of the rod-like anode. It is important that the area of the cathode surface is larger than that of the anode 5 . The cathode 6 , which is formed of a heat-resisting conductive material such as a metal, e.g. copper, or a carbonaceous material such as carbon, graphite or metal-containing graphite, is in the form of a cylinder having a distal and a proximal end whose axis is oriented in parallel with the axis of the anode 5 and their axis are substantially aligned such that the distal end of electrodes are at least 1 mm apart. The cathode 6 is supported by a holder having a hole to fix the cathode electrode. The holder is electrically connected to a negative pole of a direct current source. The cylindrical cathode 6 has a proximal end surface which is opposite to the cathode distal end surface, and to which a coaxial, electrically insulating shaft is secured for rotation with the cathode 6 . The shaft extends out of the chamber 10 and is connected to a driving mechanism including an electric stepper motor 7 for rotating the shaft.
As a result of the above construction, by mounting the rod-like anode 5 on the holder, the distal end surface faces in the direction of the distal end surface of the cathode 6 . By operating the stepper motor, the gap between the distal end surface of the anode 5 and the cathode distal end surface is adjustable at will.
Designated as 3 is the opening of an inert gas such as helium, argon or nitrogen for feeding the inert gas with a controlled pressure to the chamber 10 .
The chamber consisted of an ingenious cooling assembly 4 surrounding the electrodes. Such type of assembly has not been used by any previous inventors. The assembly consists of specially designed cooling device, the distance of which could be varied w.r.t. the electrodes so as to main proper thermal gradient inside the chamber during arcing. The assembly, shown in FIG. 2 , is made of copper tube in the form of a coil. The diameter of the copper tube can vary from 6 mm to 20 mm and preferably from 8 to 12 mm. The coil is fixed to the base plate 11 through SWAGELOK® tube fittings 12 and 13 . Both the electrodes anode and cathode can be changed at will. This ingenious cooling device helped in the growth of SWNTs around it in the form of webs and sheets. This was not possible without the assembly and the carbon material formed was either amorphous or contained small amounts of MWNTs. No SWNTs were found to be present without the use of the device.
A method of producing carbon nanotubes according to the present invention using the device of FIG. 1 will be now described.
In starting up, A graphite rod, 6-15 mm diameter preferably 8-10 mm diameter was filled with the catalysts consisting of Fe, Co and Ni or mixture thereof, and used as anode. The other graphite rod, 10-20 mm diameter preferably 12-14 mm diameter was used as cathode. The cathode (mobile) moves towards the anode (stationary) by auto controlled stepping up motor as described earlier maintaining desired arcing distance. The anode and cathode electrodes are fixed in the chamber and the chamber is closed and evacuated, with the help of vacuum pump which consisted of rotary vacuum pump along with diffusion pump, to reduce the pressure within the chamber 10 to 0.1-760 Torr, preferably 1-20 Torr.
Helium/Argon/Nitrogen gas preferably Helium gas is then fed from the source to the chamber 10 and the helium gas pressure is maintained at 10 Torr to 2 atm, preferably at 100 to 700 Torr. Thereafter, stepper motor is operated to adjust the distance between the distal end surface of cathode 6 and the anode distal end surface to generally 0.1-5 mm, preferably 0.5-2 mm, while applying the direct current voltage of generally 10-50 V, preferably 25-35 V there between, so that an arc discharge occurs with the simultaneous deposition of a carbonaceous material containing carbon nanotubes on the tip of the cathode surface 6 which is adjacent to the distal end surface of the anode 5 as well as on the surface of copper coil and inside surface of chamber. The DC current in this case is controlled to 100-200 A and preferably 100-150 A. While continuing the arc discharge, the driving mechanism 7 is continuously operated to rotate the cathode 6 and to change the relative position between the distal end surface of the cathode and the anode surface. The rotational speed may be such that the average running speed of the distal end surface of the cathode relative to the anode surface ranges from 1 to 10 mm/minute. The distance between the cathode distal end surface and the distal end surface of anode is also controlled in the above range since the anode 5 is consumed as the arc discharge proceeds. Upon completion of the arcing process the system is allowed to cool down and carbonaceous material deposited at the cathode, inside walls of the chamber and surrounding the copper coil are collected.
In a feature of the present invention single walled carbon nanotubes can be synthesized by the dc-arc discharge of carbon electrode.
In yet another feature under the present invention catalyst free MWNTs may be synthesized in the same experiment.
In yet another feature of the present invention a catalyst containing carbon electrode was synthesized to ensure uniform distribution of catalyst particles.
In still another feature of the present invention an ingenious device was assembled inside the arc chamber to produce desired temperature gradient around the arcing electrodes.
Another feature of the invention is the use of specially prepared carbon composite electrode that ensured uniform dispersion of catalyst whereby maximum number of carbon atoms and chains are in contact with catalyst during arc evaporation.
Upon completion of the arcing process, the inner walls of the chamber were coated with web-like deposits which could be readily peeled away as a rolled-up fibrous mat. A typical SEM micrograph of such material ( FIG. 3 ) revealed a multitude of nanotubes or ropes in the mat. These nanotubes are entangled with amorphous soot and catalyst particles (or catalyst encapsulated in graphitic nanoshells). In addition, a large amount of straight micro-structures aligned preferentially along the length of the cathode (or electric field) was also found. This “cathode deposit” is depicted in FIG. 4 . The cathode deposit comprised of graphitized carbon and sharp needle-like structures. Upon detailed microscopic examination, these needles resembled the MWNT structure with an outer diameter of ˜20-25 nm.
The Raman spectra of these two deposits are shown in FIGS. 5( a ) and 5 ( b ). The chamber deposit comprised of SWNT bundles since its Raman spectrum ( FIG. 5( a )) showed the presence of the radial breathing and tangential bands at 165-183 and 1591 cm −1 respectively. The TEM image of the material ( FIG. 6) shows the presence of SWNTs alongwith the graphite nanoshells. The strong G-band at 1580 cm −1 in FIG. 5( b ) and the TEM image in FIG. 7 suggest that the cathode deposit is predominantly comprised of MWNTs. The prominent D-band seen in both the spectra is attributed to the presence of disordered carbon material present in the deposit. Several runs under similar conditions were carried out to collect sufficient amount of carbon deposits. These were found to be of reproducible quality and the production rate of total deposit (chamber+cathode) per run was estimated to be around 5-8 gms. The total time taken to consume a ˜6 cm long electrode was about 30 minutes. We also found that the amount of webs in the chamber deposits obtained with 2 at. % Ni/Co catalyst were almost double than that obtained with 1 at. % of the same catalyst composition. However, the length of the cathode deposit was relatively shorter in the latter case. Energy dispersive spectroscopic (EDS) analysis of the two deposits showed that the cathode deposit did not contain any metal impurity while the chamber deposit contained ˜36 wt. % catalyst (Table 1).
The novelty of the invention lies in obtaining a desired temperature gradient by cooling the arc chamber by using a cooling coil around the electrodes in the said chamber so as to obtain the simultaneous deposition of MWCNTs at the cathode and SWCNTs in the chamber.
The following examples are given by way of illustration and therefore should not be construed to limit the scope of the present invention.
Example-1
3 mm dia hole was drilled in one of the graphite electrodes of diameter 8 mm and length 60 mm. The hole was filled with 2 at % Ni and 2 at % Co powder, purity 99.9%. This electrode was arced against a cathode of dia. 10 mm. A current of 100 A and 20 Volts was maintained during arcing. Helium pressure was maintained at 300 torr. The electrode was moved to and fro by stepping up motor to maintain 1 mm separation between the electrodes to achieve suitable arcing condition during the arcing process. The soot which was collected from the chamber, contained small amount of SWNTs, whereas the cathode deposit comprised of almost 80% of the total evaporated carbon and contained mostly MWNTs.
Example-2
3 mm dia hole was drilled in one of the graphite electrodes of diameter 8 mm and length 60 mm. The hole was filled with 2 at % Ni and 2 at % Co powder, purity 99.9%. This electrode was arced against a cathode of dia. 10 mm. A current of 100 A and 20 Volts was maintained during arcing. Helium pressure was maintained at 500 torr. The electrode was moved to and fro by stepping up motor to maintain 1 mm separation between the electrodes to achieve suitable arcing condition during the arcing process. The soot which was collected from the chamber, contained 50% more of SWNTs compared to previous experiment, whereas the cathode deposit comprised of almost 80% of the total evaporated carbon and contained mostly MWNTs.
Example-3
3 mm dia hole was drilled in one of the graphite electrodes of diameter 8 mm and length 60 mm. The hole was filled with 4 at % Ni and 4 at % Co powder, purity 99.9%. This electrode was arced against a cathode of dia. 10 mm. A current of 100 A and 20 Volts was maintained during arcing. Helium pressure was maintained at 500 torr. The electrode was moved to and fro by stepping up motor to maintain 1 mm separation between the electrodes to achieve suitable arcing condition during the arcing process. The carbon soot which was collected from the chamber was found to be doubled as compared to the soot in example 1. The amount of catalyst in the soot as measured by EDS was also found to be 36% by wt. of the total soot deposits. Additionally, the soot was also found to contain amorphous carbon and confirmed by Thermal Gravimetric Analysis. The cathode deposit weigh about 70% of the total carbon evaporated during the arcing.
Example-4
3 mm dia hole was drilled in one of the graphite electrodes of diameter 8 mm and length 60 mm. The hole was filled with the catalyst comprising of 3% Y+2% Ni+2% Co, purity 99.9%. This electrode was arced against a cathode of dia. 10 mm. A current of 100 A and 20 Volts was maintained during arcing. Helium pressure was maintained at 500 torr. The electrode was moved to and fro by stepping up motor to maintain 1 mm separation between the electrodes to achieve suitable arcing condition during the arcing process. The carbon soot which was collected in the chamber was found to contain sea urchin like deposits when viewed under the SEM. The tubes were of much shorter length as compared to one produced in examples 1-3. The amount of catalyst in the soot as measured by EDS was also found to be >36% of the total soot deposits. Additionally, the soot was also found to contain amorphous carbon and confirmed by Thermal Gravimetric Analysis. The cathode deposit weigh about 70% of the total carbon evaporated during the arcing.
Example-5
Graphite anode comprised of self-synthesized composite electrode containing, coke, binder pitch and the catalyst Ni and Co 2 at % each. The processing of the electrode ensured that all the catalyst was distributed uniformly within the electrode, which was machined to 8 mm OD. A 10 mm uniform diameter, 60 mm long synthetic graphite electrode (99.9% pure carbon), was used as cathode. A constant current of 100 A at 20V was maintained between the electrodes during arcing. The pressure of He inside the chamber was maintained at ˜500 torr. The arc gap of ˜1 mm was maintained through a stepper motor connected to cathode. The soot which was collected from the chamber, contained 50% more of SWNTs compared to previous experiment, whereas the cathode deposit comprised of almost 80% of the total evaporated carbon and contained mostly MWNTs.
According to the present invention, it is possible to synthesize directly single wall carbon nanotubes and catalyst free multiwalled carbon nanotube separately. This has been possible by modifying the cooling profile or temperature gradient inside the chamber by employing an ingenious device. The system is capable of growing sufficient amount of web like structure around the device. Another novelty of the technique is the use of graphite composite electrode that ensured uniform dispersion of catalyst whereby maximum number of carbon atoms and chains are in contact with catalyst during arc evaporation.
TABLE 1
EDS analysis of deposits containing carbon nanotubes
produced inside the de-arc discharge reactor
As-produced sample
Sample description
Element
(% by weight)
Chamber deposit
C
60.00
O
2.99
Ni
18.22
Co
18.79
Cathode deposit
C
95.14
O
4.86
Ni
—
Co
—
The main advantages of the present invention are:
1. Single walled as well as Multi walled carbon nanotubes can be synthesized simultaneously in the same arc discharge set-up and in single experiment. 2. By using the process the amount of carbon nanotubes in the arc soot are found to be doubled as compared to conventional process. 3. In this development process the multi walled CNTs are synthesized free from catalyst impurities. | Processes for the simultaneous and selective growth of single walled and multiwalled carbon nanotubes in a single set of experiments are disclosed. The processes may include preparing a graphite electrode rod containing catalyst selected from Fe, Co, Ni, and a mixture thereof, acting as an anode. The process may include preparing another graphite electrode rod, each electrode having a distal and a proximal end. The process may include placing the above said two electrodes parallel to each other and their axis being substantially aligned in a chamber. The process may further include creating a DC-arc discharge inside the chamber by applying a DC-current voltage. The process may further include an cooling assembly having a cooling coil that surrounds the two electrodes. The cooling assembly may be used to maintain a temperature gradient that permits the depositing of single walled and multiwalled carbon nanotubes simultaneously in one experiment. | 2 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to novel heterocyclic substituted phenoxyalkylpyrazines, to methods of preparation thereof and to methods of use thereof as antipicornaviral agents; and to intermediates in their preparation and the use of those intermediates as antipicornaviral agents.
2. Information Disclosure Statement
U.S. Pat. No. 4,857,539 to Diana et al., issued Aug. 15, 1989, discloses compounds of the formula; ##STR2## wherein:
Y is an alkylene bridge of 3-9 carbon atoms;
Z is N or HC:
R is hydrogen or lower-alkyl of 1-5 carbon atoms, with the proviso that when Z is N, R is lower-alkyl;
R 1 and R 2 are hydrogen, halogen, lower-alkyl, lower-alkoxy, nitro, lower-alkoxycarbonyl or trifluoromethyl; and
Het is selected from; ##STR3## which are stated to be useful as antiviral agents.
U.S. Pat. No. 4,861,791 to Diana et al., issued Aug. 29, 1989 discloses compounds of the formula: ##STR4## wherein R to R 8 represent various radicals and y. The compounds are stated to be useful as antiviral agents, in particular against picornaviruses.
U.S. Pat. No. 5,242,924, to Diana, issued Sep. 7, 1993 from application filed Jul. 2, 1992, discloses compounds of the formula: ##STR5## wherein
Y is a bond, or C 1 -C 6 alkylene;
R 1 is hydrogen or C 1 -C 3 lower-alkyl;
R 2 and R 3 are each independently hydrogen, C 1 -C 3 lower-alkyl or halogen;
R 4 is hydrogen, or C 1 -C 3 lower-alkyl; or pharmaceutically acceptable acid addition salts thereof which are stated to be useful as antiviral agents, particularly against picornaviruses.
European Patent Application 435381, published Jul. 3, 1991, discloses pyridazinamines of formula: ##STR6## wherein
R 1 is hydrogen, C 1-4 alkyl, halo, hydroxy, trifluoromethyl, cyano, C 1-4 alkoxy, C 1-4 alkylthio, C 1 -alkylsulfinyl, C 1-4 alkylsulfonyl, C 1-4 alkyloxycarbonyl, C 1 -alkylcarbonyl or aryl;
R 2 and R 3 are hydrogen or C 1-4 alkyl;
Alk is C 1-4 alkanediyl;
R 4 and R 5 are hydrogen, C 1-4 alkyl or halo; and
Het is ##STR7## wherein
R 6 is hydrogen, C 1-6 alkyl; hydroxyC 1-6 alkyl; C 3-6 cycloalkyl; aryl; arylC 1-4 alkyl; C 1-4 alkyloxyC 1-4 alkyl; C 3-6 cyclo- alkylC 1-4 alkyl; trifluoromethyl or amino;
each R 7 independently is hydrogen; C 1-6 alkyl; C 3-6 cyclo-alkyl; aryl; arylC 1-4 alkyl; C 1-4 alkyloxyC 1-4 alkyl; C 3-6 cyclo- alkylC 1-4 alkyl or trifluoromethyl; and
each aryl independently is phenyl or phenyl substituted with 1 or 2 substituents each independently selected from halo, C 1-4 alkyl, trifluoromethyl, C 1-4 alkyloxy or hydroxy. The compounds are stated to have antiviral activity.
SUMMARY OF THE INVENTION
It has now been found that compounds of Formula I and II are effective antipicornaviral agents. Accordingly, the present invention relates to compounds of the formula; ##STR8## wherein:
Y is an alkylene bridge of 3-9 carbon atoms;
R 1 and R 2 are each independently chosen from hydrogen, halo, alkyl, alkenyl, amino, alkylthio, hydroxy, hydroxyalkyl, alkoxyalkyl, alkylthioalkyl, alkyl sulfinyl alkyl, alkylsulfonylalkyl, alkoxy, nitro, carboxy, alkoxycarbonyl, dialkylaminoalkyl, alkyl aminoalkyl, aminoalkyl, difluoromethyl, trifluoromethyl or cyano;
R 3 and R 4 are each independently chosen from hydrogen, alkyl, alkoxy, hydroxy, cycloalkyl, hydroxyalkyl, hydroxyhaloalkyl, alkoxyalkyl, hydroxyalkoxy, alkylthioalkyl, alkanoyl, alkanoyloxy, alkylsulfinylalkyl, alkylsulfonylalkyl, aminoalkyl, alkylaminoalkyl, dialkylaminoalkyl, alkoxycarbonyl, carboxy, cyanomethyl, fluoroalkyl, or halo;
R 5 is alkoxycarbonyl, alkyltetrazolyl, phenyl or heterocyclyl chosen from benzoxazolyl, benzathiazolyl, thiadiazolyl, imidazolyl, dihydroimidazolyl, oxazolyl, thiazolyl, oxadiazolyl, pyrazolyl, oxazolinyl, isoxazolyl, isothiazolyl, furyl, triazolyi, thiophenyl, pyridyl, pyrimidinyl, pyrazinyl, pyridazinyl or substituted heterocyclyl or substituted phenyl; wherein the substitution is with alkyl, halo, alkoxyalkyl, cycloalkyl, haloalkyl, hydroxyalkyl, alkoxy, hydroxy, furyl, thienyl or fluoroalkyl;
or a pharmaceutically acceptable acid addition salt thereof.
The present invention also relates to compounds of the formula; ##STR9## wherein:
Y is an alkylene bridge of 3-9 carbon atoms;
R 1 and R 2 are each individually chosen from hydrogen, halo, alkyl, alkenyl, amino, alkylthio, hydroxy, hydroxyalkyl, alkoxyalkyl, alkylthioalkyl, alkylsulfinyl alkyl, alkylsulfonylalkyl, alkoxy, nitro, carboxy, alkoxycarbonyl, dialkylaminoalkyl, alkylaminoalkyl, aminoalkyl, difluoromethyl, trifluoromethyl or cyano;
R 3 and R 4 are each independently chosen from is hydrogen, alkyl, alkoxy, hydroxy, cycloalkyl, hydroxyalkyl, alkoxyalkyl, hydroxyalkoxy, alkylthioalkyl, alkanoyl, alkanoyloxy, alkylsulfinylalkyl, alkylsulfonylalkyl, aminoalkyl, alkylaminoalkyl, dialkylaminoalkyl, alkoxycarbonyl, carboxy, cyanomethyl, fluoroalkyl, or halo; and
R 5 is alkoxycarbonyl, alkyltetrazolyl, phenyl or heterocyclyl chosen from benzoxazolyl, benzathiazolyl, thiadiazolyl, imidazolyl, dihydroimidazolyl, oxazolyl, thiazolyl, oxadiazolyl, pyrazolyl, isoxazolyl, isothiazolyl, furyl, triazolyl, thiophenyl, pyridyl, pyrimidinyl, pyrazinyl, pyridazinyl or substituted heterocyclyl or substituted phenyl; wherein the substitution is with alkyl, alkoxyalkyl, cycloalkyl, haloalkyl, hydroxyalkyl, halo, alkoxy, hydroxy, furyl, thienyl, fluoroalkyl or a pharmaceutically acceptable acid addition salts thereof.
The invention also relates to compositions for combating picornaviruses comprising an antipicornavirally effective amount of a compound of Formula I or II with a suitable carrier or diluent, and to methods of combating picornaviruses therewith, including the systemic treatment of picornaviral infections in a mammalian host.
In addition to their use as antipicornaviral agents, the compounds of formula II are useful as intermediates for preparing the compounds of formula I.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
Compounds of Formula I and II are useful as antipicornaviral agents, and are further described hereinbelow.
Alkyl and alkoxy refer to aliphatic radicals, including branched radicals, of from one to five carbon atoms. Thus the alkyl moiety of such radicals include, for example methyl, ethyl, propyl, isopropyl, n-butyl, secbutyl, t-butyl, pentyl and the like. Alkoxy refers to alkyloxy, such as methoxy, pentoxy and the like.
Cycloalkyl means an alicyclic radical having from three to seven carbon atoms as illustrated by cyclopropyl, cyclobutyl, cyclopentyl, cycloheptyl, and cyclohexyl; and
Halo means bromo, chloro, iodo or fluoro.
Heterocyclyl or Het refers to a 5 or 6 membered carbon based heterocycle radical, having from one to about four nitrogen atoms and/or one oxygen or sulfur atom, provided that no two oxygen and/or sulfur atoms are adjacent in the heterocycle. Examples of these include furyl, oxazolyl, isoxazolyl, pyrazyl, imidazolyl, thiazolyl, tetrazolyl, thienyl, pyridyl, oxadiazolyl, thiadiazolyl, triazinyl, pyrimidinyl and the like.
The term heterocyclyl includes all known isomeric radicals of the described heterocycles unless otherwise specified, for example, thiadiazolyl encompasses 1,3,4-thiadiazol-2-yl, 1,2,4-thiadiazol-5-yl, and 1,2,4-thiadiazol-3-yl; thiazolyl encompasses 2-thiazolyl, 4-thiazolylyl and 5-thiazolyl and the other known variations of known heterocyclyl radicals. Thus any isomer of a named heterocycle radical is contemplated. These heterocycle radicals can be attached via any available nitrogen or carbon, for example, tetrazolyl contemplates 5-tetrazolyl or tetrazolyl attached via any available nitrogen of the tetrazolyl ring; furyl encompasses furyl attached via any available carbon, etc. The preparation of such isomers are well known and well within the scope of skilled artisan in medicinal or organic chemistry.
Certain heterocycles can exist as tautomers, and the compounds as described, while not explicity describing each tautomeric form, are meant to embrace each and every tautomer. For example, pyridazin-6-ones and 6-hydroxypyridazines are tautomers. Thus the compounds of formula I depicted as hydroxypyridazines (R 3 =OH) are understood to include the tautomeric pyridazinones.
In the use of the terms hydroxyalkyl and alkoxyalkyl, it is understood that the hydroxy and alkoxy groups can occur at any available position of the alkyl. Thus hydroxyalkyl and alkoxyalkyl include, for example, hydroxymethyl, 1-hydroxyethyl, 2-hydroxyethyl, 2-hydroxypropyl, 2-hydroxyisopropyl, 2-, 3-, 4- and 5-hydroxypentyl and the like; alkoxy refers to the corresponding alkyl ethers thereof.
In the use of the term hydroxyalkoxy, it is understood that the hydroxy group can occur at any available position of alkoxy other than the C-1 (geminal) position. Thus hydroxyalkoxy includes, for example, 2-hydroxyethoxy, 2-hydroxypropoxy, 2-hydroxyisopropoxy, 5-hydroxypentoxy and the like.
Alkylene refers to a linear or branched divalent hydrocarbon radical of from 1 to about 5 carbon atoms such as methylene, 1,2-ethylene, 1,3-propylene, 1,4-butylene, 1,5-pentylene, 1,4-(2-methyl)butylene and the like. Alkylene also includes the above group having an alkene or alkyne linkage therein.
Halogen refers to the common halogens fluorine, chlorine, bromine and iodine.
As used herein, the term haloalkyl refers to a halo substituted alkyl, such as fluoroalkyl, chlorofluoroalkyl, bromochloroalkyl, bromofluoroalkyl, bromoalkyl, iodoalkyl, chloroalkyl and the like where the haloalkyl has one or more than one of the same or different halogens substituted for a hydrogen. Examples of haloalkyl include chlorodifluoromethyl, 1-chloroethyl, 2,2,2 -trichloroethyl, 1, 1-dichloroethyl, 2-chloro, 1,1,1,2 -tetrafluoroethyl, bromoethyl and the like.
As used herein the term fluoroalkyl is a preferred subclass of haloalkyl, and refers to fluorinated and perfluorinated alkyl, for example fluoromethyl, difluoromethyl, trifluoromethyl, 2,2,2-trifluoroethyl, 1,2-difluoroethyl, 1-fluoroethyl, 1,1-difluoroethyl, 1,1,2,3-tetrafluorobutyl and the like.
The compounds of Formula I wherein R 5 is a basic nitrogen containing heterocycle are sufficiently basic to form acid addition salts and are useful both in the free base form and the form of acid-addition salts, and both forms are within the purview of the invention. The acid-addition salts are, in some cases, a more convenient form for use, and in practice the use of the salt form inherently amounts to the use of the base form. The acids which can be used to prepare the acid-addition salts include preferably those which produce, when combined with the free base, medicinally acceptable salts, that is, salts whose anions are relatively innocuous to the animal organism in medicinal doses of the salts so that the beneficial properties inherent in the free base are not vitiated by side effects ascribable to the anions. Examples of appropriate acid-addition salts include the hydrochloride, hydrobromide, sulfate, acid sulfate, maleate, citrate, tartrate, methanesulfonate, p-toluenesulfonate, dodecyl sulfate, cyclohexanesulfamate, and the like. However, other appropriate medicinally acceptable salts within the scope of the invention are those derived from other mineral acids and organic acids. The acid-addition salts of the basic compounds can be prepared by dissolving the free base in aqueous alcohol solution containing the appropriate acid and isolating the salt by evaporating the solution, or by reacting the free base and an acid in an organic solvent, in which case the salt separates directly, is precipitated with a second organic solvent, or by concentration of the solution or by any one of several other known methods. Although medicinally acceptable salts of the basic compounds are preferred, all acid-addition salts are within the scope of the present invention. All acid-addition salts are useful as sources of the free base form even if the particular salt per se is desired only as an intermediate product, as, for example, when the salt is formed only for purposes of purification or identification, or when it is used as an intermediate in preparing a medicinally acceptable salt by ion exchange procedures.
The structures of the compounds of the invention were established by the mode of synthesis, by elemental analysis, and by infrared, ultraviolet, nuclear magnetic resonance and mass spectroscopy. The course of the reactions and the identity and homogeneity of the products were assessed by thin layer chromatography (TLC) or gas-liquid chromatography (GLC) or other art accepted means.
As described herein a noninteracting solvent can be N-methyl pyrrolidinone (NMP), methylene chloride (CH 2 Cl 2 ), tetrahydrofuran (THF), benzene or any other solvent that will not take part in the reaction. In a preferred method, the preparation of compounds of the invention is done in dried solvents under an inert atmosphere. Certain reagents used in example preparations are specified by abbreviation: triphenylphosphine (TPP), m-chloroperbenzoic acid (MCPBA) triethylamine (TEA), diisopropylethylamine (DIPEA), and diethyl azodicarboxylate (DEAD). Ether is diethyl ether unless otherwise specified.
Compounds of Formula I can be prepared by several different methods:
Compounds of formula I can be prepared by the reaction of the appropriate hydroxyalkyl furan and the appropriate R 1 -R 2 -4-R 5 -phenol, as described in U.S. Pat. Nos. 5,242,924, and 5,051,437 incorporated herein by reference, giving a compound of formula II. The compound of formula II is then reacted with a peroxide, such as m-chloroperbenzoic acid (MCPBA) and then reacted with hydrazine, providing a compound of formula I.
Compounds of formula I can also be prepared by reaction of the appropriate R 1 -R 2 -4-R 5 -phenol and the appropriate furanylalkylhalide as described in U.S. Pat. No. 4,942,241, incorporated herein by reference, to form a compound of formula II which is then treated with an oxidizing agent such as dimethyldioxirane, MMPA or MCPBA and then reacting this oxidized intermediate with hydrazine as described above.
A compound of formula I can be prepared from a R 1 -R 2 -4-R5-phenol and ω-pyrazinyl alkynol (wherein the alkyne linkage preferably is proximal to the pyridazine ring) by the reaction methods disclosed in U.S. Pat. No. 5,242,924 incorporated herein by reference. Such compounds of formula I have an alkynyl linkage in Y, the alkylene bridge. These linkages can be partially reduced to yield alkenyl linkages or reduced to provide a preferred saturated alkylene bridge.
Compounds of formula II wherein R 5 is heterocyclyl can be prepared by the reaction of a hydroxyalkyl furan or furanylalkylhalide with a R 1 -R 2 -4-functionalized phenol. The 4-substituted is then converted to the heterocycle as described hereinbelow.
Likewise, compounds of formula I wherein R 5 is heterocyclyl can be prepared by reaction of the R 1 -R 2 -4-functionalized phenol and a ω-pyridazyl alkynol, then elaboration of the R 5 heterocycle deferred to the final steps of the synthesis.
For example, if R 5 is a heterocyclic ring, the heterocycle can be elaborated or substituted on to the phenyl ring by means of the appropriate 4-functionalized phenoxyalkyl furan or pyridazine. In this method, the heterocycle on the phenoxy ring can be elaborated in the final step to yield a compound of formula II or formula I as described in U.S. Pat. No. 5,075,187 incorporated herein by reference. Suitable functionalization of the 4-phenoxy position will depend upon the heterocycle sought in the final product. (It will be understood that this method, when applied to a suitably protected 4-functionalized phenol, the product is a suitably protected R 1 -R 2 -4-heterocyclyl phenol, which can then be deprotected. The resulting phenol is then used to prepare a compound of formula I or II.)
For example, where Her is 1,2,4-oxadiazolyl ##STR10## compounds are prepared from either the appropriate 4-Z-O-R 1 -R 2 -benzonitrile (where z is alkyl or benzyl if the target compound is a phenol intermediate), where z is -Y-furan if the target compound is the compound of formula II, or when z is -Y-pyridazine if the target compound is a compound of formula I. The benzonitrile is reacted with, for example, hydroxylamine hydrochloride in a noninteracting solvent, preferably an alkanol, for example; methanol, ethanol, n-butanol and the like, in the presence of a base, such as potassium carbonate, or in a preferred method, an alkali metal salt of a carboxylic acid such as sodium trifluoroacetate or sodium acetate, at a temperature between ambient and the boiling point of the solvent. The product thus obtained can then be reacted with for example an acid anhydride of formula (R'CO) 2 O, (where R' is alkyl, haloalkyl and the like), for example, trifluoroacetic anyhdride, or acetic anhydride, at a temperature between ambient temperature and the boiling point of the reaction mixture in a basic solvent such as pyridine. The R' appears on the R 5 of the product. The product of the reaction is a 4-ZOR 1 -R 2 -phenyloxadiazole, where the starting material is the 4-ZO-R 1 -R 2 -benzonitrile. The product is a compound of formula II where the starting material is the 4-cyanophenoxyalkylfuran (or formula I where 4-cyanophenoxyalkyl pyridazine issued; or a suitably protected 4-heterocyclyl phenol, if Z is a protective group) .
Alternatively, the compounds of formula I and II can be prepared by reaction of a R 1 -R 2 -R 5 -phenol with, for example, an ω-functionalized haloalkane. The resulting functionalized alkoxy-R 1 -R 2 -R 5 -phenyl moiety is then reacted with a suitably functionalized furan or pyridazine to provide compounds of formula II or formula I respectively. This method for preparing compounds of the invention is analogous to the preparation of furanyl alkylhalides, hydroxyalkylfurans, and ω-pyridazyl alkynols discussed hereinbelow.
Thus it will be appreciated that neither the timing of the elaboration of the heterocyclic substituents or pyridazine nor the order of assembly of the intermediate; is crucial to the successful synthesis of compounds of Formula I or II. By judicious choice of reactants one can prepare any of the compounds of Formula I or II.
The R 1 -R 2 -4-R 5 -phenols used to prepare compounds of Formula I and of Formula II wherein R 5 =heterocyclyl or alkoxycarbonyl are known in the art. Their preparation is described in U.S. Pat. Nos. 4,942,241; 4,945,164; 5,051,437; 5,002,960; 5,110,821; 4,939,267; 4,861,971; 4,857,539; 5,242,924; or 4,843,087 incorporated herein by reference. Any 4-alkoxycarbonyl phenol or any 4-heterocyclyl phenol disclosed in these patents, or others which are known in the art, can be reacted with a hydroxyalkylfuran or furanyl alkylhalide by the methods described (or incorporated above) to prepare compounds of formula II, which can be elaborated to pyridazines of formula I. R 1 -R 2 -R 5 -phenols can be reacted with pyridazine alkynols, to form compounds of formula I directly. Other known phenols can be used to prepare compounds of formula I or II, including for example any 4-phenyl phenol, or 4-alkoxyphenol, substituted or unsubstituted as described above, each is well known and useful.
R 1 -R 2 -4-R 5 -phenols wherein R 5 is heterocyclyl can be prepared from the suitably protected phenol, such as the phenoxyalkyl ether or phenoxybenzyl ether which has been suitably functionalized at the 4- position by a functional group such as cyanide, aldehyde, halide, acetyl, acid chloride group or other suitable functional group, as described in U.S. Pat. No. 4,942,241; 4,945,164; 5,051,437; 5,002,960; 5,110,821; 4,939,267; 4,861,971; 4,857,539; 5,242,924; or 4,843,087 each incorporated herein by reference, to obtain the heterocyclyl phenoxyalkyl ether or heterocyclyl phenoxybenzyl ether which is then cleaved to the corresponding phenol by means well known in the art.
It is preferred for certain R 5 heterocycles that they be attached to a suitably protected phenol precursor by standard coupling methods. For example, when R 5 is pyrimidyl, phenyl, pyridyl and the like, a protected R 1 -R 2 -4-hydroxyphenyl borate can be reacted with a haloheterocycle, such as bromopyridine, to prepare a suitably protected 4-pyridyl phenol, which is then deprotected, to liberate the pyridyl phenol.
The skilled practitioner will realize certain heterocyclyls, such as oxazolyl, oxadiazolyl and the like are easiest prepared by elaborating functional groups attached to the phenol, thus forming the R 5 heterocycle "in situ" rather than attaching it to the phenol or suitably protected phenol. This method of preparing R 5 heterocycles is also applicable to 4-functionalized phenoxyalkyl furans and 4-functionalized phenoxy alkyl pyridazines, which upon elaboration of the R 5 heterocycle are compounds of formula II and I respectively.
Furanyl alkyl halides and hydroxyalkyl furans are known, or prepared by known methods. See Katritsky and Rees, Comprehensive Heterocyclic Chemistry, Vol. 14. Useful starting materials in the preparation of hydroxyalkyl furans and furanyl alkylhalides, as well as compounds of formula II are furans. As described above, the furanyl radical can be attached via any available carbon on the furanyl ring to the Y moiety (the alkylene bridge portion of the molecule) . Many furans are commercially available, such as 2-furaldehyde, 3-furaldehyde, 3-furaldehyde diethyl acetal, 2-furaldehyde dimethyl hydrazone, 2-furanyl acrolein, 2-furylacrylic acid, 3-furylacrylic acid, 2-furanacrylonitrile, 2,5-furan dimethanol, furfuryl alcohol, furfuryl mercaptan, 3-furan methanol, furfuryl acetate. These and other known furans can be functionalized by known methods. The preparation of the ω-hydroxy or ω-haloalkyl furans are described in U.S. Pat. Nos. 4,942,241; 4,945,164; 5,051,437; 5,002,960; 5,110,821; 4,939,267; 4,861,971; 4,857,539; 5,242,924; or 4,843,087 incorporated herein by reference. These processes are useful for preparing the hydroxyalkyl furans and furanyl alkylhalide intermediates, as well as in preparing compounds of formula II directly.
Pyridazine alkynols can be prepared by any known method. A preferred method of forming the alkynol is by the reaction of a suitably protected ω-alkyn-1-ol with the appropriate halo, hydroxy or other suitably functionalized pyridazine, for example, under Heck conditions (PdCl 2 (P.O slashed. 3 ) 2 , CuI, base such as Et 3 N), or using known tin coupling chemistry. Where R 3 is halo, this method is particularly useful as the product has the halide present and need not be added later.
Of course other useful starting materials in the preparation of ω-pyridazinylalkynols, pyridazinyl alkyl halides and of course, compounds of formula I are pyridazines. As described above, the pyridazinyl radical can be attached via any available carbon on the pyridazinyl ring to the Y moiety (the alkylene bridge portion of the molecule). Many pyridazines are commercially available, others are known or can be prepared by known methods, and they can be functionalized by known methods. See for example, Katritzky and Rees Comprehensive Heterocyclic Chemistry, Vol 3, and Castle Heterocyclic Compounds Vol 27-28. Pyridazine species may be reacted with terminally unsaturated species, other than alkynes and alkanols. For example, a tin-pyridazyl species can be reacted with an acrylic ester, which can later be reduced to the alkanol and then used to prepare compounds of formula I.
The pyridazines described above are commercially available, known or are prepared by known methods. For example, they may be formed directly by ring closure reactions especially preferred reactions provide pyridazinones which can be used to prepare a host of intermediates or compounds of formula I. 6-hydroxy pyridazines are prepared by known methods, for example the reaction of a zinc/β iodoester and an ω-R 1 -R 2 -R 3 -phenoxy acylhalide or a ω-protected acylhalide which forms a γ-dione which is elaborated to the pyridazine by reaction of hydrazine. Such pyridazines are useful in preparing final products or intermediate compounds of formula I wherein R 3 is halo, thio, sulfinyl, sulfonyl, alkoxy, alkanoyloxy.
Where R 3 is halo, other than fluoro, it is preferred to react the ω-pyridazine alkyn-1-ol with the heterocyclyl phenol and if desired to reduce the alkynyl linkage after ether formation. The skilled artisan will also appreciate the advantage of reacting the phenol with the alkyn-1-ol before the pyridazine is attached. The advantage in protecting the alcohol functionality of the alkyn-1-ol is that any unwanted side reactions of the alcohol with the π deficient ring are avoided. This method advantageously provides for a more "flexible" synthetic route to many different products.
Where R 3 is hydroxy, these are preferably prepared from the appropriate ω-(hydroxy furan) alkanol preferably wherein the alkanol has already been suitably protected, by protecting the hydroxy on the furan ring. This can be done by reaction of the furan with dimethyldioxirane to form the 2-hydroxy-5, 6-dihydro-5-pyran-5-on-2-yl compound. If the alkanol has been protected, it is deprotected and reacted with the R 1 -R 2 -R 5 -phenol or R 1 -R 2 -4-functionalized phenol. The resulting compound can be reacted with hydrazine to yield the corresponding hydroxy pyridazine compound.
Simple chemical transformations which are conventional and well known to those skilled in the art of chemistry can be used for effecting changes in functional groups in the compounds of the invention. For example, acylation of hydroxy- or amino-substituted species to prepare the corresponding esters or amides, respectively; alkylation of phenyl or furyl substituents; preparation of thionyls from carbonyls; cleavage of alkyl or benzyl ethers to produce the corresponding alcohols or phenols; and hydrolysis of esters or amides to produce the corresponding acids, alcohols or amines, the preparation of fluoroalkyls from corresponding alkanols and ketones; oxidation of hydroxyls to carbonyls, oxidation of thiols to sulfinyls to sulfonyls, preparation of anhydrides, acid halides, aldehydes, simple aromatic alkylation and the like as desired can be carried out.
Moreover, it will be appreciated that obtaining the desired product by some reactions will be better facilitated by blocking or rendering certain functional groups non reactive. This practice is well recognized in the art, see for example, Theodora Greene, Protective Groups in Organic Synthesis (1991). Thus when reaction conditions are such that they can cause undesired reactions with other parts of the molecule, the skilled artisan will appreciate the need to protect these reactive regions of the molecule and act accordingly.
Starting materials used to prepare the compounds of Formula I are commercially available, known in the art, or prepared by known methods. Many of the preparations of starting materials herein are incorporated by reference from the patent literature.
EXEMPLARY DISCLOSURE
For the purpose of naming substituents in Formula I, the phenyl ring of any compound of formula I shall be numbered; ##STR11##
Thus when a compound of formula I has substitution on the phenyl ring, it is referred to by this numbering system regardless of how the compound may be named. For example, if a compound is prepared and the designation R 1 , R 2 =3,5-dimethyl, this means ##STR12## regardless of whether 3,5-dimethyl or 2,6-dimethyl appears the name of the compound.
For the purpose of naming substituents in compounds of formula I the pyridazine ring of any compound of formula I shall be numbered: ##STR13## Thus when a compound of formula I has a substituted pyridazine ring, substitution thereof is referred to by the numbering system above regardless of how the compound might otherwise be named, for example; ##STR14## is denoted (R 3 =5-bromo, R 4 =6-acetyl) and not (R 3 =3-bromo; R 4 =2-acetyl) regardless of how the compound might properly be named by IUPAC or other commonly used nomenclature conventions.
Likewise, for the purpose of naming substituents attached to the furan in compounds of formula II, the furan ring is numbered; ##STR15##
Thus when a compound has substitution on the furanyl ring, it is referred to by this numbering system when describing the compound of formula I regardless of how the compound may be named for other purposes. For example, ##STR16## is a 2-furanyl compound with R 3 =5-acetyl and R 4 =4-bromo, regardless of whether the conventional name is 2-acetyl-3-bromo-5-(Y)furan or 5-acetyl-4-bromo-2-Y-furan.
PREPARATION OF INTERMEDIATES
Intermediate 1
methyl 3-(5-ethyl-2-furanyl)prop-2-enoate
a) To a solution of trimethylphosphonoacetate (16.2 g; 89 mmol) in 200 mL of THF cooled to -78° C. under nitrogen with stirring 89 mL (89 mmol) of lithium bis(trimethylsilyl)amide was added dropwise over a 1/2 h period. The reaction mixture was stirred continuously at -78° C. for 1 hr. To the mixture was added 10 g (81 mmol) of 2-ethyl-5-furfural and 3 mL of THF over a 10 rain period with stirring. After 1/2 hr, stirring was stopped and the reaction mixture was allowed to stand for 3 days. An aqueous solution of saturated ammonium chloride was added to a gel like solid with stirring, and 20 mL of water was added to dissolve the precipitated salts into solution. The organic layer was separated, washed with 300 mL water, 300 mL brine, dried over anhydrous magnesium sulfate, filtered, and concentrated in vacuo to yield 20 g of crude product. The product was passed through silica gel and eluted with hexane (400 mL), ethyl acetate/hexane (1:9) (200 mL), and ethyl acetate/hexane (2:8), and the appropriate fractions were concentrated in vacuo to afford 14.8 g of methyl 3-(5-ethyl-2-furyl)propenoate.
b) methyl 3-(5-ethyl-2-furanyl)propionate To a suspension of ethanol (200 mL) and 300 mg of 5% palladium on carbon was added 14.8 g (82.1 mmol) of 3-(5-ethyl-2-furanyl)propenoate at room temperature and the mixture was placed on a Paar hydrogenator and hydrogenated with H 2 . Palladium on carbon was filtered off by passing the reaction mixture through a filter aid, Super-Cel™ and the residue was washed with ethanol several times. The filtrate was concentrated in vacuo, methylene chloride was added to the residue and the solvent was removed in vacuo to afford 14.9 g methyl 3-(5-ethyl-2-furanyl)propanoate. This ester was used without further purification.
3-(5-ethyl-2-furanyl)propan-1-ol
c) To a mixture of 3.42 g (90.1 mol) of LAH in THF under nitrogen and stirring at 0° C., was added dropwise 14.9 g (81.9 mmol) of methyl 3-(5-ethyl-2-furyl)propanoate in THF. The reaction mixture was quenched with 3.4 mL of water, 3.4 mL of sodium hydroxide solution, and 10.2 mL of water. Magnesium sulfate was added to the mixture with stirring, filtered and concentrated in vacuo. The residue was passed through silica gel and eluted with ethyl acetate/hexane (2:8) to yield 10.7 g (85%) of the desired product as a clear colorless oil, used in the next preparation without further purification.
Intermediate 2
1-chloro-3- (2-furanyl)propane
a) To 16 mL of furan (0.208 mmol) in 300 mL of THF, cooled to -78° C., was added 100 mL of n-butyllithium in hexane (2.5 M), and then 71 mL(0.4081 mol) of hexamethylphosphoramide (HMPA), 22 mL (0.2148 mol) 1-bromo-3-chloropropane and 120 mL of THF were slowly added to the above mixture. The reaction mixture was warmed to room temperature and allowed to react overnight.
The above reaction mixture was partitioned between water (250 mL and ethyl acetate (250 mL), and the aqueous layer was extracted with ethyl acetate (200 mL). The combined organic layer was washed with water (2×100 mL) and brine (200 mL), dried (MgSO 4 ), and concentrated in vacuo to afford a brown oil. The oil was distilled under diminished pressure (0.05-0.1 mm) to afford 11.106 g (37%)of 5-(3-chloropropyl)furan.
Intermediate 3
a) 2-furanyl-2-methyl-1, 3-dioxolane
A mixture of 4 mL (139.6 mmol) 2-acetylfuran, 8.7 mL (156 mmol) of ethylene glycol, 198 mg (1 mmol) of ptoluenesulfonic acid monohydrate, and 22 mL (132.3 mmol) of triethyl orthoformate was reacted at room temperature under N 2 for 3 days. The reaction mixture was poured into a mixture of ethyl acetate (100 mL) and water (100 mL). The aqueous layer was extracted with ethyl acetate (3×50 mL), and the combined organic layer was washed with water (100 mL), sodium bicarbonate solution (150 mL), and brine (100 mL). The organic layer was dried over MgSO 4 , concentrated in vacuo, and the residue was distilled under reduced pressure (1.5 tort) to afford 9.98 g (50%) of 2-(2-methyl-1,3-dioxolan-2-yl)-furan, as a clear oil, b.p. 24° C./1.5 min.
b) 5 2- 5-(3-chloropropyl)-2-furanyl!-2-methyl-1,3-dioxolane
To 9.98 g (64.74 mmol) of 2-furanyl-2-methyl-1,3-dioxolane in 125 mL of THF, cooled to -78° C., was added 46 mL (78.2 mmol) of t-butyllithium in hexane (2.5 M) while maintaining the reaction temperature below -60° C. and then 23 mL (132.2 mmol) of hexamethylphosphoramide (HMPA), 7 mL (68.35 mmol) of 3-bromopropyl chloride in 100 mL of THF were slowly added to the above mixture at or below -60° C. After addition reaction mixture allowed to come to room temperature overnight. The above reaction mixture was poured into water (100 mL), and the aqueous layer was extracted with ether (100 mL). The organic layer was washed with water (5×100 mL) and brine (100 mL), and concentrated in vacuo. The residue contaminants were distilled away under vacuum (1.5 tort 23°-93° C.) to afford 7 g (46%) of the described compound.
Intermediate 4
a) Methyl 3-(5-propyl-2-furanyl)prop-2-enoate
To a solution of trimethylphosphonoacetate (13.09 mL; 66 mmol) in 500 mL of THF cooled to -78° C. under nitrogen with stirring, 132 mL (61.6 mmol) of 0.5 M potassium bis(trimethylsilyl)amide in toluene was added dropwise over 1/2 h period. The reaction mixture was stirred continuously at -78° C. for 1 hr. To the mixture was added 6.66 g (66 mmol) of 5-propylfuryl-2-carboxaldehyde and 3 mL of THF over a 10 rain period with stirring. After 1 h, stirring was stopped and the reaction mixture was allowed to warm to room temperature over a 2 h period. The reaction mixture was quenched with an aqueous solution of saturated ammonium chloride with stirring, and water was added to dissolve the precipitated salts into solution. The THF/aqueous solution was washed with ether (200 mL), and the aqueous layer was washed again with 100 mL of ether. The combined organic layer was washed with brine, dried over anhydrous magnesium sulfate, filtered, and concentrated in vacuo and distilled (130°-135° C./16 mm) to yield 8 g (87.9%) of methyl-3-(5-methyl-2-furanyl)prop-2-enoate.
b) Methyl 3- (5-propyl-2-furanyl)propionate
A mixture of ethyl methyl-3-(5-methyl-2-furanyl)prop-2-enoate (8 g) in methanol (200 mL) and 1.5 g of 5% palladium on carbon was placed on a Paar hydrogenator and hydrogenated with H 2 . Palladium on carbon was filtered off by passing the reaction mixture through Super-Cel™ (filter agent) and the residue was washed with ethanol. The filtrate was concentrated in vacuo to yield 8 g of methyl 3- (5-propyl-2-furanyl)propionate.
c) 3-(5-methyl-2-furyl)propan-1-ol
To a solution of methyl 3-(5-methyl-2-furanyl)propionate (3.6 g, 20 mmol) in 50 mL of THF at 0° C. was added dropwise under nitrogen 8 mL of diisobutylaluminum hydride (1M in hexane), and the mixture was stirred at room temperature over-night. The resulting solution was diluted with 2 mL of water in 10 mL of THF and brine, and the mixture was stirred for 30 min. The solid was removed by filtration, and the filtrate was diluted with 20 mL of water, extracted with methylene chloride. The organic layer was washed with water, dried over magnesium sulfate, and concentrated in vacuo. The residue was purified by passing through MPLC column (ethyl acetate/hexane) to afford 1.11 g of 3-(5-methyl-2-furyl) propan-1-ol.
Intermediate 5
Preparation of 2-methyl-5-(4-hydroxyphenyl)tetrazole
a) A mixture containing 325 g of 4-cyanophenol, 346 mL of benzyl chloride and 758 g of potassium carbonate in 1.2 L of NMP was heated at 95° C. with stirring for 1.5 hrs. The reaction mixture was cooled to room temperature and poured into 5L of cold water. The resulting white solid was collected, washed with water and hexanes and dried at 70° C. in vacuo giving 570.0 g of 4-benzyloxybenzonitrile.
b) A mixture of 285 g of the nitrile, 262.5 g triethylamine hydrochloride and 124 g of sodium azide in 1.5 L of DMF under nitrogen was stirred under reflux for 18 hrs. The reaction mixture was cooled to room temperature, poured into 4 L of cold water and acidified with 3N HCl. The resulting white solid was collected, washed with water and dried at 60° C. in vacuo for 48 hrs to give 337 g of 5-(4-benzyloxyphenyl)-tetrazole.
c) To a stirred solution containing 337 g of the tetrazole and 362 mL of DIPEA in 1 L of NMP cooled to 18° C. under N 2 was added dropwise over 1.5 hrs 200 g of methyl iodide in 170 mL NMP. After stirring an additional hour at room temperature, the reaction mixture was diluted with 340 mL of water and cooled to 18° C. The resulting solid was collected, washed with water, recrystallized from ethanol and dried in vacuo at 50° C. to give 232.3 g of 2-methyl-5(4-benzyloxyphenyl)tetrazole.
d) A mixture containing 214.2 g of the methyl tetrazole, 140 mL of concentrated hydrochloric acid and 1.08 L of glacial acetic acid was heated under reflux for 19 hrs. Most of the acetic acid was removed by evaporation under reduced pressure at 60° C. and the resulting slurry was diluted with 1.5 L of cold water. The resulting solid was collected, washed with water and dried. Recrystallization from ethanol afforded, after drying at 60° C. for 20 hrs, 104.3 g of 2-methyl-5-(4-hydroxyphenyl)tetrazole.
Intermediate 6
Preparation of 2-methyl-5-(3,5-dimethyl-4-hydroxyphenyl)tetrazole was prepared by the procedure described above for Intermediate 5 starting with 2,6-dimethyl-4-cyanophenol.
Intermediate 7
3-(3,5-Difluoro-4-hydroxyphenyl)-5-trifluoromethyl-1,2,4,-oxadiazole
0.1 mol 3, 5-difluoro-4-methoxybenzonitrile, 0.3 mL of hydroxylamine hydrochloride and 0.3 mol of potassium carbonate were added to 400 mL ethanol and refluxed overnight. The product was filtered and recrystallized from methanol giving 3.04 g of 3,5-difluoro-4-methoxybenzamide oxime. This product was dissolved in 5 mL pyridine and 5.6 mL of trifluoroacetic anhydride was added dropwise at room temperature. Upon cooling the product solidified and was rinsed with water yielding 4.1 g of the product.
Intermediate 8
3-(4-hydroxyphenyl)-5-trifluoromethyl-1,2,4-oxadiazole 13.32 g (0.1 mol) 4-methoxybenzonitrile, 20.85 g (0.3 mol) of hydroxylamine hydrochloride and 41.40 g (0.3 mol) potassium carbonate was added to 400 mL absolute ethanol and refluxed 21 hours. The product was filtered and recrystallized from methanol to give 3.12 g (0.02 mol) of 4-methoxybenzamide oxime.
This product was dissolved in 5 mL pyridine and 5.7 mL (0.04 mol) of trifluoroacetic anhydride was added dropwise at room temperature. Upon cooling, the mixture solidified and was rinsed with water yielding 4.3 g of a product wherein R 1 =R 2 =hydrogen; R 5 =5-trifluoromethyl-oxadiazol-3-yl.
Intermediate 9
0.384 g of 4-hydroxy-3,5-dimethyl borate and 4 mL 2 M Na 2 CO 3 in methanol and 0.4 mL of 2-chloropyridine was combined in 35 mL toluene. 0.260 g (Pφ 3 ) 4 Pd was added and the mixture was refluxed for 24 hours. The mixture was purified by MPLC in ethyl acetate and hexane. The resultant methoxy phenyl compounds taken up in 25 mL CH 2 Cl 2 and 3.8 mL of BBr 3 added, and the mixture stood overnight. The mixture was diluted with 400 mL CH 2 Cl 2 and extracted with brine, dried and concentrated in vacuo giving 1.38 g (37%) 4-(2-pyridyl)2, 6-dimethylphenol.
The following phenols were made using the above procedure but substituting the appropriate R 5 X species.
______________________________________R.sub.5 Z Yield M.P.______________________________________4 pyrimidyl Br 42% 89.5 (wet)2 pyrimidyl Br 42% --______________________________________
The following R 5 X are contemplated to be useful in preparing phenols of the invention.
______________________________________R.sub.5 X______________________________________3 pvrimidyl bromo3 pvridyl bromo4 pyridvl bromo3 pyrazyl bromo2 fluorophenyl bromo3 fluorophenyl bromo4 fluorophenyl bromo4 methoxyphenyl bromo______________________________________
As well as other known bromo- and iodo-aromatic species.
PREPARATION OF EXAMPLE COMPOUNDS OF FORMULA I
EXAMPLE 1
a) Preparation of 3- 3,5-dimethyl-4- 3-(5-methyl-2-furanyl)propyl!oxy!phenyl!-5-methyl-1,2,4-oxadiazole. ##STR17## Diethyl azodicarboxylate(DEAD, 1.15 mL; 7.3 mmol) was added dropwise over a 3 min period to a solution of triphenylphosphine (1.91 g; 7.3 mmol), 3-(5-methyl-2-furanyl)propanol (see Ex. 9c) prepared according to the method of Intermediate 1 (1.2 g; 8.56 mmol), and 2,6-dimethyl-4- 3-(5-methyl) 1,2,4-oxadiazol)-yl!phenol (1.5 g; 7.3 mmol) prepared by the method of Intermediate 8, but substituting the appropriate starting materials therefor at room temperature under nitrogen (mild exotherm), cooled to room temperature, and was added to ethyl acetate/hexane. The precipitated triphenyl phosphate oxide (0.2 g) was removed by filtration. The filtrate was washed succesively with water (1x), dil. sodium hydroxide (2×50mL), water (1x), and brine (1×50 mL), dried over anhydrous magnesium sulfate, and concentrated in vacuo to yield 5.3 g of a white solid. The solid product was chromatographed on silica gel while eluting with ethyl acetate/hexane (1:9). The appropriate fractions were concentrated in vacuo to afford 1.2 g (50%) of 2-methyl-5- 3- 2,6-dimethyl-4-(5-methyl-1,2,4-oxadiazol-2-yl-phenoxy)!-propyl!-furan, as a clear colorless oil.
b) Preparation of 8- 2,6-dimethyl-4-(5-methyl-1,2,4-oxadiazol-3-yl)phenoxy!oct-3-en-2,5-dione 0.71 (2.2 mmol) of 2-methyl-5- 3- 2,6-dimethyl-4-(5-methyl-1,2,4-oxadiazol-2-yl -phenoxy)propyl!-furan in 8 mL of ethanol was added to 0.68 g (1.1 mmol) of magnesium monoperoxyphthalate (MMPP) at room temperature under nitrogen with stirring and allowed to stir for 3 hours. The mixture was then allowed to stand overnight. An additional MMPP (0.14 g) was added to the mixture and then dilute sodium bicarbonate solution was added. The reaction mixture was extracted with methylene chloride (2x), the organic layer was dried (MgSO 4 ) and concentrated in vacuo to afford 0.664 g of the title compound which was used in the next step without further purification.
c) Preparation of 3- 3,5-dimethyl-4- 3-(6-methyl-3-pyridazinyl)propyl!oxy!phenyl!-5-methyl-1,2,4-oxadiazole ##STR18## Hydrazine hydrate (0.060 mL; 1.94 mmol) was added solution of 0.664 g (1.94 mmol) of 6- 2- 2,6-dimethyl-4-(5-methyl-1, 2,4-oxadiazol-2-yl-phenoxy)!-ethyl!-hex-3-en-2,4-dione in methanol. Water and methylene chloride were added to the reaction mixture. The organic layer was separated, dried over anhydrous magnesium sulfate, filtered, and the filtrate was concentrated in vacuo to yield a yellow oil, which crystallized. The product was passed through silica gel eluting with ethyl acetate/hexane (4:6) and then gradiated to 100% ethyl acetate. The resulting product was rechromatographed on the silica gel eluting with ethyl acetate to afford 436 mg (66%) of a compound of formula I (Formula I; R 1 , R 2 =3,5-dimethyl, R 3 -6-methyl, R 4 =-hydrogen, R 5 =5-methyl-1,2,4-oxadiazol-3-yl, Y=1,3 propylene), as a yellow solid, m.p. 106°-107.5° C.
EXAMPLE 2
a) Preparation of 4- 3,5-dimethyl-4- 3-(2-furanyl)propyl!oxy!benzonitrile
Potassium iodide (1.43 g; 8.6 mmol) was added to a mixture of 2-(3-chloropropyl)-furan (Intermediate 2) (11.1 g; 76.8 mmol) from preparation 4 in 100 mL of NMP, and the reaction mixture was allowed to react for 10 min. To the above mixture was added 2,6-dimethyl-4-cyanophenol (11.29 g; 76.71 mmol) and potassium carbonate (11.79 g; 85.3 mmol), and the reaction mixture was warmed. Cooled to room temperature, turned into ice K 2 CO 3 extracted with EtOAc (4×200 mL), the combined organics were washed with H 2 O (2×100 mL), dried over MgSo and filtered and concentrated in A5 vaccuo and purified by chromatography on MPLC eluting with 5% ethyl acetate/hexane, 15.56 g (79%) of 2- 3-(2,6-dimethyl-4-cyanophenoxy)-propyl!furan, as a clear oil, was obtained.
b) Preparation of N-hydroxy-3,5-dimethyl-4- 3-(2-furanyl)propyl!oxy!benzenecarboximidamide. ##STR19## To a solution of 4.997 g (19.57 mmol) of 4- 3,5-dimethyl-4- 3-(2-furanyl)propyl!oxy!benzonitrile in 120 mL of ethanol was added at room temperature potassium carbonate (13.43 g; 97.17 mmol) and 6.92 g (79.58 mmol) of hydroxylamine hydrochloride and the mixture was stirred for 70 h at room temperature. The reaction mixture was filtered, the filtrate concentrated in vacuo, the residue was dissolved in ethyl acetate, and the organic layer was washed with water (2×25 mL) and dried over anhydrous magnesium sulfate The ethyl acetate solution was concentrated in vacuo to yield 6.0 g of a crystalline product which upon recrystallization from methylene chloride/hexane afforded 5.07 g (89.9%) of N-hydroxy-3,5-dimethyl-4- 3-(2-furanyl)propyl!oxy!benzenecarboximidamide, as a crystalline solid, m.p. 100.5°-101° C.
c) Preparation of 3- 3,5-dimethyl-4- 3(2-furanyl)propyl!oxy!phenyl!-5-methyl-1,2,4-oxadiazole ##STR20## Pyridine (15 mL) was added at room temperature to 1.19 g (4.15 mmol) of N-hydroxy-3,5-dimethyl-4- 3-(2-furanyl)propyl!oxy!benzenecarboxyimidamide and then 0.45 mL of acetyl chloride was added slowly (slightly exothermic) to the above mixture. The resulting mixture was refluxed for 4 h. The above reaction mixture was poured into water, the aqueous mixture was extracted with ethyl acetate (5×50mL), the combined organic layers were washed with water (4×50 mL), brine (50mL), dried over anhydrous magnesium sulfate and concentrated in vacuo. The brown oil was purified by chromatography on MPLC eluting with 10% ethyl acetate/hexane to afford 0.759 g (59%) of 3- 3,5-dimethyl-4- 3(2-furanyl)propyl!oxy!phenyl!-5-methyl-1,2,4-oxadiazole (Formula II; R 3 =R 4 =hydrogen, R 1 , R 2 =3,5-dimethyl, Y=1,3-propylene, R 5 =5-methyl-1,2,4-oxadiazolyl), as a crystalline solid, m.p. 44°-45° C. It is contemplated that a compound of formula I is prepared by the method of Example 1b and 1c.
d) Preparation of 4- 3,5-dimethyl-4- 3-(3-pyridazinyl)propyl!oxy!benzonitrile ##STR21##
To a solution of 3- 3,5-dimethyl-4- 3(2-furanyl)propyl!oxy!phenyl!-5-methyl-1,2,4-oxadiazole (2.18 g; 8.93 mmol) from 2a (above) in 60 mL of acetone at room temperature was added 17 mL of 0.05M dimethyldioxirane in acetone, and the mixture was stirred at room temperature for 2.5 h. The mixture was concentrated in vacuo, the residue was dissolved in methylene chloride under nitrogen at room temperature with stirring, and 0.35 mL 85% hydrazine hydrate was added to the methylene chloride solution. The desired product was isolated by the procedure of Example 8e and purified by chromatography (2x) on MPLC eluting with ethyl acetate then 90% ethylacetate/hexane followed by 70% ethyl acetate/hexane to afford 1.069 g of 4- 3,5-dimethyl-4- 3-(3-pyridazinyl)propyl!oxy!benzonitrile.
e) Preparation of N-hydroxy-3,5-dimethyl-4- 3-(3-pyridazinyl!propyl!oxy!benzenecarboximidamide ##STR22##
To a solution of 4- 3,5-dimethyl-4- 3-(3-pyridazinyl)propyl!oxy!benzonitrile (1.069 g; 3.99 mmol) in 5 mL of ethanol was added 2.76 g (19.97 mmol) of potassium carbonate followed by 1.39 g hydroxylamine hydrochloride (20 mmol) at room temperature and the mixture was stirred for 2.5 days. The reaction mixture was filtered, the filtrate concentrated in vacuo, and the residue collected was dissolved in 100 mL of water. Sodium chloride was added to the aqueous solution, and the resulting aqueous layer was extracted with ethyl acetate (5×100 mL). The organic layer was dried over MgSO 4 , filtered, and the filtrate was concentrated in vacuo to afford 0.745 g (62%) of N-hydroxy-3,5-dimethyl-4- 3-(3-pyridazinyl!propyl!oxy!benzenecarboximidamide, as a white solid.
f) Preparation of 5-difluoromethyl-3- 3,5-dimethyl-4- 3-(3-pyridazinyl)propyl!oxy!phenyl!-1,2,4-oxadiazole. ##STR23##
A mixture of 0.745 g (2.48 mmol) of 4- 3,5-dimethyl-4- 3-(3-pyridazinyl)propyl!oxy!benzonitrile and 0.8 mL (8.0 mmol) of ethyl difluoroacetate in 8 mL of NMP was heated to 100° C. under nitrogen with stirring for 4 days. The mixture was poured into 200 mL of water, and the aqueous solution was extracted with ethyl acetate(5×100 mL). The combined organic layer was washed with water (2×100 mL) and brine (1×100 mL), dried (over MgSO 4 ), and concentrated in vacuo to yield a clear oil. The oil was purified by chromatography on MPLC eluting with 60% ethyl acetate/hexane to afford 0.255 g (29%) of 5-difluoromethyl-3- 3,5-dimethyl-4- 3-(3-pyridazinyl)propyl!oxy!phenyl!-1,2,4-oxadiazole. (Formula I; R 1 , R 2 =3,5-dimethyl, R 3 =R 4 -hydrogen, R 5 =5-difluoromethyl-1,2,4-oxadiazol-3-yl, Y=1,3 propylene). Recrystallization from ether yields a crystalline solid, m.p. 94°-95° C.
g) Preparation of 5-trifluoromethyl-3- 3,5-dimethyl-4- 3-(3-pyridazinyl)propyl!oxy!phenyl!-1,2,4-oxadiazole. ##STR24## A mixture of 0.654 g (2.18 mmol) of the compound of Example 2e, above, 0.45 mL of ethyl trifluoroacetate, and 0.66 g (4.78 mmol) of potassium carbonate in 8 mL of NMP was heated to 100° C. under nitrogen with stirring for 24 hrs. The mixture was poured into 500 mL of water, and the aqueous solution was extracted with ethyl acetate(5×100 mL). The combined organic layer was washed with water (5×100 mL) and brine (1×100 mL), dried (over MgSO 4 ), and concentrated in vacuo. The residue was purified by chromatography on MPLC eluting with 80% ethyl acetate/hexane to afford a compound of formula I, R 3 =R 4 =hydrogen, R 1 , R 2 =3,5-dimethyl, R5=5-trifluoromethyl-1,2,4-oxadiazol-3-yl, Y=1,3 propylene, as a crystalline solid, m.p. 50.5°-51.5° C.
EXAMPLE 3
a) Preparation of 5- 3- 2,6-dimethyl-4- 3-(5-methyl-1,2,4-oxadiazolyl)!phenoxy!propyl!-2-furancarboxaldehyde ##STR25## A solution of the compound prepared in example 2C, (0.84 g; 2.69 mmol) dissolved in 10 mL of DMF (dried over molecular sieves) with stirring under nitrogen was chilled in an ice-bath and 0.5 mL (5.38 mmol) of phosphorus oxychloride was added dropwise and the resulting reaction mixture was 5 stirred for 30 min, and then the ice bath was removed. The reaction mixture was diluted with 100 mL of water, basified (to pH 10) with 2 N sodium hydroxide solution, and the solid that formed was filtered, and dried to yield 0.85 g of yellow solid. Recrystallization from ether, after treatment with charcoal, yielded a bright yellow solid, 0.58 g (63%) of a compound of formula II, (Formula II; R 3 =5-formyl, R 4 =hydrogen, R 1 , R 2 =3,5-dimethyl, R 5 =5-methyl-1,2,4-oxadiazol-3-yl, Y=1,3-propylene) (OGL-2298-88; WIN 68774), m.p. 68°-69° C. It is contemplated that by blocking the carbonyl and then using the methods of Example 1b and 1c, then deblocking, the corresponding compound of formula I is obtained.
b) Preparation of 5-difluoromethyl-2- 3- 2, 6-dimethyl-4-(5-methyl-1,2,4-oxadiazol-3-yl)phenoxy!-propyl!-furan ##STR26## The compound prepared in example 3a (1.74 g; 5.11 mmol) and 3 mL of diethylaminosulfurtrifluoride (DAST) were combined at room temperature with stirring under argon. After stirring 5 days at room temperature, the above solution was diluted with methylene chloride and the mixture was slowly poured onto ice. The organic layer was separated, washed with water(1x) and brine (1x), decolorized with charcoal, dried over magnesium sulfate, and concentrated in vacuo to yield a brown oil. The brown oil was chromatographed on silica gel column eluting with 10% hexane/methylene chloride and then methylene chloride to afford 1.17 g (63%) of a compound of Formula II, R 4 =hydrogen, R 3 =5-difluoromethyl, R 1 , R 2 =3,5-dimethyl; Y=1,3-propylene, R 5 =5-methyl-1,2,4-oxadiazolyl, as a viscous yellow oil, which upon recrystallization from methanol, yielded off-white needles, m.p.38°-39° C.
c) Preparation of ##STR27## The compound prepared in example 3b (0.92 g; 2.54 mmol) was dissolved in 30 mL of acetone under argon at room temperature with stirring. To the above solution, 30 mL (2.7 mmol) of dimethyldioxirane (0.09 M) in acetone, chilled to -80° C., was added in one portion. Additional dimethyldioxirane (0.09 M) in acetone (2×10 mL) was added, the reaction mixture was stirred at room temperature for 1.5 days, and the mixture was concentrated in vacuo at 40° C. The residue was dissolved in 10 mL of methylene chloride under nitrogen at room temperature with stirring, and 0.3 mL (8.2 mmol) of 85% hydrazine hydrate was added to the methylene chloride solution. The reaction mixture was diluted with methylene chloride and shaken with water. The mixture was filtered, the organic layer was washed with water (1x), brine (1x), dried over magnesium sulfate, and concentrated in vacuo to afford 0.74 g of a viscous yellow oil. Chromatography on silica gel eluting with 60% hexane/ethyl acetate yielded 80 mg (8%) of a compound of formula I, (Formula I; R 4 =6-difluoromethyl, R 3 =hydrogen, R 1 , R 2 =3,5-dimethyl, Y-1,3 propylene, R 5 =5-methyl-1,2,4-oxadiazol-3-yl) a yellow oil that crystallized on standing.
EXAMPLE 4
a) 5-propyl-2-furancarboxaldehyde
To a solution of 13.04 g (0.118 mol) of 2-propylfuran in 800 mL of ether cooled at 0° C. with stirring under nitrogen was added dropwise 52 mL (0.130 mol) of 2.5 M n-butyllithium. The reaction mixture was allowed to warm to room temperature and then refluxed for 40 min. The reaction mixture was cooled to -60° C. 10.1 mL (0.130 mol) of DMF in 10 mL of ether was added, and the resulting mixture was stirred at -60° C. for 45 min, and warmed to room temperature. The above mixture was quenched with 10 mL of saturated aqueous ammonium chloride, diluted with water to form a clear aqueous layer, and the organic layer was washed with water, and brine. The organic layer was dried over anhydrous magnesium sulfate, treated with a small amount of a charcoal, filtered, and concentrated to yield 13.95 g of a crude oil. The kughelrohr distillation of this oil (75°-105° C.) afforded 10.5 g (64.5 %) of 5-propyl-2-furancarboxaldehyde.
b) Methyl 3-(5-propyl-2-furanyl)prop-2-enoate To a solution of trimethylphosphonoacetate (12.34 g; 61.6 mmol) in 500 mL of THF cooled to -78° C. under nitrogen with stirring, 136 mL (61.6 mmol) of 0.5 M potassium bis(trimethylsilyl)amide was added dropwise over a 1/2 h period. The reaction mixture was stirred continuously at -78° C. for 1 hr. To the mixture was added 8.5 g (61.6 mmol) of 5-propyl-2-furancarboxaldehyde and 3 mL of THF over a 10 min period with stirring. After 1 h, stirring was stopped and the reaction mixture was allowed to warm to room temperature over a 2 h period. The reaction mixture was quenched with an aqueous solution of saturated ammonium chloride with stirring, and water was added to dissolve the precipitated salts into solution. The THF/aqueous solution was washed with ether (200 mL), and the aqueous layer was washed again with 100 mL of ether. The combined organic layer was washed with brine, dried over anhydrous magnesium sulfate, filtered, and concentrated in vacuo to yield 10.95 g (87.9%) of methyl 3-(5-propyl-2-furanyl)prop-2-enoate.
c) Methyl 3-(5-propyl-2-furanyl)propionate
A solution of the compound from (b) above, (12.57 g, 64.5 mmol) in ethanol (200 mL) was added to a suspension of 500 mg of 5% palladium on carbon in 100 mL of ethanol, and the mixture was placed on a Paar hydrogenator and hydrogenated with H 2 . Palladium on carbon was filtered off by passing the reaction mixture through Super-Cel™ (filter agent) and the residue was washed with ethanol. The filtrate was concentrated in vacuo to yield 13 g of an oil. After the Kughelrohr distillation, the oil (40°-75° C.) was purified by passing through flash silica column (hexane, 20% ether/hexane) followed by MPLC chromatography (5% ethyl acetate/hexane ) to yield 6.5 g (51.4 % ) of methyl 3-(5-propyl-2-furanyl)propionate.
d) 3-(5-propyl-2-(furan)propan-1-ol
To a mixture of 1.25 g (33 mmol) of LAH in THF under nitrogen with stirring at 0° C. 6 g (31 mmol) of methyl 3-(5-propyl-2-furyl)propionate in THF was added dropwise, and the mixture was warmed to room temperature and stirred overnight. The reaction mixture was quenched with 1.25 mL of water, 1.25 mL of 15% sodium hydroxide solution, and 3.75 mL (x3) of water. The white mixture was filtered to remove the solid, and water, ether, and ethyl acetate were added to the filtrate. The organic layer was separated, dried over magnesium sulfate and concentrated in vacuo, and the residue was passed through a dry flash silica column to afford 4.63 g (88.8 %) of the desired product.
e) 5-Propyl-2- 3- 2,6-dimethyl-4-(2-methyl-tetrazol-5-yl)phenoxy!-propyl!fura
Diethyl azodicarboxylate (DEAD, 3.88 g; 22.3 mmol) was added under nitrogen to a stirred and cooled (-10° C.) solution of triphenylphosphine (5.84 g; 22.3 mmol), of the compound prepared in d, above, (3.75 g; 22.3 mmol), and Intermediate 8 (5 g; 24.5 mmol) and the mixture was stirred for 20 min. Water and methylene chloride (25 mL) were added to the mixture and the layers were separated. The organic layer was washed with 2N NaOH solution (2x), HCl solution, brine, dried over magnesium sulfate, and concentrated in vacuo to yield a white solid (13 g) . The white solid was purified by a large dry flash silica column (hexane, 30% and 70% ethyl acetate/hexane) followed by a medium size MPLC column chromatography (15% and 30% ethyl acetate/hexane) to afford 6.64 g (84%) of a compound of formula II, (Formula II; R 1 , R 2 =3,5-dimethyl, R 3 =hydrogen, R 4 =5-n-propyl, R 5 =2-methyltetrazol-5-yl), m.p. 38°-39° C.
EXAMPLE 5
a) Preparation of 2-ethyl-5- 3-(2,6-dimethyl-4-cyanophenoxy)-propyl!furan ##STR28## Diethyl azodicarboxylate (DEAD, 12 g; 69 mmol) was added to a solution of triphenylphosphine (18 g; 69 mmol), 2-ethyl-4-(3-hydroxypropyl)furan (Intermediate I) (10.7 g; 69 mmol), and 4-cyano-2,6-dimethylphenol (11.2 g; 76 mmol) in 150 mL of methylene chloride at 10° C. The mixture was stirred for 10 min. The reaction mixture was then allowed to stand at room temperature overnight. Solids were removed by filtration. Water was added to the filtrate, layers were separated, the organic layer was washed with dilute sodium hydroxide solution and brine (2×100 mL), dried over anhydrous magnesium sulfate, filtered, and the filtrate was concentrated in vacuo to yield a brown solid (40 g) . The brown solid was passed through a silica gel eluting first with ethyl acetate/hexane (1:9) and followed by ethyl acetate/hexane (4:6). The appropriate fraction was concentrated in vacuo to afford 20 g of the product which was chromatographed (3x) through a medium size MPLC column eluting with 5% ethyl acetate/hexane (1st), 5% ethyl acetate/hexane (2nd), and hexane (3rd) followed by 5% ethyl acetate/hexane, respectively, to afford 9.2 g (42.7%) of 2-ethyl-5- 3-(2,6-dimethyl-4-cyanophenoxy)-propyl!furan.
b) The cyano moiety is then elaborated to a suitably substituted 1,2,4-oxadiazolyl or 5-tetrazolyl moiety as in the preparation of Intermediates 7-8 and 5-6 respectively, giving a compound of formula II, wherein Y is 1,3-propylene, R 1 , R 2 is 3,5-dimethyl, R 3 is ethyl, R 4 is hydrogen and R 5 is as described above.
c) Preparation of 3-ethyl-6- 3-(2,6-dimethyl-4-cyanophenoxy)-propyl!-pyridazine ##STR29## The magnesium salt of monoperoxyphthalic acid (MMPP, 2.9 g; 5.85 mmol) in 25 mL of water was added to a solution of 1.1 g (3.9 mmol) of the compound prepared in 5b above in 50 mL of ethanol at room temperature and under nitrogen with stirring. After 1 hr, 50 mL of dilute sodium bicarbonate solution and ether were added to the mixture. The ether layer was separated, washed with water and brine. Hydrazine hydrate (1.5 mL) was added to the ether solution. The ether layer was washed with brine, dried over anhydrous magnesium sulfate, filtered, and concentrated in vacuo. The residue was chromatographed (2x) on a small alumina column eluting with ethyl acetate to afford 0.352 g (30.6%) of the described product, as a yellow oil.
d) Preparation of 3-ethyl-6- 3-(2,6-dimethyl-4-aminohydroximinomethylphenoxy)-propyl-pyridazine ##STR30##
0.672 g (2.27 mmol) of the pyridazine prepared in 5c, above, 0.789 g (11.35 mmol) of hydroxylamine hydrochloride, 1.57 g (11.35 mmol) of potassium carbonate, and 25 mL of ethanol were combined at room temperature under nitrogen with stirring, and the mixture was warmed to reflux for 24 hr. The reaction mixture was allowed to stand overnight at room temperature. The next day it was filtered, and the filtrate was concentrated in vacuo to afford 0.66 g (88.6%) of 3-ethyl-6- 3-(2,6-dimethyl-4-hydroxyimideamide-phenoxy)-propyl!-pyridazine, as a yellow solid.
e) Preparation of 3-ethyl-6- 3- 2,6-dimethyl-4-(5-methyl-1,2,4-oxadiazol-2-yl-phenoxy)!-propyl!-pyridazine ##STR31##
0.5 g (1.5 mmol) of hydroxyimideamide prepared in 5d above, 0.207 g (1.5 mmol) of potassium carbonate were combined in 10 mL of N-methylpyrrolidine (NMP) at room temperature and under nitrogen with stirring. 0.11 mL (1.5 mmol) of acetyl chloride was added to the reaction mixture (the brown suspension became yellow and solids went into solution). The mixture was (slowly) heated to 100°-105° C. where it remained for 45 min, cooled to room temperature, and water was added to the mixture. The resulting suspension was filtered, the filtrate was washed with ether (2×50mL), and the combined organic layers were washed with ice-water (3×50mL) and brine (1×50mL). The organic layer was dried over anhydrous magnesium sulfate, filtered, and concentrated in vacuo to afford a brown oil. The brown oil was chromatographed on a small MPLC column to yield 0.23 g of clear oil which was rechromatographed on a neutral alumina column eluting with hexane/ethyl acetate (8:2) to afford a colorless oil (0.22 g) . This oil was crystallized from warm ether/pentane to yield 120 mg of 3-ethyl-6- 3- 2,6-dimethyl-4-(5-methyl-1,2,4-oxadiazol-2-yl-phenoxy)!-propyl!-pyridazine (Formula I; R 1 , R 2 =3,5dimethyl, R 3 =hydrogen, R 4 =6-ethyl, R 5 =5-methyl-1,2,4-oxadiazol-3-yl), as colorless needles, m.p. 72°-75° C.
f) The N-oxide of 5e was by exposing Example 5e to MCPBA; m.p. 135°-136° C.
EXAMPLE 6
a) Preparation of 2-methyl-5- 3-(2,6-dimethyl-4-cyanophenoxy)-propyl)furan ##STR32## Diethyl azodicarboxylate (DEAD, 11.9 mL; 75.6 mmol) was added dropwise over a 10 rain period to a solution of triphenylphosphine (19.8 g; 75.6 mmol), (2-methyl-5-furanyl)propanol (ex 1a, 9c and 12a) (10.6 g; 75.6 mmol), and 4-hydroxy-3,5-dimethyl-benzonitrile (12.2 g; 83.2 mmol) in methylene chloride cooled in an ice-bath under nitrogen with stirring. After 10 rain, a solid formed. Additional methylene chloride (50 mL) was added to the mixture and the resulting suspension was filtered. The filtrate was washed with water (2×100mL) and brine (1×100mL). The organic layer was dried over anhydrous magnesium sulfate, and concentrated in vacuo to yield a brown oil which crystallized on standing. The solid product was chromatographed on silica gel eluting with ethyl acetate/hexane (2:8), and the appropriate fractions were concentrated in vacuo to afford 16.43 g (81%) of 2-methyl-5- 3-(2,6-dimethyl-4-cyanophenoxy) -propyl)furan. The cyano moiety is then elaborated to a suitably substituted 5-tetrazolyl moiety as in the preparation of Intermediates 5-6 or oxadiazolyl as in Intermediates 7-8, giving a compound of formula II wherein R 3 is methyl, R 4 is hydrogen, R 1 , R 2 is 3,5-dimethyl Y is 1,3-propylene and R 5 is as described.
b) Preparation of 3-methyl-6- 3-(2,6-dimethyl-4-cyanophenoxy)-propyl)-pyridazine ##STR33## The compound prepared in 6a (9.6 g; 35.6 mmol) in 125 mL of ethanol was added to MMPP (26.38 g; 53.4 mmol) in 75 mL of water at room temperature under nitrogen with stirring. After 1 hr, dilute sodium bicarbonate solution was added and the mixture was stirred for 1 hr. The reaction mixture was extracted with ether (2×250 mL), organic layer was separated, and 7 mL of hydrazine (aqueous) was added to the ether solution. The organic layer was washed with brine (1×100mL), dried over anhydrous magnesium sulfate and concentrated in vacuo to yield a yellow oil. The oil was chromatographed on silica gel eluting with ethyl acetate/hexane (3:7) first and then gradiating to 100% ethyl acetate. The appropriate fractions were concentrated in vacuo to afford 6.55 g (65.5%) of 3-methyl-6- 3-(2,6-dimethyl-4-cyanophenoxy)-propyl)pyridazine.
c) Preparation of 3-methyl-6- 3-(2,6-dimethyl-4-aminohydroxyiminomethyl-phenoxy)-propyl!pyridazine ##STR34## A mixture of 3-methyl-6- 3-(2,6-dimethyl-4-cyanophenoxy)propyl)pyridazine from example 6b (1.21 g; 4.3 mmol), 1.49 g (21.5 mmol) of hydroxylamine hydrochloride, and 2.97 g (21.5 mmol) of potassium carbonate in ethanol was stirred at room temperature for 10 days. The reaction mixture was filtered, and the filtrate was concentrated in vacuo to afford 0.57 g (43%) of 3-methyl-6- 3-(2, 6-dimethyl-4-aminohydroxyiminomethyl-phenoxy)-propyl!pyridazine, as a yellow solid.
d) Preparation of 3-methyl-6- 3- 2,6-dimethyl-4-(5-difluoromethyl-1,2,4-oxadiazol-2-yl -phenoxy)!-propyl!pyridazine ##STR35## A mixture of 0.60 g (1.91 mmol) of 3-methyl-6- 3-(2,6-dimethyl-4-amino-hydroxyiminomethyl -phenoxy)-pyridazine from example 6c and 0.57 mL (5.73 mmol) of ethyl difluoroacetate in 7 mL of NMP was briefly heated to 120° C. and then heated at 100° C. for 2.5 days. Upon cooling ether and water were added to the mixture and the layers were separated. The aqueous layer was extracted with ether (2×30mL). The combined organic layers were washed with cold water (1×50mL) and brine (1×50 mL), respectively, and dried over anhydrous magnesium sulfate and concentrated in vacuo to yield a yellow oil (120 mg;16.8%). This oil was combined with a previous sample prepared by the same method and purified by TLC preparative plate eluting with ethyl acetate to afford 171 mg of a yellow oil which crystallized on standing. This solid was chromatographed on MPLC small column eluting with ethyl acetate to afford 151 mg of a compound of formula I wherein R 1 , R 2 =3,5-dimethyl, R 4 =hydrogen, R 3 =6-methyl, R 5 =5-difluoromethyl-1,2,4-oxadiazol-3-yl, Y=1,3-propylene, as a light yellow solid, m.p. 102.5°-103° C.
EXAMPLE 7
a) Preparation of 4- 3,5-dimethyl-4- 3-(5-furanyl-2-furanyl)propyl!oxy!benzonitrile ##STR36## To a stirred solution of 4.43 g (17 mmol) of 2- 3-(2,6-dimethyl-4-cyanophenoxy)-propyl!furan, prepared in example 2a in dry DMF cooled to 0° C. under nitrogen was slowly added 3.3 mL (35 mmol) of phosphorus oxychloride dropwise, and the reaction mixture was stirred at 0° C. for 30 rain and then was allowed to warm to room temperature. After standing overnight the reaction mixture was poured into 400 mL of water, 10% NaOH solution was added in portions until the pH was 9.0, and the mixture was stirred for 30 min. A yellow solid formed was filtered and dried to afford 4.65 g (95%) of 4- 3,5-dimethyl-4- 3-(5-furanyl-2-furanyl)propyl!oxy!benzonitrile. The yellow solid was recrystallized from methanol to afford 3.97 g of the nitrile, m.p. 61°-62° C. The compound can be protected and the cyano moiety elaborated to a suitably substituted 1,2, 4-oxadiazole or 5-tetrazolyl moiety as in the preparation of Intermediates 7-8 or 5-6, respectively, giving a compound of formula II, which can be further elaborated to a compound of formula I using the method of Example 1b and 1c.
b) Preparation of 5-hydroxymethyl-2- 3-(2, 6-dimethyl-4-cyanophenoxy)-propyl!-furan ##STR37## 5-Formyl-2- 3-(2,6-dimethyl-4-cyanophenoxy)-propyl!-furan from example 7a (21.69 g; 76 mmol) was dissolved in 200 mL of methanol/THF (1:1) with stirring under nitrogen, and the solution was chilled in an ice-water bath for 30 rain and 2.88 g (76 mmol) of sodium borohydride was added in one portion. The resulting mixture was stirred in the ice-water bath. The mixture was quenched with 10% NaOH solution after 10 min and allowed to stand overnight. The reaction mixture was concentrated in vacuo and the residue was partitioned between methylene chloride and water. The organic layer was washed with water (1x) and brine (1x), dried over magnesium sulfate, filtered through Super-Cel™, and the filtrate was concentrated in vacuo to yield 20.96 g of an orange oil. The residue was chromatographed on silica gel, eluting with 5-6% ethyl acetate/methylene chloride to afford 11.32 g (52%) of 5-hydroxymethyl-2- 3-(2,6-dimethyl-4-cyanophenoxy)-propyl!-furan, as a viscous oil which crystallized on standing; m.p. 37°-38° C. The alcohol is protected, then the 4-cyano moiety is then elaborated to a suitably substituted 1,2,4-oxadiazolyl or 5-tetrazolyl moiety as in the preparation of Intermediates 7-8 or 5-6, respectively, giving a compound of formula II, which can be further elaborated to the corresponding compound of formula I.
c) Preparation of 5-methoxymethyl-2- 3-(2, 6-dimethyl-4-cyanophenoxy)-propyl!-furan ##STR38## A solution of 5-hydroxymethyl-2- 3-(2,6-dimethyl-4-cyanophenoxy)-propyl!-furan from example 7b (0.44 g: 1.54 mmol) in 5 mL of dioxane with stirring under nitrogen was heated to 40° C., and 0.28 g (5 mmol) of crushed KOH was added. To the above reaction mixture dimethylsulfate (0.15 mL; 1.59 mmol) was added dropwise with stirring. After 1 hr, additional dimethylsulfate (0.15 mL) was added to the mixture, and the reaction mixture was allowed to react at 40° C. for 2 h and then at room temperature overnight. The mixture was filtered through Super-Cel™ the residue was washed with methylene chloride, the filtrate was washed with water (1x) and brine (1x), and dried over magnesium sulfate. The solvent was concentrated in vacuo to yield 0.48 g of a yellow oil which was purified by chromatography on silica gel eluting with a gradient of 20% 10% and 0% hexane/methylene chloride to afford 0.4 g (87%) of 5-methoxymethyl-2- 3-(2,6-dimethyl-4-cyanophenoxy)-propyl!-furan, as a clear viscous oil. The cyano moiety can be elaborated to a suitably substituted 1,2,4-oxadiazolyl or 5-tetrazolyl moiety as in the preparation of Intermediates 7-8 or 5-6, respectively, giving a compound of formula II. d) Preparation of 5-Methoxymethyl-2- 3-(2,6-dimethyl-4-cyanophenoxy)-propyl!-furan; (4.23g prepared as in 1c) was dissolved in 50 mL of acetone under nitrogen with stirring at room temperature, and 100 mL (1.35 mmol) of chilled (to -78° C.) dimethyldioxirane (0.09 M) in acetone was added to the above solution and the reaction mixture was allowed to stir at room temperature for 16h. The mixture was concentrated in vacuo to yield, 0.75g of a viscous yellow oil.
e) Preparation of 3-methoxymethyl-6- 3-(2,6-dimethyl-4-cyanophenoxy)-propyl!-pyridazine ##STR39## The compound from example 7d was dissolved in 25 mL of methylene chloride at room temperature under nitrogen with stirring, and 1 mL of 85% hydrazine hydrate was added. The resulting yellow solution was stirred for 30 rain and then was allowed to stand at room temperature overnight. The reaction mixture was diluted with methylene chloride, the organic layer was washed with water (4×50mL) and brine (1×50mL), dried over MgSO 4 , and concentrated in vacuo to yield 0.33 g of a viscous orange oil. The orange oil was purified by chromatography on silica gel eluting with ethyl acetate to afford 750 mg of 3-methoxymethyl-6- 3-(2,6-dimethyl-4-cyanophenoxy)-propyl!-pyridazine, as an orange viscous oil.
f) Preparation of 3-methoxymethyl-6- 3-2,6-dimethyl-4-aminohydroximino-methylphenoxy)-propyl!-pyridazine ##STR40## 3-Methoxymethyl-6- 3-(2,6-dimethyl-4-cyanophenoxy)-propyl!pyridazine from example 7e (750 mg; 2.4 mmol), hydroxylamine hydrochloride (830 mg; 12 mmol), potassium carbonate (1.66 g; 12 mmol), and 20 mL of ethanol were combined at room temperature under nitrogen with stirring. The reaction mixture was allowed to stir for 24 h at room temperature, diluted with ethyl acetate, filtered, and the solid residue was washed with ethyl acetate. The combined organic layer was concentrated in vacuo to afford 720 mg (87%) of 3-methoxymethy16- 3-(2,6-dimethyl-4-aminohydroximino-methylphenoxy)-propyl!-pyridazine, as a yellow solid.
g) Preparation of 3-methoxymethyl-6- 3- 2,6-dimethyl-4-(5-difluoromethyl-1,2,4-oxadiazol -2-yl-phenoxy)!-propyl!-pyridazine ##STR41## The compound prepared in example 7f (720 mg; 2.09 mmol) was dissolved in 10 mL of dry N-methylpyrrolidinone with stirring under nitrogen, and 0.63 mL (6.27 mmol) of ethyl difluoroacetate was added in one portion and the resulting mixture was heated at 100° C. for 3.5 days. The brown solution was diluted with brine, extracted with ether, and the aqueous layer and the organic layer were separated. The ether solution was washed with water (1x) and brine (1x), dried over MgSO 4 , and concentrated in vacuo to yield 0.24 g of an oil. The aqueous layer was extracted with methylene chloride (1x), and the organic layer was washed with water (1x) and brine (1x) . The methylene chloride solution was dried (MgSO 4 ) and concentrated in vacuo to yield 0.13 g of an oil. The combined product was purified by chromatography on MPLC eluting with hexane/ethyl acetate (4:96) to afford 77 mg (9%) of a compound of formula I, 3-methoxymethyl-6- 3- 2,6-dimethyl-4-(5-difluoromethyl-1,2,4-oxadiazol-2-yl) -phenoxy!-propyl!pyridazine, (Formula I; R 1 , R 2 =3,5-dimethyl, R 3 =hydrogen, R 4 =6-methoxymethyl, R 5 =5-difluoromethyl-1,2,4-oxadiazolyl, Y=1,3-propylene) as a solid, m.p. 79°-81° C. (after drying in vacuo).
EXAMPLE 8
a) Preparation of 5-(2-methyl-1,3-dioxolan-2-yl)-2- 3-(2, 6-dimethyl-4-cyanophenoxy) -propyl!furan. ##STR42## To a mixture of 5-(2-methyl-1,3-dioxolan-2-yl)-2-(3-chloropropyl)-furan (7.0 g; 30.34 mmol) (Intermediate 3b) and potassium iodide (0.506 g; 3.04 mmol) in NMP heated to 50° C., was added potassium carbonate (4.71 g; 34.08 mmol) and 2,6-dimethyl-4-cyanophenol (4.62 g; 31.39 mmol) and the reaction mixture was allowed to react at 50° C. for 4 days. The reaction mixture was then cooled to room temperature poured into water (100 mL) and extracted with ethyl acetate, washed with water twice, then brine, then dried over magnesium sulfate and concentrated in vacuo. The product was further purified by chromatography on MPLC eluting with 12% ethyl acetate/hexane 6.87 g (74%) of 5-(2-methyl-1,3-dioxolan-2-yl)-2- 3-(2,6-dimethyl-4-cyanophenoxy)-propyl!furan, as a clear oil was obtained. The cyano moiety is then elaborated to a suitably substituted 1,2,4-oxadiazolyl or 5-tetrazolyl moiety as in the preparation of Intermediates 7-8 or 5-6, respectively, giving a compound of formula II or can be used in the next step.
b) Preparation of 6-(2-methyl-1,3-dioxolan-2-yl)-3- 3-(2,6-dimethyl-4-cyanophenoxy)-propyl !-pyridazine ##STR43## Following a procedure similar to that described in Example 3c, 5-(2-methyl-1,3-dioxolan-2-yl)-2- 3-(2,6-dimethyl-4-cyanophenoxy)-propyl!furan; (1.05 g; 3.08 mmol), 48 mL (0.06 M) of dimethyldioxirane in acetone, and 10 mL of acetone were reacted. The resulting product was dissolved in methanol and reacted with 85% hydrazine hydrate (0.15 mL; 4.49 mmol) then purified by chromatography on silica gel with 65% ethyl acetate/hexane to afford 0.511 g (47%) of 6-(2-methyl-1,3-dioxolan-2-yl)-3- 3-(2,6-dimethyl-4-cyanophenoxy) -propyl!-pyridazine.
c) Preparation of 6-(2-methyl-1,3-dioxolan-2-yl)-3- 3-(2, 6-dimethyl-4-hydroxyimideamidephenoxy)-propyl!pyridazine ##STR44## To a solution of the compound prepared in example 8c, 6-(2-methyl-1,3-dioxolan-2-yl)-3- 3-(2,6-dimethyl-4-cyanophenoxy)-propyl!-pyridazine (0.511g; 1.45 mmol) in 9 mL of ethanol was added potassium carbonate (1.09 g; 7.05 mmol) and hydroxylamine hydrochloride (490 mg; 12 mmol). The reaction mixture was allowed to stir overnight at room temperature, concentrated in vacuo, and the residue was dissolved in 50 mL of water. The aqueous solution was extracted with ethyl acetate (4×50 mL), and the combined organic layer was washed with water (1×50mL) and brine (1×50mL), and dried over MgSO 4 . The organic layer was concentrated in vacuo to afford 502 mg (89.6%) of 6-(2-methyl-1,3-dioxolan-2-yl) -3- 3-(2,6-dimethyl-4-aminohydroximinomethylphenoxy) -propyl!-pyridazine, as a white solid.
d) Preparation of 6-(2-methyl-1,3-dioxolan-2-yl)-3- 3- 2,6-dimethyl-4-(5-difluoromethyl-1,2,4-oxadiazol-2-yl-phenoxy)!-propyl!-pyridazine ##STR45## Following a procedure similar to that described in Example 2f, 6-(2-methyl-1,3-dioxolan-2-yl)-3- 3-(2,6-dimethyl-4-aminohydroximinomethylphenoxy) -propyl!-pyridazine from example 8c (1.023 g; 2.65 mmol), 5 drops of dry Nmethylpyrrolidine, and 5 mL of ethyl difluoroacetate were combined with stirring under nitrogen, and the resulting mixture was heated at 100° C. for 3 days. The mixture was concentrated in vacuo, the residue was dissolved in ethyl acetate, ethyl acetate solution was washed with water (5×50 mL) and brine (1×50mL) and dried over MgSO 4 . The organic solvent was concentrated in vacuo and the residue was purified by chromatography on MPLC eluting with 70% ethyl acetate/hexane and ethyl acetate to afford the desired product 6-(2-methyl-1,3-dioxolan-2-yl)-3- 3- 2,6-dimethyl-4-(5-difluoromethyl -1,2,4-oxadiazol-2-yl)-phenoxy!-propyl!pyridazine.
e) Preparation of 6-acetyl-3- 3- 2,6-dimethyl-4-(5-difluoromethyl-1,2,4-oxadiazol-2-yl) -phenoxy!-propyl!pyridazine ##STR46## A mixture of 0.24 g (0.538 mmol) of 6-(2-methyl-1,3-dioxolan-2-yl)-3- 3- 2,6-dimethyl-4-(5-difluoromethyl-1,2,4-oxadiazol-2-yl)-phenoxy!-propyl!-pyridazine from example 8d, 20 mL of acetic acid, 5 mL of water, and 5 mL of 2 M HCl solution was heated to reflux for 24 hr. The reaction mixture was added to a freshly prepared sodium bicarbonate solution, the aqueous layer was extracted with ethyl acetate (4×50mL), and the combined organic layer was washed with water (50mL) and brine (100mL), dried and concentrated in vacuo. The residue was purified by chromatography on MPLC eluting with 30% ethyl acetate/hexane followed by recrystallization from ethyl acetate/hexane to afford 165 mg (76%) of 6-acetyl-3- 3- 2,6-dimethyl-4-(5-difluoromethyl -1,2,4-oxadiazol-2-yl)phenoxy!-propyl!-pyridazine (Formula I; R 1 , R 2 =3,5-dimethyl, R 3 -6-acetyl, R 4 =hydrogen, R 5 =5-difluoromethyl-1,2,4-oxadiazolyl, Y=1,3-propylene), m.p. 95°-96° C.
f) Preparation of 6-(2-methyl-1,3-dioxolan-2-yl)-3- 3- 2,6-dimethyl-4-(5-trifluoromethyl-1,2,4-oxadiazol-2-yl)phenoxy!-propyl!-pyridazine ##STR47## Following a procedure similar to that described in Example 8d, to a solution of 6-(2-methyl-1,3-dioxolan-2-yl)-3- 3-(2,6-dimethyl-4-aminohydroximino-methylphenoxy)-propyl!pyridazine (0.502 g; 1.3 mmol) dissolved in 8 mL of dry N-methylpyrrolidine was added 0.36 g (2.6 mmol) of potassium carbonate and 0.28 mL (1.98 mmol ) of trifluoroacetic anhydride, and the mixture was heated to 70° C. One additional equivalent of trifluoroacetic anhydride was added and the mixture was heated to 70° C. The mixture was poured into 200 mL of water, the aqueous solution was extracted with ethyl acetate (5×50 mL), and the combined organic layer was dried and concentrated in vacuo to residue. The residue was taken up and was purified by chromatography on MPLC eluting with 50% ethyl acetate/hexane to afford 0. 395 g (65%) of 6-(2-methyl-1,3-dioxolan-2-yl)-3- 3- 2,6-dimethyl-4-(5-trifluoromethyl-1,2,4-oxadiazol-2-yl-phenoxy)!-propyl!-pyridazine.
g) Preparation of 6-acetyl-3- 3- 2,6-dimethyl-4-(5-trifluoromethyl-1,2,4-oxadiazol-2-yl) -phenoxy!-propyl!pyridazine ##STR48## A mixture of 0.5 g (1.08 mmol) of 6-(2-methyl-1,3-dioxolan-2-yl)-3- 3- 2,6-dimethyl-4-(5-trifluoromethyl-1,2,4-oxadiazol-2-yl)-phenoxy!-propyl!-pyridazine from example 8f, 8 mL of acetic acid, and 2 mL of water was heated to reflux. After adding acid solution, the reaction mixture was refluxed for 5 h. Upon cooling, the above reaction mixture was added to a freshly prepared sodium bicarbonate solution with stirring. The product was isolated and purified by chromatography on MPLC eluting with 30-50% ethyl acetate/hexane and recrystallized from hexane to afford 0.30 g (66 %) of 6-acetyl-3- 3- 2,6-dimethyl-4-(5-trifluoromethyl-1,2,4-oxadiazol-2-yl)-phenoxy!-propyl!pyridazine (R 1 , R 2 =3,5-dimethyl, R 3 =6-acetyl, R 4 =hydrogen, R 5 =5-trifluoromethyl-1,2,4-oxadiazolyl, Y=1,3-propylene), as a crystalline solid, m.p. 86°-87° C .
h) Preparation of 6-(1,1-difluoro-ethyl)-3- 3- 2,6-dimethyl-4-(5-trifluoromethyl-1,2,4-oxadiazol-2-yl) phenoxy!-propyl!-pyridazine ##STR49##
To a mixture of 220 mg (0.523 mmol) of 6-acetyl-3- 3- 2,6-dimethyl-4-(5-trifluoromethyl -1,2,4-oxadiazol-2-yl)phenoxy!-propyl!-pyridazine (from Example 8g) in 2 mL of methylene chloride was added 0.1 mL of diethylaminosulfur trifluoride (DAST) and the mixture was left at room temperature for 3 days. Additional DAST was added (1.0 mL) and the mixture heated to reflux then left at room temperature for 2 days. Finally DAST (4 mL) were added and the mixture heated to reflux until starting material was not evident by TLC. The product was purified by chromatography on MPLC eluting with 30% ethyl acetate/hexane to afford 6-(1,1-difluoroethyl)-3- 3- 2,6-dimethyl-4-(5-trifluoromethyl-1,2,4-oxadiazol-2-yl)phenoxy!-propyl!-pyridazine (Formula I; R 1 , R 2 =3,5-dimethyl, R 3 =6-1,1-difluoroethyl, Y=1,3-propylene, R 4 =hydrogen, R 5 =5-trifluoromethyl-1,2,4-oxadiazolyl), as a crystalline solid, m.p. 54.5° C.
i) Using the methods described above, for reacting DAST with a carbonyl of compound I, and the compound of example 8e as a substrate compound of formula I was obtained wherein R 1 , R 2 are 3, 5 dimethyl, R 3 =6-1,1 difluoroethyl, R 4 is H, Y is 1,3-propylene and R 5 is 5-difluoromethyl-1,2,4-oxadiazol-3-yl, m.p. 73.5°-74° C.
EXAMPLE 9
a) Methyl β0(5-methyl-2-furanyl)-propenoate To a solution of trimethylphosphonoacetate (13.09 mL; 66 mmol) in 500 mL of THF cooled to -78° C. under nitrogen with stirring, 132 mL (61.6 mmol) of 0.5 M potassium bis(trimethylsilyl)amide in toluene was added dropwise over a 1/2 h period. The reaction mixture was stirred continuously at -78° C. for 1 hr. To the mixture was added 6.66 g (66 mmol) of 5-methyl-2-furanyl-2-carboxaldehyde and 3 mL of THF over a 10 min period with stirring. After 1 h, stirring was stopped and the reaction mixture was allowed to warm to room temperature over a 2 h period. The reaction mixture was quenched with an aqueous solution of saturated ammonium chloride with stirring, and water was added to dissolve the precipitated salts into solution. The THF/aqueous solution was washed with ether (200 mL), and the aqueous layer was washed again with 100 mL of ether. The combined organic layer was washed with brine, dried over anhydrous magnesium sulfate, filtered, and concentrated in vacuo and distilled (130°-135° C./16 mm) to yield 8 g (87.9%) of the desired product.
b) Methyl 3-(5-methyl-2-furanyl)propionate A mixture of ethyl β-(5-methyl-2-furanyl)acrylate (8 g) in methanol (200 mL) and 1.5 g of 5% palladium on carbon was placed on a Paar hydrogenator and hydrogenated with H 2 . Palladium on carbon was filtered off by passing the reaction mixture through Super-Cel™ (filter agent) and the residue was washed with ethanol. The filtrate was concentrated in vacuo to yield 8 g of methyl 3-(5-methyl-2-furanyl)propionate.
c) 3-(5-methyl-2-furanyl)propanol (Example 1a, 6a and 12a)
To a solution of ethyl 3-(5-methyl-2-furanyl)propionate (3.6 g, 20 mmol) in 50 mL of THF at 0° C. was added dropwise under nitrogen 8 mL of diisobutylaluminum hydride (1M in hexane), and the mixture was stirred at room temperature over-night. The resulting solution was diluted with 2 mL of water in 10 mL of THF and brine, and the mixture was stirred for 30 min. The solid was removed by filtration, and the filtrate was diluted with 20 mL of water, extracted with methylene chloride. The organic layer was washed with water, dried over magnesium sulfate, and concentrated in vacuo. The residue was purified by passing through MPLC column (ethyl acetate/hexane) to afford 1.11 g of the desired product.
d) 5-methyl-2- 3- 2,6-dimethyl-4-(2-methyl-tetrazol-5-yl) phenoxy!-propyl!furan
Diethyl azodicarboxylate (DEAD, 1.4 g in 20 mL of THF) was added dropwise under nitrogen to a stirred and cooled (-10° C.) solution of triphenylphosphine (2.09 g) , 3-(5-methyl-2-(propanol)furanyl) (1.11 g; 8 mmol), and 4-(2-methyl-tetrazol-5-yl)-2,6-dimethylphenol (1.632 g; 8 mmol)in 50 mL of THF and the mixture was stirred for 20 min. The mixture was diluted with 200 mL of water, extracted with ether (3×50 mL), and the organic layer was washed with water (3×25 mL), 10% NaOH solution, and water. The organic layer was dried over magnesium sulfate, and concentrated in vacuo to yield an oil which was passed through MPLC column (ethyl acetate/hexane 3:7) to afford 1.75 g (67.1%) of 5-methyl-2- 3- 2,6-dimethyl-4-(2-methyl-tetrazol-5-yl)phenoxy!-propyl!furan (Formula II; R 3 =5-methyl, R 1 , R 2 =3,5-dimethyl R 4 =hydrogen, Y=1,3-propylene, R 5 =2-methyltetrazol-5-yl).
e) 5-Methyl-2- 3- 2,6-dimethyl-4-(2-methyl-tetrazol-5-yl)phenoxy!-propyl!-2,5 dimethoxy-2,5-dihydrofuran
Sodium carbonate (1.2 g) was added to a cooled (-10° C.) solution of 5-methyl 2- 3- 2,6-dimethyl-4-(2-methyltetrazol-5-yl)phenoxy!-propyl!furan from example 9d (780 mg, 2.4 mmol) in 18 mL of methanol with stirring, and then bromine (0.135 g, 14 mmol) in 8 mL of methanol was added dropwise until the brown color persisted, and the resulting reaction mixture was allowed to stir at -10° C. for 45 min. To the mixture was added brine, extracted with ether (3×25 mL), and the organic layer was washed with water, dried over magnesium sulfate, and concentrated in vacuo to yield an oil which was purified by MPLC chromatography (ethyl acetate/hexane 3:7) to afford 820 mg (76.3 %) of 5-methyl-2- 3- 2,6-dimethyl-4-(2-methyl-tetrazol-5-yl)phenoxy!propyl!2,5-dimethoxy-2,5-dihydrofuran.
f) 3-Methyl-6- 3- 2,6-dimethyl-4-(2-methyl-tetrazol-5-yl)-phenoxy!-propyl!-pyridazine
Under nitrogen with stirring 5-methyl-2- 3- 2, 6-dimethyl-4-(2-methyl-tetrazol-5-yl) phenoxy!-propyl!-2,5-dimethoxy-2,5-dihydrofuran (820 mg, 1.8 mmol), 0.8 mL of methanol, and 1.5 mL of 1% aqueous acetic acid solution were combined at room temperature, refluxed for 10 min, and then cooled to room temperature. To the above solution was added hydrazine hydrate (0.26 mL) over a 2 min period, and the mixture was allowed to reflux for 1 h, and cooled to room temperature. The mixture was diluted with water, the aqueous layer was extracted with methylene chloride, and the organic layer was washed with brine, dried over magnesium sulfate, and concentrated in vacuo to afford 180 mg (29 %) of 3,methyl-6- 3- 2,6-dimethyl-4-(2-methyltetrazol-5-yl)-phenoxy!propyl !-pyridazine (Formula I; R 1 , R 2 =3,5-dimethyl, R 3 =6-methyl, R 4 =hydrogen, R 5 =2-methyltetrazol-5-yl), m.p. 114°-115° C.
EXAMPLE 10
a) 5-Ethyl-2- 3- 2,6-dimethyl-4-(2-methyl-tetrazol-5-yl)phenoxy!-propyl!furan
Diethyl azodicarboxylate (DEAD, 4.84 g; 27.8 mmol) was added under nitrogen to a stirred and cooled (-20° C.) solution of triphenylphosphine (7.37 g; 27.8 mmol), 5-ethyl-2-(3-hydroxypropyl)furan (Intermediate 1c) (3.9 g; 25.3 mmol) , and 4-(2-methyl-tetrazol-5-yl)-2,6-dimethylphenol (5.69 g; 27.8 mmol). The mixture was stirred at -20° C. for 1/2 h, and then was allowed to warm to room temperature overnight. Water (50 mL) was added to the mixture and the layers were separated. The aqueous layer was extracted with ether (3×50 mL), the organic layer was washed with 10 % NaOH solution (3×50 mL), water, and dried over magnesium sulfate. The solvent was concentrated in vacuo to yield a residue and purified by MPLC column chromatography (ethyl acetate/hexane, 3:7) to afford 5.63 g (65 %) of 5-ethyl-2- 3- 2,6-dimethyl-4-(2-methyl-tetrazol-5-yl)phenoxy!-propyl!furan (Formula II; R 3 =5-ethyl, R 4 =hydrogen, R 1 , R 2 =3,5-dimethyl, R 5 =2-methyltetrazol-5-yl, Y=1,3-propylene).
b) The compound prepared in 9e was transformed into a compound of formula I by the method of Example 1b and 1c. (R 3 =6-ethyl, Y=(CH 2 ) 3 , R 1 , R 2 =3,5-dimethyl, R 4 =hydrogen, R 5 =2-methyltetrazol-5-yl).
EXAMPLE 11
a) 5-Propyl-2- 3- 2,6-dimethyl-4-(2-methyl-tetrazol-5-yl)phenoxy!-propyl!furan
Diethyl azodicarboxylate (DEAD, 3.88 g; 22.3 mmol) was added under nitrogen to a stirred and cooled (-10° C.) solution of triphenylphosphine (5.84 g; 22.3 mmol), 3-(5-propyl-2-(furanyl)propanol (Intermediate 4c) (3.75 g; 22.3 mmol), and 4-(2-methyl-tetrazol-5-yl)-2,6-dimethylphenol (5 g; 24.5 mmol) and the mixture was stirred for 20 min. Water and methylene chloride (25 mL) were added to the mixture and the layers were separated. The organic layer was washed with 2N NaOH solution (2x), HCl solution, brine, dried over magnesium sulfate, and concentrated in vacuo to yield a white solid (13 g) . The white solid was purified by a large dry flash silica column (hexane, 30% and 70% ethyl acetate/hexane) followed by a medium size MPLC column chromatography (15% and 30% ethyl acetate/hexane) to afford 6.64 g (84%) of 5-propyl-2- 3- 2,6-dimethyl-4-(2-methyl-tetrazol-5-yl)phenoxy!-propyl!furan (Formula II; R 1 , R 2 =3,5-dimethyl, Y=1,3-propylene, R 3 =5-propyl, R 4 =hydrogen, R 5 =2-methytetrazol-5-yl), m.p. 38°-39° C.
b) 1-Propyl-4- 3- 2,6-dimethyl-4-(2-methyl-tetrazol-5-yl-phenoxy)!-propyl!but-2-en -1,4-dione Sodium carbonate (6.32 g, 60 mmol) was added to a cooled (-10° C.) solution of 5-propyl-2- 3- 2, 6-dimethyl-4-(2-methyl-tetrazol-5-yl)phenoxy!-propyl!furan (4.46 g, 13 mmol) in 35 mL of methanol with stirring, and then bromine (2.23 g, 14 mmol) in 10 mL of methanol was added dropwise, and the resulting reaction mixture was allowed to stir at -10° C. for 45 min. To the mixture was added brine and water, and the mixture was extracted with ether (3x), the organic layer was washed with brine, dried over magnesium sulfate, and concentrated in vacuo to yield 4.74 g of a yellow oil. The oil was purified by a large dry flash silica column (2x) chromatography (hexane, 30% ethyl acetate/hexane) to afford 1-propyl=4- 3- 2,6-dimethyl-4-(2-methyl-tetrazol-5-yl-phenoxy)!-propyl!but-2-en -1,4-dione as a 2nd fraction and 5-propyl-2- 3- 2,6-dimethyl-4-(2-methyl-tetrazol-5yl)-phenoxy!-propyl!-2,5-dimethoxy -2,5-dihydrofuran, as a first fraction.
c) 3-Propyl-6- 3- 2,6-dimethyl-4-(2-methyl-tetrazol-5-yl)-phenoxy!-propyl!-pyridazine
Under nitrogen with stirring 1-propyl-4- 3- 2,6-dimethyl-4-(2-methyl-tetrazol-5-yl-phenoxy) !-propyl!but-2-en-1,4-dione (1.42 g, 3.8 mmol), 1.42 mL of methanol, and 2.63 mL of 1% aqueous acetic acid solution were combined at room temperature, refluxed for 10 min, and then cooled to room temperature. To the above solution was added hydrazine hydrate (0.29 mL; 9.5 mmol) over a 2 min period, and the mixture was allowed to reflux for 1 h, and cooled to room temperature. The mixture was diluted with water, the aqueous layer was extracted with methylene chloride (3x), and the organic layer was washed with brine, dried over magnesium sulfate, and concentrated in vacuo to afford 1.4 g of a yellow oil. The oil was passed through a silica column eluting with ethyl acetate/hexane (1:1) to afford 0.25 g (17.98 %) of 3-propyl-6- 3- 2,6-dimethyl-4-(2-methyl-tetrazol-5-yl)-phenoxy!-propyl!pyridazine (Formula I; R 1 , R 2 =3,5-dimethyl, Y=1,3-propylene, R 4 =hydrogen, R 3 =6propyl, R 5 =2-methyltetrazol-5-yl), as a yellow oil. This oil was further purified by MPLC column chromatography and flurosil column chromatography (ethyl acetate/hexane) to yield a clear oil which crystallized, m.p.78°-80° C.
EXAMPLE 12
Using the protocols described above, and the appropriate intermediates the following compounds of formula I were prepared.
__________________________________________________________________________FORMULA I R.sub.3,R.sub.4Ex Pyridazyl R.sub.1 R.sub.2 Y = R.sub.5 M.P.__________________________________________________________________________a 6-propyl-3- 3,5-dimethyl (CH.sub.2).sub.3 5-CHF.sub.2 -1,2,4- 124-125 pyridazyl oxadiazolylb 6-propyl-3- 3-CH.sub.3 H (CH.sub.2).sub.3 5-CHF.sub.2 -1,2,4- 131.5-136.5 pyridazyl oxadiazolylc 6-ethyl-3- 3,5-dimethyl (CH.sub.2).sub.3 5-CHF.sub.2 -1,2,4- 82.5-83.5 pyridazyl oxadiazolyld 6-ethyl-3- 3-CH.sub.3 H (CH.sub.2).sub.3 5-CHF.sub.2 -1,2,4- 85.5-86 pyridazyl oxadiazolyle 6-ethyl-3- H H (CH.sub.2).sub.3 5-CF.sub.3 -1,2,4- 111.5-112 pyridazyl oxadiazolylf 6-ethyl-3- 3,5-dimethyl (CH.sub.2).sub.3 5-CF.sub.3 - 60-60.5 pyridazyl 1,2,4 oxadiazolylg 6-methyl-3- 3,5-dimethyl (CH.sub.2).sub.3 5-CF.sub.3 -1,2,4- 68.5-70 pyridazyl oxadiazolylh 6-methyl-3- 3,5-dimethyl 1,3propylene 5-CHF.sub.2 - 67.5-69 pyridazyl 1,2,4-oxadiazolyli 6-methyl-3- 3-CH.sub.3 H 1,5pentylene 5-CHF.sub.2 - 70.8-72.3 pyridazyl 1,2,4-oxadiazolylj 6-propy,1-3- 3,5-dimethyl 1,3propylene 5-cyclopropyl -- pyridazyl 1,2,4-oxadiazolylk 6-propy,1-3- 3-CH.sub.3 H 1,3propylene 5-cyclopropyl 75.6-77.2 pyridazyl 1,2,4-oxadiazolyll 6-ethyl-3 3-CH.sub.3 H 1,3propylene 5-CF.sub.3 - 91-91.5 pyridazyl 1,2,4-oxadiazolylm 6-ethyl-3 3-CH.sub.3 H 1,3propylene 5-CF.sub.2 H-1,2,4- 90.5-91.5 pyridazyl oxadiazolyl__________________________________________________________________________
EXAMPLE 13
a) A slurry of 19 g of 2-acetyl furan (Aldrich), 57.8 g of aluminum chloride and 17.7 mL and bromine was heated to 65° C. for 2 hours. A resulting dark brown slurry was poured over ice and extracted with an ether. The organic phase was then washed twice with water and dried over potassium carbonate. Concentration of the organic phase provided 25 g of the dark brown oil. Distillation (0.5 mmHg 62° C. to 69° C.) provided 13.1 g. (28%) of a pale yellow oil which crystallized upon standing and was used without further purification.
b) To a solution of 13 g. of the product prepared in A above in 100 mL of 70% acetic acid, 3.6 g. of zinc powder was added slowly over 30 minutes. The mixture was filtered and concentrated in vacuo. The dark red mixture was diluted with ether and washed with water followed by sodium bicarbonate solution. The organic phase was dried over potassium carbonate and concentration of the organic phase provided 9 g. of the dark red oil. Crystallization from isopropyl acetate and hexanes provided 3.4 g. of a tan solid product melting point 57° C. to 59° C.
c) A solution of 3.4 g of 3-bromo 5-acetyl furan, 1.23 g of ethylene glycol and a catalytic amount of tosyl acid in 50 mL of benzene was refluxed under nitrogen with a Dean Stark Trap for 3 days. Upon cooling, the mixture was concentrated in vacuo, diluted with ether and washed with dil bicarbonate solution. The organic phase was dried over K 2 CO 3 . Concentration provided 4.2 g of the product as a viscous red liquid. Used without further purification (Quantitative).
d) To a solution of 4.2 g. of the product produced in B, C above in 100 mL of ether at -78° C. under nitrogen was added 1.9 mL of 10 M n-butyl lithium. After 15 minutes the brown slurry was quenched with 4 g. of 3-chloro-1-iodopropane in 10 mL of HMPA. Upon warming to room temperature, the mixture was poured into water and washed four times. The organic phase was dried over potassium carbonate. Concentration of the organic phase provided 3.7 g. of crude product which was distilled (0.1 mmg; 91°-95° C.) to provide 0.9 g. of the corresponding propylchloride product used without further purification.
e) A suspension of 1.2 g. of the phenol of Example 1a, 1.5 g. of the alkyl chloride prepared in 13d above, 0.4 g. of powdered potassium hydroxide and 0.9 g. of potassium iodide in 40 mLs of acetonitrile was refluxed under nitrogen for 20 hours. Filtration, concentration and flash filtration through kieselgel 60 with 2;1 hexane/EtOAc provided 3.7 g. of an orange oil which was subjected to MPLC affording 0.53 g. of the product as a yellow viscous oil.
f) To a solution of 0.53 g. of the dioxolane prepared in above in 20 mL of acetone was added 0.1 g. of PPTs. The mixture was allowed to stir at room temperature for 14 hours, followed by reflux under nitrogen for 5 hours, concentration and extraction with ethyl acetate followed by a water wash and drying of the organic phase over potassium carbonate provided 0.48 g. of the product as a pale yellow viscous oil. Crystallization from isopropyl acetate and hexane provided 245 mg of the product as a tan powder, melting point 95° C. to 97° C., which can be reacted with MCPBA and hydrazine to prepare a compound of Formula I after the blocking of the acetyl moiety (Formula I R 1 , R 2 =3,5 dimethyl, R 3 =6-acetyl, R 4 =H, R 5 =5-methyl-1,2,4-oxadiazolyl, Y=1,3 propylene)m.p. 99°-100.5° C.
EXAMPLE 14
As further examples of the invention, the following antipicornavirally effective 2-furanyl compounds of formula II can be elaborated to the corresponding pyridazines of formula I using the procedures previously described.
__________________________________________________________________________ExampleR.sub.1 R.sub.2 R.sub.3 R.sub.4 Y R.sub.5 M.P.__________________________________________________________________________a H H H 5-acetyl (CH.sub.2).sub.5 ethoxy-carbonyl 85-87b H H H H (CH.sub.2).sub.5 ethoxy-carbonyl oilc H H H H (CH.sub.2) ethoxy-carbonyl 59-61d 3-bromo,H H 5-acetyl (CH.sub.2).sub.5 4,5-dihydro 91-92 oxazolee 3,5-dichloro H H (CH.sub.2).sub.5 4,5-dihydro oil oxazolef 3,5-dimethyl H 5-acetyl (CH.sub.2).sub.5 2-methyl-5- 77-78 tetrazolylg 3,5-dimethyl H 5-(hydroxy) (CH.sub.2).sub.5 2-methyl-5- 92-94 ethyl tetrazolylh 3,5-dimethyl H 5-formyl (CH.sub.2).sub.5 2-methyl-5- 63-65 tetrazolyli 3,5-dimethyl H 5-hydroxy (CH.sub.2).sub.5 2-methyl-5- 74-75 methyl tetrazolyli 3-bromo,H H 5-propyl (CH.sub.2).sub.3 phenylk 3-bromo,H H H (CH.sub.2).sub.3 phenyll 3,5-dimethyl H 5-ethyl (CH.sub.2).sub.3 4-fluorophenyl__________________________________________________________________________
The following Examples of compounds of formula I were prepared by the method of 1b-c described above:
______________________________________14m 3-bromo, H H 6 propyl (CH.sub.2).sub.3 phenyl 102.6-103.114n 3-bromo, H H H (CH.sub.2).sub.3 phenyl --______________________________________
o. Using Example 14j in the method of 1b and 1c one obtains a compound of formula I wherein R 1 =3-bromo, R 2 , R 4 =H, R 3 =propyl, R 5 =phenyl and Y=1,3 propylene.
p. Using the method of example 14o, example 141 was transformed to the corresponding compound of formula I, m.p. 114°-116° C.
EXAMPLE 15
a. 0.5 g of 5-difluoromethyl-1,2,4-oxadiazol-3-yl-2,6-dimethyl-phenol was dissolved in 5 mls of THF and 0.11 g of propargyl alcohol and 0.81-g of triphenylphosphine was added. The reaction was cooled to 0° C. and DEAD (0.54 g) in 5 mls of THF was added slowly. The mixture was stirred and allowed to come to room temperature overnight. This mixture was absorbed onto silica gel and eluted using 2:1 hexane/EtOAc yielding 0.6 g of a yellow solid used without purification in the next step.
The product obtained above was taken up in 8 mL of triethylamine and combined with 0.53 g of 3-iodo-6-methoxy pyridazine. To this mixture 14 mg of PdCl 2 (φ3P) 2 and 11 mg of CuI was added. The mixture was allowed to stir at room temperature and the methoxy was allowed to stir at room temperature for 3 days. The mixture was filtered through Celite and absorbed onto silica gel eluted with a hexane/EtOAc mixture. The appropriate fractions were concentrated at a yield of 0.86 g or an amber oil that crystallized upon standing. Upon purification via MPLC 0.68 g of a compound of formula I wherein R 3 is methoxy, R 4 =hydrogen, R 5 is 5-difluoromethyl-1,2,4-oxadiazol-3-yl, R 1 , R 2 represent 3,5-dimethyl and Y is 1,3-propyl-1-yne.
b. 0.58 g of the compound described above was exposed to Lindlar catalyst in EtOAc to provide a compound of formula I wherein R 3 is methoxy, R 4 is hydrogen, R 1 , R 2 represent 3,5-dimethyl, R 5 is 5-difluoromethyl-1,2,4-oxadiazol-3-yl and Y is 1,3-propylene, (m.p. 91°-93° C.)
c. Using the method of example 15a, but substituting a compound the appropriate materials of formula I was obtained; Y=1,3-propyl-1-yne, R 1 , R 2 =3,5-dimethyl, R 3 =6-methoxy, R 4 =H, R 5 =5-trifluoromethyl-1,2,4-oxadiazol-3-yl, m.p. 110°-112° C.
d. Upon reduction as described in 15, one obtains the corresponding compound of formula 1 where Y=1,3-propylene, R 1 , R 2 =3,5-dimethyl, R 3 =6-methoxy, R 4 =H, R 5 =5-trifluoromethyl-1,2,4-oxadiazol -3-yl, m.p. 59°-61° C.
EXAMPLE 16
a. 3-(4-cyano-2,6-dimethylphenoxy)propionic acid (20.02 g) was combined with 45 mls of SOCl 2 in methylene chloride at room temperature and was allowed to stir overnight. Zn-Cu in 500 mL benzene, 39 mL DMA and 1.3 equiv. of ethyl-(3-iodo)propionate was heated to 69° C. for 3 hours, 1 equiv. of Pd Pφ 3 ! 4 was added, after cooling 5 minutes, the acid chloride was added, and the mixture sat overnight. Upon workup ethyl (6-(4-cyano-2,6-dimethylphenoxy)-3-keto hexanoate is obtained in 80% yield, m.p. 45°-46° C.
b. 20.76 g of the product of 16a was taken up in 200 mL EtOH and 3.2 mL hydrazine was added. The mixture was then heated to reflux for 2 hours. Upon workup one obtains 6-(3-(4-cyano-2,6-dimethylphenoxy) propyl)-4,5-dihydro-pyridazin-3-one (93%), m.p. 124.5° C.
c. 5.713 g of the dihydro pyridazinone from 16b was taken up in 90 mL EtOAc and 1.4 mL Br 2 added. Upon workup 6-(3-(4-cyano-2,6-dimethylphenoxy)propyl)-3-hydroxypyridazine was obtained quantitative yield.
d. Using the method of example 6c and d a compound of formula I where R 1 , R 2 =3,5-dimethyl, R 3 =6-hydroxy, R 4 =H, R 5 =5-difluoromethyl-1,2,4-oxadiazol-3-yl, Y=1,3-propylene was obtained.
e. The compound obtained in 16d was exposed to POCl 3 to afford a compound of formula I wherein R 1 , R 2 =3,5-dimethyl, R 3 =6-chloro, R 4 =H, R 5 =5-difluoromethyl-1,2,4-oxadiazol-3-yl, Y=1,3-propylene, (87% yield), m.p. 100.5°-101.5° C.
f. The compound of 16d was exposed to POBr 3 yield a compound of formula I wherein R 1 , R 2 =3,5-dimethyl, R 3 =6bromo, R 4 =H, R 5 =5-difluoromethyl-1,2,4-oxadiazol-3-yl, Y=1,3-propylene, m.p. 91°-92° C.
g. 2.1 g of the compound of 16d was taken up in THF and 1.93 g of Lawesson's reagent added, the mixture was refluxed until starting material is no longer present. Upon workup a compound of formula I was obtained, R 1 , R 2 =3,5-dimethyl, R 3 =6-thio, R 4 =H, R 5 =5-difluoromethyl-1,2,4-oxadiazol-3-yl, Y=1,3-propylene, m.p. 146°-148° C.
h. 200 mg of the compound of example 16g was taken up in DMF and 80 mg CH3I and 56 mg Et3 N added, and after 1 hour the mixture was worked up yielding a compound of formula I, R 1 , R 2 =3,5-dimethyl, R 3 =6-methylthio, R 4 =H, R 5 =5-difluoromethyl-1,2,4-oxadiazol -3-yl, Y=1,3-propylene, (m.p. 98°-101 ° C.).
i. 32 g of the compound of 16h was treated with 0.285 g of 50-60% MCPBA. Upon workup 0.167 g of a compound of formula I was obtained, R 1 , R 2 =3,5-dimethyl, R 3 =6-methylsulfinyl, R 4 =H, R 5 =5-difluoromethyl-1,2,4-oxadiazol-3-yl, Y=1,3-propylene, m.p. 87°-89° C.
j. The compound of 16c was transformed to a compound of formula I by the method of example 6c and then 8f giving a compound of formula I (53%) (R 1 , R 2 =3,5-dimethyl, R 3 =6-hydroxy, R 4 =H, R 5 =5-trifluoromethyl-2,2,4-oxadiazol-3-yl, Y=1,3-propylene.
k. The compound of 16g was exposed to POCl 3 yielding (48%) of a compound of formula I, (R 1 , R 2 =3,5-dimethyl, R 3 =6-chloro, R 4 =H, R 5 =5-trifluoromethyl-1,2,4-oxadiazol-3-yl, Y=1,3-propylene), m.p. 96°-98° C.
l. The compound of 16j was acetylated to give a compound wherein Y=1,3 propylene, R 1 , R 2 =3,5 dimethyl, R 3 -acetoxy, R 4 =H, R 5 =5-methyl-1,2,4-oxadiazolyl, m.p. 69°-71° C.
EXAMPLE 17
a. 130 mL of trifluoro acetic anhydride (chilled) was added to 50 g of 1-valine and allowed to warm to room temperature. The resulting material was vacuum distilled at 69°-71° C. giving 68.05 g of (81%) of 2-trifluoromethyl-2,5-dihydro-4-(1-methylethyl)-5-oxazalone.
b. 54.64 g of the oxazalone obtained in 17a was taken up in 150 mL of CH 2 Cl 2 , chilled and 50 mL of t-butylacrylate added followed by 50 mL Et 3 N, dropwise. The reaction stirred overnight giving a yellow oil, yielding 95.9 g of the desired product 1,1-dimethylethyl 3- 2-(2-trifluoromethyl-2,5-dihydro-4-methylethyl-5-oxooxazolinyl) !propionate.
c. The product obtained above was taken up in 500 mL glacial acetic acid and 100.5 g of hydrazine hydrochloride added then the mixture was refluxed for 2 hours. Upon workup 6-trifluoro 4,5-dihydro-pyridazin-3-one was obtained in 59% yield. This product was treated with bromine in glacial acetic acid yielding 77.5%, 3-hydroxy-6-trifluoromethyl pyridazine. This product was exposed to POBr 3 giving 7.92 g 3-bromo-6-trifluoromethyl pyridazine.
d. The pyridazine above was reacted with propargyl alcohol (under Heck conditions), the product was then reacted with 4-cyano-3,5-dimethyl-phenol (according to the method of example 6a then reduced with palladium and carbon and elaborated to the 5-difluoromethyl, 1,2,4-oxadiazolyl species according to the method of 6c and d. To give a compound of formula I (R 3 =CF 3 , R 4 =H, R 1 , R 2 =3,5-dimethyl, Y=1,3-propylene, R 5 =5-difluoromethyl-1,2,4-oxadiazol-3-yl) m.p. 80°-81° C.
e. The following compound of formula I was prepared using the materials and methods described above. Each compound has the formula R 3 =CF 3 , R 4 =H, R 5 =5-methyl-1,2,4-oxadiazol-3-yl, Y=1,3-propylene, and R 1 , R 2 =3,5-dimethyl, m.p. 147°-148° C.
EXAMPLE 18
a. 4-pentyne-1-ol was protected with t-butyldimethylsilychloride, the protected pentynol was reacted with 2-chloro-2-propen-1-ol under Heck Conditions. The resulting product was exposed to potassium t-butoxide in 18-crown-6 to yield 2-(3-(t-butyl dimethylsilyloxy)propyl)-4-methyl furan (15%) . This product was then acid-deprotected.
b. 0.68 g of the furan alkanol and 0.88 g of 5-methyl-1,2,4-oxadiazol-3-yl was reacted under conditions of example 5, giving a compound of formula II in 67% yield.
c. The compound of example 18b was reacted with dimethyl dioxane and then hydrazine according to the method of example 3c to provide a compound of formula I wherein R 1 , R 2 =3,5-dimethyl, R 3 =5-methyl, R 4 =H, Y=1,3-propylene, R 5 =5-methyl-1,2,4-oxadiazol-3-yl, m.p. 73°-74° C.
EXAMPLE 19
a. To 42.1 g 3,6-dichloro pyridazine in acetone 10.5 g of NaI followed by 105 mL HI catalyst (Aldrich 21002-1) was added and left at room temperature for three days, upon workup a quantitative yield of 3,6-diiodopyridazine was obtained.
b. 5 g of 3,6-diiodopyridazine was dissolved in 30 mL DMSO with 0.6 g KF. The mixture was refluxed for 4 hours upon cooling. The mixture was taken up in CHCl 3 , washed with water twice, then brine and dried over MgSO 4 , and then concentrated in vacuo. The product was recrystallized from isopropylacetate giving 2.21 g (75%) of 3-iodo-6-fluoropyridazine.
c. 1.16 g of the product of 19b and 0.75 mL propargyl alcohol were reacted under Heck conditions (CuI, PdCl 2 (Pφ 3 ) 2 , Et 3 N) for 36 hours at room temperature. The product was absorbed onto silica, which was washed with hexane, then eluted with 1:1 EtOAc/hexane and used without purification in the next step.
d. 1.2 g of the alcohol obtained above was taken up in EtOAc and hydrogenated with Pd/carbon (0.5 g) under H 2 . Solids were filtered off and the filtrate concentrated in vacuo to yield 3-(6-fluoro-3-pyridazyl)propanol.
e. 0.43 g of 4-(5-trifluoromethyl-1,2,4-oxadiazolyl) 2,6-dimethyl phenol in 10 mL THF was combined with 0.53 g triphenyl phosphine and 0.35 g of DEAD at -50° C., and the 0.26 g of the fluoropyridazinyl alkanol of 19d was added. Upon warming the mixture was absorbed on silica and eluted with 2:1 hexane/EtOAc, the crude product was then purified on MPLC yielding 200 mg of an oil that crystallized upon standing. The product was recrystallized from t-butylmethylether (m.p. 86°-87° C.) to give a compound of formula I; Y=1,3-propylene, R 1 , R 2 =3,5-dimethyl, R 5 =5-trifluoromethyl-1,2,4-oxadiazol-3-yl, R 4 =H, R 3 =6-fluoro.
f. Using the method of 19e, the alcohol of 7d was reacted with 4-(5-difluoromethyl-1,2,4-oxadiazol-3-yl) 2,6-dimethylphenol to provide a compound of formula I wherein R 1 , R 2 =3,5-dimethyl, R 3 =6-fluoro, R 4 =H, Y=1,3-propylene, R 5 =5-difluoromethyl-1,2,4-oxadiazol-3-yl; m.p. 92°-94° C. g. 10.55 g of 3,6-dichloropyridazine was taken up in 100 mL Et 3 N and CuI (0.676 g), and PdCl 2 (Pφ 3 ) 2 (2.5 g) added (Heck conditions). To this propargyl alcohol (4.2 mL) was added in 30 mL of Et 3 N upon work up 10.4 g of the chloropyridazyl alcohol was obtained.
h. 0.479 g of the unsaturated alcohol obtained in 19 g was reacted with 0. 422 g of 4-hydroxy-3,5-dimethyl benzonitrile using the method of example 19e to provide 0.448 (53%) of the corresponding phenoxy ether. The product was transformed into a compound of formula I by the method of 2e and 2f; (formula I; R 1 , R 2 =3,5-dimethyl, R 3 =6-chloro, R 4 =H, Y=1,3-propyl-1-yne, R 5 =5-trifluoromethyl-1,2,4-oxadiazol-3-yl), m.p. 118°-118.5° C. The acetylene linkage in Y can be reduced using Lindlar catalyst and the like to provide the corresponding compound of formula I wherein Y is 1,3-propylene.
i. Using the diiodo pyridazine of example 19A and the method of example 15A one obtains a compound of formula I wherein R 1 , R 2 =3,5-dimethyl, Y=1,3,-propylene, R 3 =6-iodo, R 4 =H, R 5 =5-difluoromethyl-1,2,4-oxadiazol-3-yl, m.p. 113°-114.5° C.
EXAMPLE 20
a. 2-acetyl 5-(3-(4-cyano-2,6,-dimethylphenoxy)propyl) furan was prepared from example 8A by deprotection of the carbonyl moiety. 21.42 g of this material was dissolved in 200 mL of 1:1 methanol/THF at 0° C., 2.88 g of NaBH 4 was added. After 5 minutes the reaction was quenched with 10% NaOH. Upon workup 11.32 g (52%) of the hydroxy ethyl compound is obtained.
b. 0.434 g of the compound of formula 20A was taken up in mL acetone and was exposed to 26 mL dimethyl dioxyrane at room temperature forming the corresponding 2-hydroxy-5,6-dihydro-5-pyran-5-on-2-yl compound. (m.p. 104°-105° C., after workup).
c. 7.25 g of the compound as prepared in 20B was taken up in 66 mL of 1:1 THF/H 2 O and 27.60 mL hydrazine was added. The mixture was diluted with 200 mL CH 2 Cl 2 . The mixture was washed with water, then brine, dried over MgSO 4 and concentrated in vacuo, to an oil and used without further purification.
d. The 6-(1-hydroxyethyl)pyridazine formulation formed in 20c above was protected using diphenyl-t-butyl silylchloride. The product (an oil) was obtained in 99% yield.
e. Using the method of example 20D and finally deblocking the compound of formula I was obtained wherein R 3 =1-hydroxyethyl, R 1 , R 2 =3,5-dimethyl, R 4 =hydrogen, R 5 =5-difluoromethyl-1,2,4-oxadiazol -3-yl and Y=1,3-propylene (71%).
f. 0.468 g of the compound of 20E was taken up in 20 mL CH 2 Cl 2 and 0.16 mL DAST added. A compound of formula I was obtained (R 3 =1-fluoroethyl, R 4 =H, R 1 , R 2 =3,5-dimethyl, Y=1,3-propylene, R 5 =5-difluoromethyl-1-1,2,4-oxadiazol-3-yl) m.p. 85° C. (66% yield).
g. 0.680 g of the compound of example 20F was exposed to 0.72 g of MnO 2 in EtOAc yielding the compound of example 8C; formula I (R 1 , R 2 =3,5-dimethyl, R 3 =6-acetyl, R 4 =H, Y=1,3-propylene, R 5 =5-difluroromethyl-1,2,4-oxadiazol-3-yl); in quantitative yield.
h. Using 0.7 g of the compound of example 20G and exposing it to 2 equivalents of DAST as described in 7F, a compound of formula I wherein R 1 , R 2 is 3,5-dimethyl, R 3 =1,1-difluoromethyl, R 4 =H, R 5 =5-difluoromethyl-1,2,4-oxadiazol-3-yl, Y=1,3-propylene (68%), m.p. 73.5°-74° C.
Using the methods described herein the following compounds of formula I were prepared, wherein R 1 , R 2 =3,5-dimethyl, Y is 1,3-propylene, R 4 is H, R 5 is 5-R 1 -1,2,4-oxadiazol-3-yl.
______________________________________Example 6-R.sub.3 R.sup.1 M.P. Yield______________________________________i 1 fluoroethyl CH.sub.3 41-42° C. 67%j acetyl CH.sub.3 99.5-100° C. --k 1,1-difluoroethyl CH.sub.3 137-140° C. 66%l 1 hydroxyethyl CF.sub.3 143° C. --m 1 fluoroethyl CF.sub.3 48.5-50° C. --n 1,1-difluoroethyl CF.sub.3 54-55° C. --______________________________________ -- = not recorded
EXAMPLE 21
a. 7.5 g of the compound prepared in example 7B was treated with dimethyl dioxyrane as in example 20B, then hydrazine as in 20c yielded the corresponding hydroxy methyl pyridazine compound (77%) as an oil. The hydroxy methyl moiety was protected with pyran and the benzonitrile portion of the molecule elaborated to difluoromethyl-1,2,4-oxadiazol-3-yl using the method of example 7F and G to give, upon deprotection of the hydroxy methyl, a compound of formula I wherein R 1 , R 2 =3,5-dimethyl, R 3 =6-hydroxymethyl, R 4 =H, Y=1,3-propylene, R 5 =5-difluoro-1,2,4-oxadiazol-3-yl, m.p. 120°-150° C.
b. The compound in 21A, when treated with MnO 2 according to example 20g yields the compound of formula I wherein R 1 , R 2 =3,5-dimethyl, R 3 =6-formyl, R 4 =H, Y=1,3-propylene, R 5 =5-difluoro-1,2,4-oxadiazol-3-yl, m.p. 107-109.
c. The compound of 21B when treated with DAST according to example 21h yields a compound of formula I wherein R 3 =6-difluoromethyl, R 4 =H, Y=1,3-propylene, R 5 =5-difluoro-1,2,4- oxadiazol-3-yl, m.p. 75°-76.3° C.
Using the methods described above, compounds of formula I were obtained wherein Y is 1,3-propylene, R 1 , R 2 are 3,5-dimethyl, R 4 is hydrogen and R 5 is 5-R 1 -1,2,4-oxadiazol-3-yl;
______________________________________Example 6-R.sub.3 R.sup.1 M.P.______________________________________d hydroxymethyl propyl 106-107° C.e formyl propyl 95-96° C.f methoxymethyl CF.sub.3 61-62° C.g methoxymethyl CH.sub.3 57-59° C.h CF.sub.2 H Ethyl 125-129° C.i hydroxymethyl CF.sub.3 149-150° C.______________________________________
EXAMPLE 22
As further examples, phenols described only generally thus far can be reacted with any known furan alkanol, furanyl alkyl halide or those described herein using the methods previously described herein to provide a compound of formula II, which can then be transformed into a compound of formula I. It is contemplated that any phenol disclosed in allowed application Ser. No. 07/869,287, now U.S. Pat. No. 5,349,068 incorporated herein by reference, is elaborated to a pyridazine of formula I, using the methods described above. For the reader's convenience the same nomenclature conventions described herein for compounds of formula I are adhered to, and a literature reference describing the known phenol is included.
__________________________________________________________________________ ReferenceR.sub.1 R.sub.2 R.sub.5 U.S. Pat.__________________________________________________________________________H H 1,2,4-oxadiazol-2yl 4,857,539H H 4,2-dimethyl-2-thiazolyl 4,857,539H H 2-benzoxazolyl 4,857,5393,5 dichloro 3-furanyl 4,857,5393,5 dichloro 2-furanyl 4,857,5393,5 dichloro 2-thienyl 4,857,5393,5 dichloro 2-pyridinyl 4,857,5393,5 dichloro 1-methyl-1H-pyrrol-2yl 4,857,5393,5 dichloro 3-thienyl 4,857,5393,5 dichloro 4-pyridinyl 4,857,5393 nitro H benzothiazol-2-yl 4,857,539H H 2-(4,5-dihydro-4 methyl)oxazolyl 4,843,0873 methyl H 2-oxazolyl 4,843,0873 bromo H 2-oxazolyl 4,843,0873,5 dimethyl 3-methyl-5-isoxazolyl 4,843,0872,6 dimethyl 3-methyl-5-isoxazolyl 4,843,087H H 5-methyl-3-isoxazolyl 4,942,241H H 4-hydroxy phenyl (Aldrich)H H phenyl (Aldrich)H H 5-ethyl-thiazol-2-yl 5,100,893H H 4,5-dimethyl-thiazol-2-yl 5,100,893H H 2-ethyl-thiazol-4-yl 5,100,893H H 5-ethyl-1,3,4-thiadiazol-2-yl 5,100,893H 3-Cl 3-ethyl-1,2,4-oxadiazol-5-yl 5,100,893H H 3-cyclopropyl-1,2,4-oxadiazol-5-yl 5,100,893H H 3-tbutyl-1,2,4-oxadiazolyl 5,100,893H H 5-ethyl-1,3,4-oxadiazol-2-yl 5,100,893H H 3-cyclopropyl,2,4-oxadiazol-5-yl 5,100,893H H 3-ethyl-1,3,4-thiadiazol-5-yl 5,100,893H H 3-(2hydroxy)propyl- 5,100,893 1,2,4-oxadiazol-5-ylH H 4-ethyl-3-thiazol-2-yl 5,100,893H H 5-ethyl-3-thiazol-2-yl 5,100,8933-chloro H 3-ethyl-1,2,4-oxadiazol-5-yl 5,100,893H H 4,5-dimethyl-3-thiazol-2-yl 5,100,8932-methoxy H 4,5dihydro oxazol-2-yl 4,843,0873-methoxy H 4,5dihydro oxazol-2-yl 4,843,0873-chloro H 4,5dihydro oxazol-2-yl 4,843,0873-hydroxy H 4,5dihydro oxazol-2-yl 4,843,0873,5 di-t-butyl 4,5dihydro oxazol-2-yl 4,843,0873-difluoromethyl H 4,5dihydro oxazol-2-yl 4,843,0873-hydroxymethyl H 4,5dihydro oxazol-2-yl 4,843,0873-carboxy H 4,5dihydro oxazol-2-yl 4,843,0872-methyl 3-hydroxy 4,5dihydro oxazol-2-yl 4,843,0872,6 dichloro 4,5dihydro oxazol-2-yl 4,843,0873,5 difloro 4,5dihydro oxazol-2-yl 4,843,0873-chloro 5-ethynyl 4,5dihydro oxazol-2-yl 4,843,087__________________________________________________________________________
EXAMPLE 23
It is contemplated that any of the furans disclosed in U.S. Pat. Nos. 4,857,539 and 4,861,791 can be used as starting materials for preparing compounds of formula I. Examples of these furans follow; numbering of rings is the same as in other examples, all furans are furans (attached at the x! position) where R 4 is Hydrogen and y is of the formula (CH 2 )n
__________________________________________________________________________n = R.sub.1 R.sub.2 R.sub.3 X = R.sub.5__________________________________________________________________________a 5 H H 5 acetyl 2 Ethoxy carbonylb 5 H H 5 acetyl 2 2-4,5dihydrooxazolec 7 H H H 2 2-4,5dihydrooxazoled 5 3-bromo H 5 acetyl 2 2-4,5dihydrooxazolee 5 3,5-dichloro H 2 2-4,5dihydrooxazolef 5 3,5-dichloro H 2 2-4,5dihydrooxazoleg 5 H H H 2 Ethoxy carbonylh 7 H H H 2 Ethoxy carbonyli 5 3,5-dimethyl 5-hydroxy- 2 2-methyl-5-tetrazol-yl methylj 5 3,5-dimethyl 2 acetyl 3 2-methyl-5-tetrazol-ylk 5 3,5-dimethyl 5 acetyl 2 2-methyl-5-tetrazol-yll 6 H H H 2 2-methyl-5-tetrazol-ylm 5 3,5-dimethyl 5-ethoxy 2 2-methyl-5-tetrazol-yln 3 3,5-dimethyl 5-acetyl 2 2-methyl-5-tetrazol-ylo 5 3,5-dimethyl 5-formyl 2 2-methyl-5-tetrazol-ylp 3 3,5-dimethyl 5-methyl 2 2-methyl-5-tetrazol-ylq 2 H H H 2 2-methyl-5-tetrazol-ylr 3 3,5-CH.sub.3 5-ethyl 2 2-methyl-5-tetrazol-yls 2 3-NO.sub.2 H 5-(2 methyl- 2 2-benzothiazole 5-isoxazolyl)t 2 H H 5-(2 methyl- 2 2 methyl 5 tetrazolyl 5-isoxazolyl)u 3 3,5-dimethyl 5-acetyl 2 5-methyl-1,2,4-oxadiazolylv 3 3,5-dimethyl 3-acetyl 2 5-methyl-1 2,4-oxadiazolylw 3 3,5-dimethyl 3-acetyl 2 5-methyl-1,2,4-oxadiazolylx 3 3,5-dimethyl 3-propionyl 2 5-methyl-1,2,4-oxadiazolyly 3 3,5-dimethyl 5-propionyl 2 5-methyl-1,2,4-oxadiazolylz 3 3,5-dimethyl 4 acetyl 2 5-methyl-1 2,4-oxadiazolylaa 3 3,5-dimethyl 5 methoxy 2 5-methyl-1,2,4-oxadiazolyl carbonylbb 3 3,5-dimethyl 5 cyano 2 5-difluoromethyl-1,2,4- oxadiazlyl__________________________________________________________________________
BIOLOGICAL EVALUATION
Biological evaluation of representative compounds of formula I has shown that they possess antipicornaviral activity. They are useful in inhibiting picornavirus replication in vitro and are primarily active against picornaviruses, including enteroviruses, echovirus and coxsackie virus, especially rhinoviruses. The in vitro testing of the representative compounds of the invention against picornaviruses showed that viral replication was inhibited at minimum inhibitory concentrations (MIC) ranging from 0.033 to 0.659 micrograms per milliliter (μg/mL).
The MIC values were determined by an automated tissue culture infectious dose 50% (TCID-50) assay. HeLa cells in monolayers in 96-well cluster plates were infected with a dilution of picornavirus which had been shown empirically to produce 80% to 100% cytopathic effect (CPE) in 3 days in the absence of drug. The compound to be tested was serially diluted through 10, 2-fold cycles and added to the infected cells. After a 3 day incubation at 33° C. and 2.5% carbon dioxide, the cells were fixed with a 5% solution of glutaraldehyde followed by staining with a 0.25% solution of crystal violet in water. The plates were then rinsed, dried, and the amount of stain remaining in the well (a measure of intact cells) was quantitated with an optical density reader. The MIC was determined to be the concentration of compound which protected 50% of the cells from picornavirus-induced CPE relative to an untreated picornavirus control.
In the above test procedures, representative compounds of formula I were tested against some the serotypes from either a panel of fifteen human rhinovirus (HRV) serotypes, (noted in the table as panel T) namely, HRV-2, -14, -1A, -1B, -6, -21, -22, -15, -25, -30, -50, -67, -89, -86 and -41 or against some of the serotypes from a panel of 10 human rhinovirus serotypes namely HRV-3, -4, -5, -9, -16, -18, -38, -66, -75 and-67, (noted in the table as panel B) and the MIC value, expressed in micrograms per milliliter (mg/mL), for each rhinovirus serotype was determined for each picornavirus. Then MIC 50 and MIC 80 values, which are the minimum concentrations of the compound required to inhibit 50% and 80%, respectively, of the tested serotypes were determined. The compounds tested were found to exhibit antipicornaviral activity against one or more of these serotypes.
The following Table gives the test results for representative compounds of the invention. The panel of picornaviruses used in the test appears before the the MIC 80 and MIC 50 figure and the number of serotypes which the compound is tested against (N) is indicated after the MIC 80 and MIC 50 figure.
TABLE______________________________________Ex Panel Mic.sub.50 Mic.sub.80 N______________________________________1c T 0.241 0.272 151d T 0.459 2.216 102c T 0.475 0.83 22f B 0.1315 -- 102g B 0.071 -- 73a B 0.446 3.087 103b B 0.659 -- 73c B 0.074 0.129 104e T 0.453 -- 155a T 0.313 -- 105e B 0.0555 0.116 106d B 0.033 0.067 97g B 0.078 -- 78e B 0.07 0.189 98g B 0.1405 0.17 108i B 0.02 0.07 109d T 0.128 0.25 69f T 0.055 0.44 1010a T 0.453 99 1110b T 0.055 0.098 1411a T 0.453 -- 1111g T 0.068 0.161 1412c B 0.26 1.414 712f B 0.515 0.103 1012g B 0.036 0.117 1012h B 0.05 0.11 1012i B 0.23 0.63 912j B 0.05 0.19 912k B 0.14 0.40 912l B 0.08 0.16 1012m B 0.64 -- 1013f B 0.14 0.67 1014p B 0.01 -- 1015b B 0.03 0.15 1015c B 0.29 -- 815d B 0.09 0.28 1016d B 0.05 2.16 916e B 0.02 0.03 1016f B 0.02 0.05 1016g B 0.05 0.18 1016h B 0.03 0.15 1016k B 0.03 0.67 916l B 0.20 -- 1017d B 0.03 0.10 1018c B 0.58 -- 919e B 0.08 0.44 1019h B -- -- 1019i B -- -- 820f B 0.02 0.06 1020g B 0.04 0.19 1020h B 0.10 0.31 820i B 0.05 0.15 1020j B 0.04 0.13 1021a B 0.15 1.39 1021b B 0.05 0.33 921c B 0.01 0.03 921d B 0.02 0.44 921f B 0.10 0.14 921g B 0.15 0.44 1021h B 0.07 0.18 10______________________________________ -- insufficient data or inactive
The compounds of formula I can be formulated into compositions, including sustained release compositions together with one or more non-toxic physiologically acceptable carriers, adjuvants or vehicles which are collectively referred to herein as carriers, in any conventional form, using conventional formulation techniques for preparing compositions for treatment of infection or for propylactic use, using formulations well known to the skilled pharmaceutical chemist, for parenteral injection or oral or nasal administration, in solid or liquid form, for rectal or topical administration, or the like.
The compositions can be administered to humans and animals either orally, rectally, parenterally (intravenous, intramuscularly or subcutaneously), intracisternally, intravaginally, intraperitoneally, locally (powders, ointments or drops), or as an aerosal, for example as a nasal or a buccal spray.
Compositions suitable for parenteral injection can comprise physiologically acceptable sterile aqueous or nonaqueous solutions, dispersions, suspensions or emulsions and sterile powders for reconstitution into sterile injectable solutions or dispersions. Examples of suitable aqueous and nonaqueous carriers, diluents, solvents or vehicles include water, ethanol, polyols (propyleneglycol, polyethyleneglycol, glycerol, polyalkylene glycols and the like), suitable mixtures thereof, vegetable oils (such as olive oil) and injectable organic esters such as ethyl oleate. Proper fluidity can be maintained, for example, by the use of a coating such as lecithin, by the maintenance of the required particle size in the case of dispersions and by the use of surfactants.
These compositions can also contain adjuvants such as preserving, wetting, emulsifying, and dispensing agents. Prevention of the action of microorganisms can be ensured by various antibacterial and antifungal agents, for example, parabens, chlorobutanol, phenol, sorbic acid, and the like. It may also be desirable to include isotonic agents, for example sugars, sodium chloride and the like. Prolonged absorption of the injectable pharmaceutical form can be brought about by the use of agents that delay absorption, for example, aluminum monostearate and gelatin.
Solid dosage forms for oral administration include capsules, tablets, pills, powders, lozenges and granules which may be dissolved slowly in the mouth, in order to bathe the mouth and associated passages with a solution of the active ingredient. In such solid dosage forms, the active compound is admixed with at least one inert customary excipient (or carrier) such as sodium citrate or dicalcium phosphate or (a) fillers or extenders, as for example, starches, lactose, sucrose, glucose, mannitol and silicic acid, (b) binders, as for example, carboxymethylcellulose, alginates, gelatin, polyvinylpyrrolidone, sucrose and acacia, (c) humectants, as for example, glylcerol, (d) disintegrating agents, as for example, agar-agar, calcium carbonate, potato or tapioca starch, alginic acid, certain complex silicates and sodium carbonate, (e) solution retarders, as for example paraffin, (f) absorption accelerators, as, for example, quaternary ammonium compounds, (g) wetting agents, as for example, cetyl alcohol and glycerol monostearate, (h) adsorbents, as, for example, kaolin and bentonire, and (i) lubricants, as, for example, talc, calcium stearate, magnesium stearate, solid polyethylene glycols, sodium lauryl sulfate or mixtures thereof. In the case of capsules, tablets and pills, the dosage forms can also comprise buffering agents.
Certain solid dosage forms can be delivered through the inhaling of a powder manually or through a device such as a SPIN-HALER used to deliver disodium cromoglycate (INTAL). When using the latter device, the powder can be encapsulated. When employing a liquid composition, the drug can be delivered through a nebulizer, an aerosol vehicle, or through any device which can divide the composition into discrete portions, for example, a medicine dropper or an atomizer.
Solid compositions of a similar type may also be formulated for use in soft and hard gelatin capsules, using such excipients as lactose or milk sugar as well as high molecular weight polyethyleneglycols, and the like.
Solid dosage forms such as tablets, dmgees, capsules, pills and granules can be prepared with coatings and shells, such as enteric coatings and others well known in the art. They can contain opacifying agents, and can also be of such composition that they release the active compound or compounds in a certain part of the intestinal tract in a delayed manner.
The active compounds can also be in micro-encapsulated form, if appropriate, with one or more of the above-mentioned excipients.
Liquid dosage forms for oral administration include pharmaceutically acceptable emulsions, solutions, suspensions, syrups and elixirs. Also solid formulations can be prepared as a base for liquid formulations. In addition to the active compounds, the liquid dosage forms can contain inert diluents commonly used in the art, such as water or other solvents, solubilizing agents and emulsifiers, as for example, ethyl alcohol, isopropyl alcohol, ethyl carbonate, ethyl acetate, benzyl alcohol, benzyl benzoate, propyleneglycol, 1,3-butyleneglycol, dimethylformamide, oils, particularly cottonseed oil, ground-nut oil, corn germ oil, olive oil, castor oil and sesame oil, glycerol, tetrahydrofurfuryl alcohol, polyethyleneglycols and fatty acid esters of sorbitan or mixtures of these substances, and the like. Besides such inert diluents, the composition can also include adjuvants, such as wetting agents, emulsifying and suspending agents, sweetening, flavoring and perfuming agents.
Suspensions, in addition to the active compounds, can contain suspending agents, as for example, ethoxylated isostearyl alcohols, polyoxyethylene sorbitol, polyethyleneglycols of varying molecular weights and sorbitan esters, microcrystalline cellulose, aluminum metahydroxide, bentonite, agar-agar and tmgacanth, or mixtures of these substances, and the like.
Compositions for rectal or vaginal administration are preferably suppositories which can be prepared by mixing the compounds of the present invention with suitable non-irritating excipients or carriers such as cocoa butter, polyethyleneglycol or a suppository wax, which are solid at ordinary temperatures but liquid at body temperature and, therefore, melt in the rectum or vaginal cavity and release the active component.
Compositions for administration as aerosols are prepared by dissolving a compound of Formula I in water or a suitable solvent, for example an alcohol ether, or other inert solvent, and mixing with a volatile propellant and placing in a pressurized container having a metering valve to release the material in usefule droplet size.
The liquefied propellant employed typically one which has a boiling point below ambient temperature at atmospheric pressure. For use in compositions intended to produce aerosols for medicinal use, the liquefied propellant should be non-toxic. Among the suitable liquefied propellants which can be employed are the lower alkanes containing up to five carbon atoms, such as butane and pentane, or a alkyl chloride, such as methyl, ethyl, or propyl chlorides. Further suitable liquefied propellants are the fluorinated and fluorochlorinated alkanes such as are sold under the trademarks "Freon" and "Genetron". Mixtures of the above mentioned propellants can suitably be employed.
Preferred liquefied propellants are chlorine free propellants, for example 134a (tetrafluoroethane) and 227c (heptafluoropropane) which can be used as described above. Typically, one uses a cosolvent, such as an ether, alcohol or glycol in such aerosol formulations.
The specifications for unit dosage forms of this invention are dictated by and directly dependent on (a) the unique characteristics of the active material and the particular effect to be achieved and (b) the limitations inherent in the art of compounding such an active material for use in humans and animals, as disclosed in detail in this specification, these being features of the present invention. Examples of suitable unit dosage forms in accord with this invention are capsules adapted for ingestion or, aerosols with metered discharges, segregated multiples of any of the foregoing, and other forms as herein described.
Compounds of the invention are useful for the prophylaxis and treatment of infections of suspected picornaviral etiologies such as aseptic meningitis, upper respiratory tract infection, enterovirus infections, coxsackievirus, enteroviruses and the like. An effective but non-toxic quantity of the compound is employed in treatment. The dosage of the compound used in treatment depends on the route of administration, e.g., intra nasal, intra bronchial, and the potency of the particular compound.
Dosage forms for topical administration include ointments, powders, sprays and inhalants. The active component is admixed under sterile conditions with a physiologically acceptable carrier and any preservatives, buffers or propellants as may be required. Opthalmic formulations, eye ointments, powders and solutions are also contemplated.
It will be appreciated that the starting point for dosage determination, both for prophylaxis and treatment of picornaviral infection, is based on a plasma level of the compound at roughly the minimum inhibitory concentration levels determined for a compound in the laboratory. For example a MIC of 1 μg/mL would give a desired starting plasma level of 0.1 mg/dl and a dose for the avemge 70 Kg mammal of roughly 5 mg. It is specifically contemplated that dosage range may be from 0.01-1000 mg.
Actual dosage levels of the active ingredient in the compositions can be varied so as to obtain an amount of active ingredient that is effective to obtain a desired therapeutic response for a particular composition and method of administration. The selected dosage level therefore depends upon the desired therapeutic effect, on the route of administration, on the desired duration of treatment and other factors and is readily determined by those skilled in the art.
The formulation of a pharmaceutical dosage form, including determination of the appropriate ingredients to employ in formulation and determination of appropriate levels of active ingredient to use, so as to achieve the optimum bioavailability and longest blood plasma halflife and the like, is well within the purview of the skilled artisan, who normally considers in vivo dose-response relationships when developing a pharmaceutical composition for therapeutic use.
Moreover, it will be appreciated that the appropriate dosage to achieve optimum results of therapy is a matter well within the purview of the skilled artisan who normally considers the dose-response relationship when developing a regimen for therapeutic use. For example the skilled artisan may consider in vitro minimum inhibitory concentrations as a guide to effective plasma levels of the drug. However, this and other methods are all well within the scope of practice of the skilled artisan when developing a pharmaceutical.
It will be understood that the specific dose level for any particular patient will depend upon a variety of factors including the body weight, general health, sex, diet, time and route of administration, rates of absorption and excretion, combination with other drugs and the severity of the disease being treated and is readily determined by the skilled clinician.
When administered prior to infection, that is, prophylactically, it is preferred that the administration be within about 0 to 48 hours prior to infection of the host animal with the pathogenic picornavirus. When administered therapeutically to inhibit an infection it is preferred that the administration be within about a day or two after infection with the pathogenic virus.
The dosage unit administered will be dependent upon the picornavirus for which treatment or prophylaxis is desired, the type of animal involved, its age, health, weight, extent of infection, kind of concurrent treatment, if any, frequency of treatment and the nature of the effect desired.
The compound of the invention also finds utility in preventing the spread of picornaviral infection. the compounds can be used in aerosol sprays applied to contaminated surfaces, to disposable products, such as tissues and the like used by an infected person. In addition the compounds can be used to impregnate household products such as tissues, other paper products, disposable swabs, and the like to prevent the spread of infection by inactivating the picornavirus.
Because compounds of the invention are able to suppress the growth of picornaviruses when added to a medium in which the picornavirus is growing, it is specifically contemplated that compounds of the invention can be used in disinfecting solutions, for example in aqueous solution with a surfactant, to decontaminate surfaces on which polio, Coxsackie, rhinovirus and/or other picornaviruses are present, such surfaces including, but not limited to, hospital glassware, hospital working surfaces, restuarant tables, food service working surfaces, bathroom sinks and anywhere else that it is expected that picornaviruses may be harbored.
Hand contact of nasal mucus may be the most important mode of rhinovirus transmission. Sterilization of the hands of people coming into contact with persons infected with rhinovirus prevents further spread of the disease. It is contemplated that a compound of the invention incorporated into a hand washing or hand care procedure or product, inhibits production of rhinovirus and decreases the likelihood of the transmission of the disease. | Compounds of the formula ##STR1## wherein: R 1 and R 2 are independently hydrogen, halo, alkyl, alkenyl, alkoxy, hydroxy, hydroxyalkyl, hydroxyhaloalkyl, alkoxyalkyl, alkylthioalkynyl, hydroxyalkoxy, alkylthioalkyl, alkylsulfinylalkyl, alkylsulfonylalkyl, amino, aminoalkyl, alkylaminoalkyl, dialkylaminoalkyl, alkoxycarbonyl, carboxy or cyanomethyl, nitro, difluoromethyl, trifluoromethyl or cyano;
Y is alkylene of 3 to 9 carbon atoms;
R 3 and R 4 are independently hydrogen, alkyl, alkoxy, hydroxy, cycloalkyl, hydroxyalkyl, hydroxyhaloalkyl, alkoxyalkyl, hydroxyalkoxy, alkylthioalkyl, alkanoyl, alkanoyloxy, alkylsulfinylalkyl, alkylsulfonylalkyl, aminoalkyl, alkylaminoalkyl, dialkylaminoalkyl, alkoxycarbonyl, carboxy, cyanomethyl, fluoroalkyl, cyano, phenyl, alkynyl, alkene, or halo;
R 5 is alkoxycarbonyl, alkyltetrazolyl, phenyl or a heterocycle;
or a pharmaceutically acceptable acid addition salts thereof; N-oxides thereof, are useful as antipirconaviral agents. | 2 |
[0001] The benefit of the filing date of Sep. 18, 2002 of U.S. Provisional Application No. 60/411,549 is hereby claimed.
FIELD OF THE INVENTION
[0002] The invention pertains to management of contests or promotions where each participant competes against other participants. More particularly, the invention pertains to computer based systems and methods which assist in the management of such contests or promotions.
BACKGROUND OF THE INVENTION
[0003] Systems are known for linking video games located in proximity to one another or spaced apart in separate locations to a common site via an electronic network. In a known implementation, access can be via the Internet over conventional telephone lines or other communication mediums including but not limited to wireless or satellite technology. A site on the network which is accessible to the various games can store game results player information, and other data. Contests including but not limited to tournaments, leagues, and other forms of competition involving numerous players using spaced apart games can be implemented using a data collection and storage facility at the common site.
[0004] Such networked contests provide advantages for players and for contest operators. Players get to participate with a much larger pool of players than might otherwise be possible. Contest operators have centralized access to all of the game results for the competition even though the various game machines might be distributed over a wide area.
[0005] Despite the above noted benefits and advantages, networked games are only on the verge of exploiting the capabilities of the networked configuration. There continues to be a need for more efficient, easy to use tournament creation and administration software.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] [0006]FIG. 1 is a block diagram of a system which embodies the present invention;
[0007] [0007]FIG. 2 is an initial menu of operator options of the software tool of the invention;
[0008] [0008]FIG. 2A is a screen illustrating batches of newly received game play data;
[0009] [0009]FIG. 3 is a computer generated screen of contest criteria and date ranges of a pre-stored contest;
[0010] [0010]FIG. 4 is a computer generated set-up screen;
[0011] [0011]FIG. 5 is a computer generated screen for defining a new contest;
[0012] [0012]FIG. 5A is a computer generated screen for specifying characteristics of the new contest;
[0013] [0013]FIG. 6 is a computer generated screen for specifying dates and times of the new contest;
[0014] [0014]FIG. 7 is an exemplary computer generated screen enabling an operator to select one or more of a variety of golf courses for a golf tournament;
[0015] [0015]FIG. 8 is a computer generated screen enabling an operator to specify which of a plurality of game machines is to participate in the contest;
[0016] [0016]FIG. 9 is a computer generated screen enabling an operator to create a message to be transmitted to selected game machines;
[0017] [0017]FIG. 10 is a representation of a message, as in FIG. 9, presented at a game machine;
[0018] [0018]FIG. 11 is a computer generated screen enabling an operator to specify game types to be included in the contest;
[0019] [0019]FIG. 12 is a computer generated screen enabling the operator to specify various contest rules;
[0020] [0020]FIG. 13 is a computer generated screen enabling the operator to specify sort criteria;
[0021] [0021]FIG. 14 is a computer generated screen of contest data sorted in accordance with the criteria of FIG. 13;
[0022] [0022]FIG. 15 is a computer generated screen for establishing a leaderboard for display on one or more game machines;
[0023] [0023]FIG. 15A illustrates the leaderboard of FIG. 15 displayed at a game machine;
[0024] [0024]FIG. 16 is an overall block diagram of a process of defining a new contest; and
[0025] [0025]FIG. 16B is an overall block diagram of post-contest operations.
DETAILED DESCRIPTION OF THE EMBODIMENTS
[0026] While embodiments of this invention can take many different forms, specific embodiments thereof are shown in the drawings and will be described herein in detail with the understanding that the present disclosure is to be considered as an exemplification of the principles of the invention and is not intended to limit the invention to the specific embodiment illustrated.
[0027] In a system which embodies the invention, contest creation and administration software can be executed on a processor in intermittent communication, via an electronic network, with a plurality of electronic games. The games communicate game playing information, via the network, to a common site. The data can subsequently be downloaded to a data base local to the administration software.
[0028] The administration software enables a contest operator to define and run contests involving players of the electronic games. This is a process substantially within the control of the operator. As a result, the operator can take advantage of his market knowledge to create and profit from tournaments or contests that appeal to his player universe.
[0029] Embodiments of the present invention are directed to data delivery and management systems and methods for game machines, such as coin or currency operated as well as credit or data card operated video games. For example and without limitation, the games can include games of skill such as sports-related games including electronic golf, basketball, bowling or baseball as well as puzzle games, vehicular driving games, shooting gallery or hunting games.
[0030] Systems and methods are provided for the organization and operation of tournaments, contests, or other promotions, involving individual players who have played in one or more of the games of the tournament.
[0031] Scores and other game data can be transmitted, via a network, from the members of the plurality of game machines to one or more game servers. The data is stored locally at the game server or servers.
[0032] A contest operator can access such data via the network and the game server or servers. The game-related data can be downloaded, via the network, to the operator's computer and local disk drive. The data can subsequently be accessed and organized off-line by the operator using a locally executing, contest creation and administration software tool as described in more detail subsequently.
[0033] In one embodiment, data downloaded via the network from the game server to the operator's computer can be processed using local software to determine winners, create reports, and create messages or advertisements. The messages or advertisements can be transmitted back to the game machines, via the server for display thereat.
[0034] Game play and machine records can be stored at the game server. They can incorporate player identification, machine status, as well as machine owner or operator information. The game server can obtain the related game up-date information on a predetermined basis, for example, on a daily basis or every other day basis as the respective machines communicate with the game server.
[0035] The game owner or operator can access the game server and its data base from another site on the network and download the up-dated game play information. The operator can in turn decide the winner or winners of an on-going contest or tournament, create reports pertaining thereto, create game play volume reports to measure earnings, as well as create messages and/or advertisements to be transmitted to the game machines via the network. The messages and/or advertisements can be displayed on the respective game machines for purposes of promoting on-going tournaments or contests, new tournaments or contests or the like.
[0036] In yet another aspect, operators can locally create and store one or more contests or tournaments using the software tool. They can subsequently forward information pertaining to same through the network to the game server. The various game machines will in turn communicate with the server.
[0037] The respective tournament or contest can be carried out at the various game machines based on the parameters established by the operator. The operator can download the tournament or contest creation and administration software tool from a remote source, such as the game server via the network.
[0038] The Internet corresponds to one form of network. Other types of networks also come within the spirit and scope of the present invention.
[0039] Once an operator has become authorized to obtain the creation and administration software tool from the server, such is downloaded to the operator's local computer for storage and execution. The operator can subsequently organize collected game play data obtained via the game server while off-line.
[0040] Additional features available to the operator include being able to sort through a number of contests or promotions relatively quickly and easily. Previously created contests or promotions can be stored for re-use subsequent to initial execution. The operator will be able to create, edit and transmit messages and advertisements for presentation at the displays of the various game machines.
[0041] One particular advantage of a system which embodies the present invention is that the operator need not communicate directly with any of the game machines. Rather, the operator communicates with the game server and its data base via the network. This communication can be carried out at the convenience of the operator. Subsequently, when the game machines call in from time to time, on automatic basis, they receive information pertaining to new or up-dated contests, new or up-dated messages or advertisements to be displayed in connection with either on-going or future tournaments or contests directly from the game server.
[0042] The automatic up-dating takes place in accordance with the various game machines internal schedules which initiate communications with the game server from time to time. The game machines can, as will be understood by those of skill in the art, communicate with the network and the game server via a dial-up communication link, a dedicated communication link, or wirelessly, all without limitation.
[0043] [0043]FIG. 1 illustrates a system 10 in accordance with the present invention. The system 10 incorporate a plurality of game machines, which could be substantially the same or could be different, all without limitation, 12 a . . . 12 n . Each of the machines is designed and intended to enable to enable a player or players P to engage in or play a game of the type provided by such game machines. For example, and without limitation, the game machines 12 a . . . n could enable the players P to play various different golf courses as well as games with different rules. Alternately, the machines 12 a . . . n could enable the players P to play baseball, bowl, safari or hunt. Other types of games of skill such as vehicular racing, shooting galleries and the like come within the scope and spirit of the present invention.
[0044] By way of example, the game machine 12 a incorporates a display 14 a - 1 , an operator input interface 14 a - 2 which might include buttons, switches, track balls, joysticks or the like, all without limitation. A credit establishing device 14 a - 3 could receive coins or credit cards to authorize use and play of the machine 12 a . Finally, control circuitry which includes a disk drive, 14 a - 4 is carried within the housing of the machine 12 a and is coupled to the display 14 a - 1 , input panel 14 a - 2 and credit establishing mechanism 14 a - 3 .
[0045] One type of game machine usable with the system 10 are the GOLDEN TEE brand electronic golf games marketed by the assignee hereof. Subsequent references to golf, golf courses, tournaments, rules or the like, are exemplary only. They are for the purpose of describing embodiments of the invention so as to enable those of skill in the art to make and use same, and for the purpose of disclosing the best mode of practicing same. They are not limitations of the invention.
[0046] The machines 12 a . . . n can be intermittently linked, via communication channels such as, for example, dial-up telephone lines 14 a - 5 . . . 14 n - 5 to a network, such as the internet 20 . One or more machines can share a given communication link since none of the members of the plurality 12 a . . . n need carry-on continuous communication via the respective link.
[0047] The game machines 12 a . . . n can initiate bidirectional communication, via the internet or other networks 20 , with one or more game servers 22 . The game servers 22 support a game-related database 24 which can be periodically up-dated with information by transmissions initiated via one or more of the game machines 12 a . . . n.
[0048] The game server 22 can in turn download to the respective game machines 12 a . . . 12 n information temporarily stored in database 24 when the respective game machine communicates with the server 22 . It will be understood that communication details between the game machines 12 a . . . 12 n , network 20 and game server 22 are not limitations of the present invention.
[0049] It will also be understood that game play information or data from the respective game play machines 12 a . . . 12 n is up-loaded to the server 22 and database 24 , via network 20 , only on an intermittent basis when the respective game machine initiates communication with the server. At other times, the communication link associated with the respective game machine is not used by that game machine and is available for use by other game machines.
[0050] An operator's computer system 30 incorporates a processor 32 a , associated with database 32 b , display 32 c and input devices such as keyboards, touchscreens, track balls, mice and the like 32 d , all without limitation. The operator computer system 30 can be placed into intermittent communication via the network 20 , over a link 32 e with game server 22 . In this circumstance, game play information up-loaded from the game machines 12 a . . . n stored in database 24 can be downloaded by the link 32 e to the operator's computer 30 for local storage in database 32 . Once the operator 0 has obtained the necessary information, he/she can operate off-line to carry out various of the functions as described below.
[0051] Player information can be retrieved from server 22 . Messages and leaderboards can be sent, via the network 20 directly to online machines 12 a . . . n.
[0052] Operator software S executed at processor 32 a enables the operator or owner to create a variety of contests and promotions. If desired, the software tool S could be downloaded from server 22 and stored locally 32 b for execution at the operator's convenience.
[0053] The following FIGS. 2 - 15 A illustrate a variety of graphical displays or screens produced by software S and presented to the operator O. Operator O can interact with software S by using keyboard, mouse or trackball, or other input devices, to enter information or “click” on various lighted buttons or control elements as would be understood by those of skill in the art. FIGS. 16A,B illustrate additional details of a method of creating contests or tournaments.
[0054] It will be understood that neither the programming language nor the exact details of software S are limitations of the invention. Variations in the graphiacal displays of FIGS. 2 - 15 A also come within the spirit and scope of the invention.
[0055] Using software S an initial menu of options, see FIG. 2 can be presented to the operator O. The following exemplary functions are available to the operator O. Additional or alternate functions could also be included without departing from the spirit and scope of the invention. The “Download” button allows retrieval of game machine data from server 22 . The “New Contest” button presents all the criteria needed to set up a new contest or promotion. “Library” is where previously saved contests are stored. “Setup” establishes preferences when using the software S.
[0056] Downloading game machine data: Periodically new data from machines 12 a . . . 12 n is stored at server 22 and made ready for downloading to computer 32 a . Clicking the “Download” button on the menu begins a transfer of new data to computer 32 a and database 32 b , see FIG. 2A. Once the download is complete, the operator can disconnect from the network 20 and work off-line using the other features of the softwares to create reports, define new contests or evaluate on-going contests.
[0057] To download the latest play data, the operator's tool S sends the operator's ID and password, along with a list of dates from a “batches” table (representing days for which data has already been downloaded) to server 22 . When a reply is received from the server 22 , the program S checks to see if the password was accepted. If so, new data is added to both a main data table and the “batches” table in database 32 b.
[0058] These batches include, for example, a collection of all the shot, score, and player data that the operator's machines have collected in the last time period, for example, 24 hours.
[0059] The server 22 can send software S a list of all games currently registered to the operator. If the game machines are configured for example, as golf playing machines, a list of all standard courses and all tournament courses for the operator's country can be sent to computer 32 a . In alternate configurations, a list of stadiums could be sent to computer 32 a.
[0060] The “Library” selection enables the operator to retrieve saved contests and messages. To review the contest criteria, the contest is highlighted and the “Describe” button is clicked. This feature allows the operator to view the contest criteria, and date ranges, see FIG. 3. In addition, it will also be denoted if a group of winners has been saved in a winner's bracket. This makes it very easy to sort through a large quantity of contests very quickly.
[0061] If the operator has opted to create a contest and sort out previous winners, any winner data that is saved can be cleared. The “Open” button can be used to open this contest and change or adjust criteria. Finally, a saved contest which is no longer needed may simply be highlighted and deleted from the library.
[0062] When the contest is opened from the library, the operator's program S retrieves all information related to this contest from the “library” table. It then proceeds to simulate user's input to rebuild a contest using retrieved information.
[0063] In the Setup section, FIG. 4, some default categories are listed, including the game type and course ID. To suppress some or all of this information, the check box next to each entry is deleted. Data no longer required for contests can be deleted. Additonally, by selecting a date on a pop up calendar and then clicking a “Delete” button, all data prior to the date selected can then be permanently deleted across all of an operator's machines.
[0064] Clicking on a “Show Postings” button that can be displayed at the bottom of the page allows an operator to manage the on-screen messages such as ads or leaderboards that have been sent to that operator's games. On this screen the operator will be able to see a brief per game description of the posts being sent to machines. This screen may be used to track and delete these messages.
[0065] In the “New Contest” section the criteria that will determine the outcome of a new promotion or contest can be selected, FIG. 5. Click on “Select Criteria” to open the selection menu, see FIG. 5A which illustrates choices for an exemplary golf tournament. It will be understood that this screen would vary depending on game type. Such variations are not a limitation of the invention.
[0066] A variety of different categories can be selected, see FIG. 5A, including:
Best Score Eagles Average Score Birdies League Points Putts Total League Points Longest Drive Great Shot Points Longest Putt Holes-in-One Handicap
[0067] The operator can adjust the order of priority of these criteria by highlighting one of the entries and using the arrow to move it up or down in the list. The sort order is important when retrieving contest data that matches contest rules.
[0068] The “Sum Best Daily Score” selection allows the operator to view an over-all score for a layer throughout the entirety of a given contest. This over-all score is a player's best core from each day of the contest totaled together for a grand total score. For example, relative to the exemplary golf game, a player receives a −2 the first day of the contest, then the player returns on the second day and receives a −3. The player's Sum Best Daily Score would then be a −5. No matter how many games are played, only a player's best score from each day is counted toward the “Sum Daily Best Score”.
[0069] In the criteria selection process, the program S checks the validity of the operator's input (i.e. at least one field is selected, no more than 6 fields are selected, etc.) When it is done, the program flags and remembers the operator's input. The program also marks this segment of data input as “completed”
[0070] The operator can select the dates to be reviewed by using the popup calendars, FIG. 6. Click on the date the promotion should start, and the date promotion should end. The time of day that the contest begins and ends can also be set.
[0071] The tool S checks the validity of user's input (end date is later than start date). When done, the program S remembers user's input. The tool S then marks this segment of data input as “completed”.
[0072] Where the game machines 12 a . . . n are designed to enable a user to play a game of golf. the operator can impart realism to the contest by selecting an appropriate course or courses to be played. As illustrated in the screen of FIG. 7, a variety of courses can be selected by the operator. For a baseball game, stadiums can be selected.
[0073] In the process, the program S checks the validity of the user's input (i.e. at least some courses are selected). When the process is finished, the program remembers the user's input. The program also marks this segment of the data input as being “completed”.
[0074] The “Select Games” screen, FIG. 8, lists each game machine's serial number, along with its assigned labels, and its location name. Next to the location name are three buttons: “Include”, “Exclude”, and “Date Range”. In the disclosed embodiment, by default, with one exception, all of games should come up defaulted to the “Include” position. It will be understood that other default options could be chosen.
[0075] The only exception deals with games that are no longer in inventory, but were previously online. These machines will default to the “Exclude” position since they are no longer in inventory and it is not possible to run an on-going contest with them. By leaving the game machine included and active, the game will remain in the contest, and receive any on-screen messages and leaderboards sent by the operator. Excluded games will not be included in this contest and messages will not be sent.
[0076] The “Date Range” feature can be used if a game can only be involved in a contest for a limited time. By selecting the Date Range option, the operator will be able to set an active date range for each game. Once the end date is reached, the machine will be removed from the promotion automatically.
[0077] In the process, the program S checks the validity of user's input (at least some games are selected, date ranges do not contradict each other, etc). when done, the program remembers user's input. Program S also marks this segment of data input as “completed”.
[0078] After deciding which games will be involved in a given contest, the operator can then send on-screen advertising to promote the contest. By pressing the “Create On-Screen Message” button located at the bottom of the “Select Games” screen. A window will pop-up, FIG. 9, that will allow the operator to fill out various text fields and set an expiration date for the message.
[0079] The text entered in these fields will show up on the actual game screen, such as 14 a - 1 of the respective game machine, 12 a for example. The expiration date will be the date the message is removed from that machine. The Contest Description line is a label to keep track of various sent messages. Clicking the “Send Message” button will send the advertising screen to the server 22 .
[0080] Program S sends the operator's ID and password, followed by an on-screen message expiration date, along with 2 title lines, and 7 text lines to screen 22 . When a reply is received, the program S displays the status of the transmission (i.e. whether it was successful or not).
[0081] The program S sends the server 22 a message containing “Posting Type,” an “Identification Number,” and a “Type” flag indicating if this is an advertising or a leaderboard and which list of games are supposed to receive the posting.
[0082] The server 22 authenticates the operator by comparing the Operator ID and password sent from the tool to the values stored in the database 24 . The server 22 then checks to see if this posting exists in the database, if it does not exist, the server stores the posting information in the database 24 .
[0083] The server 22 loads the new list of game units into the database 24 . A process is run on the database that checks to see if any games that were previously sent these postings have been deleted, if any new games have been added, and if any games that have been added now have more postings assigned to them hat is allowed (these games are bumped”). The process then adjusts for any games that were removed from the posting or bumped, and adds any new games.
[0084] The server 22 then updates the posting text in the database 24 , and sets the date on the posting so that it will be sent to the game machine 12 a . . . n on the next call. When the game machine calls in, the server 22 sends the game a list of postings the game should have and the date those postings were updated.
[0085] The game machine then compares the list of files to the files on its hard drive and requests that the server 22 send it any postings it does not have and any postings that have been updated. For each posting the game requests, the server 22 takes the appropriate information from the database 24 reformats it, and sends it to the game machine.
[0086] The Server 22 sends the game machine a list of postings that it has and the ones that should be removed. The game machine then deletes these files from its hard drive.
[0087] Contest message screens will be displayed on all of the selected games, display 14 i - 1 , after the next successful call to server 22 . This screen, best seen in FIG. 10, will appear as part of the attract sequence when the machine is idle. Players can jump right to this screen by inserting an identification card into the card reader, 14 i - 3 .
[0088] This messaging system can be used for a wide variety of purposes. Contest dates, format and prizes, can be advertised. In addition, special pricing, location specials, or local events can be advertised. If desired, other products or services can be advertised.
[0089] The operator can then select the various game types to include in this promotion, FIG. 11. For example, if the contest involves best score on a course, only including 18-hole games may be appropriate. Or, for a more skill-based contest, “blind” play only might be included. Other game machines, such as games played with the on-line opponent could be excluded.
[0090] In the process, the program S checks the validity of the user's input (i.e. at least some game types are selected). When the process is completed, the program S remembers the user's input. The program S also marks the segment of data input as having been “completed”.
[0091] Special rules can be applied to the contest. By pressing the “Contest Rules” button, a screen FIG. 12 with a list of features that will affect the way the contest functions will be displayed. These include, by way of example:
[0092] Specifying how many games will each contestant need to play at a specific location in order to qualify for this contest. This option allows the operator to set a required amount of games that each player must play in a single location before their results are counted. For example, by electing to have five games set as a minimum, all players must play five games in a specific location before any results are considered;
[0093] Specifying how many games will each contestant need to play in order to qualify for this contest. This option allows the operator to set a required amount of games that each player must play before their results are counted. For example, by electing to have five games set as a minimum, all players must play five games before any results are considered;
[0094] Specifying how many top scores can a player contribute on each machine. As an example, if this field is set to ten, each player could play as many games as they wanted, but on each machine, only the top ten scores from each player will actually count toward the contest;
[0095] Specifying how many top scores a player can contribute throughout the entire contest. This feature is similar to the above except it is not machine specific. By setting this field, each player(s) can play as many games as they want on each machine. However, the results will be limited to their top “X” scores over-all;
[0096] Specifying how many top scores will be used from each machine in this contest. Setting this field determines the number of records each machine can post. As an example, only the top 10 scores from each machine will count towards the contest; and
[0097] Specifying in each report the number “X” of top players to be moved into the winners bracket. The tool S can automatically ignore the top “X”: number of players from the last time the contest was run. In this way, the operator can hold qualifying rounds and guarantee that different people can move up into the next winners bracket.
[0098] The operator can then choose how to display final results under “Order Results By”, see FIG. 13:
[0099] By default, all contests will sort results in a simple summary “best-to-worst” order, only listing the player name and the promotion results. If the operator wishes to change the way results are displayed, one of eight different options can be selected.
[0100] 1. Best-to-Worst (Summary)—This is the default selection described above. This report lists each person sorted by operator criteria in best-to-worst order.
[0101] 2. Player-By Name (Summary)—This will sort all contest results in alphabetical order by player name.
[0102] 3. Game, Best-to-Worst (Summary)—Sorts the report first by game unit, and then ranks all the players that played on that game.
[0103] 4. Location, Best-to-Worst (Summary)—If there are multiple games to a location, this sort allows operator to sort first by location name, grouping all the games in that location together, and then all players are sorted in standard Best-to-Worst order.
[0104] 5. Best-to-Worst, Time Played (Detail)—Choosing this option sorts each player in best to worst order, but shows every individual game that was played.
[0105] 6. Player, Time Played (Detail)—This option will sort all results alphabetically, and list every game each competitor played.
[0106] 7. Game, Player, Time Played (Detail)—Sorts first by game unit, and then lists all players alphabetically on each machine along with every single game they played.
[0107] 8. Location, Player, Time Played (Detail)—If there are multiple games at a location, this sort enables the operator to sort first by location name, grouping all the games in that location together, and then all players are listed alphabetically along with every single game they played.
[0108] During this process, the program S checks the validity of the user's input (for example, certain combinations of Contest Rules and Sorting Order are not allowed). When done, the program S remembers the user's input. The program also marks this segment of data input as “completed”. Other sort criteria could also be defined.
[0109] Once an operator has selected all contest criteria, the contest is named and saved by clicking the “Save in the Library” button. The contest will then be available for future reference.
[0110] The program S checks that the Contest/Message name is valid. Next, the program checks for the presence of a Contest/Message with the same name in the library table. If the program S finds either a contest or message of the same name, the program allows the user either to change the current name or to overwrite the existing Contest/Message in the library with the new one.
[0111] After saving a contest in the library, the operator can run the contest results. The “Run Contest” button can be used to retrieve contest data the contest data will be sorted based on operator selected criteria.
[0112] The program S checks to see if segments of the data have been marked as “completed”. If so, program S copies the main data table into a temporary output table. It then limits the output table to records that the satisfy conditions specified by the operator. In this exemplary embodiment, the sequence executes as follows:
[0113] Exclude all records with player name “UNKNOWN”
[0114] If any fields related to handicap were selected, exclude all records without a handicap
[0115] If the “exclude winners” option was selected, exclude all records with prior winners
[0116] Exclude records outside of the selected time period
[0117] Exclude records with courses outside of the operator's selection
[0118] Exclude records with games outside of the operator's selection (games permanently OFF)
[0119] Exclude records where game-time played combination is outside of the operator's selection (games with ON-OFF date range)
[0120] Exclude records based on contest rules
[0121] After running through all of the variables, the program S displays an output table, FIG. 14. Various options are available to the operator.
[0122] Print—This allows operator to send the results of the current promotion results to a printer. The operator can add a header and footer, and format data to fit page size for posting the results.
[0123] Export to Text—Use this option to edit results or import them into another application. The file is stored as a .txt file, which can be readily imported into programs like EXCEL, ACCESS and WORD. The text file will be saved to the local drive of computer 30 .
[0124] Leaderboard—This button allows operator to generate a leaderboard from results and send it back to the games involved in the contest. When this option is selected, depending on criteria, three different leaderboard choices are available: Standard Leaderboard, Location Specific Leaderboard, and Game Specific Leaderboard.
[0125] The Standard Leaderboard option sends the same leaderboard to every game included in the contest. The Location Specific Leaderboard will send an individual leaderboard to each location. A location can have more than one machine, and all machines in this location will share a common leaderboard. Location names assigned to the machines at a location must be identical.
[0126] The Game Specific Leaderboard will send an individual leaderboard to each game in the contest, regardless of its location. The operator will be able to choose Game Specific and Location Specific Leaderboards if he/she initially chose to use the game and location specific Display Order options.
[0127] Once a leaderboard type has been selected, a new menu, FIG. 15 can be displayed. The new menu allows various leaderboard text fields to be filled and can set an expiration date for leaderboard.
[0128] The text in these fields will show up on the actual game screen of the machines and the expiration date will be the date the message is removed from those machines. The Column Header fields will directly correspond to selected criteria and will represent the titles or headers at the top of the game Screen With Example.
[0129] The Limit Leaderboard field is the amount of results that will be allowed to show on the game screen itself. This field defaults to 50 lines of text, but operator can shorten or lengthen. To send leaderboards to the machines, the Send button is clicked.
[0130] The program S sends the operator's ID and password, followed by any information related to the leaderboard.
[0131] For a standard leaderbord, the sent information can be structured as follows:
[0132] The general leaderboard information (expiration date, titles, headers, etc)
[0133] List of games to receive leaderboard Report
[0134] For a location-specific leaderboard the sent information can be structured as follows:
[0135] General leaderboard information (expiration date, titles, headers, etc)
[0136] The list of games in each location
[0137] The portion of the report related to that particular location
[0138] (These steps are repeated for each game included in the report)
[0139] When a reply is received from the server 22 , the program S displays the status of the transmission.
[0140] The leaderboard will be displayed on the respective game machines the next time they make a successful call to server 22 , see FIG. 15A. The leaderboard is pre-formatted and will scroll from bottom to top. Players can access this leaderboard by inserting their identification card into the card reader during the attract mode.
[0141] In the Select Options section of the software S, FIG. 12, an operator has the ability to select the number of winners to move up into a winner's bracket. By utilizing the “Save Winners” option, the operator has the ability to choose new and different winners each time.
[0142] By choosing option #8, “Order by” (Location, Player, Time Player), FIG. 13, the “Summary by Location” option will become active on the report result screen. Clicking this button will bring up a location list along with the number of plays attributed to each establishment.
[0143] [0143]FIG. 16A is a flow diagram of a process 100 for defining a new contest. A new contest definition screen is displayed for an operator, step 102 , see FIG. 5 . Using the facilities of the screen of FIG. 5, the operator displays a select criteria screen and defines the specific criteria for the new contest, step 104 , see FIG. 5A. Subsequent to defining the contest criteria, contest dates are selected in a step 106 , see FIG. 6. In a step 108 , contest venues are selected such as golf courses, baseball or football stadiums or the like, 108 , see FIG. 7. The specific machines which are to participate in the contest, step 110 , see FIG. 8.
[0144] Subsequent to specifying the particular machines to participate in the contest, the operator can create on-screen messages to be transmitted to and displayed on the screens, such as the screen 14 a - 1 of the respective game machines such as the machine 12 a . In a step 112 , on-screen messages are defined, see FIG. 9. The defined on-screen messages can then be sent to the respective game machines, step 114 . In a step 116 , the operator can specify the type of game machines at the various locations which will be permitted to participate in the contest, see FIG. 11.
[0145] Contest rules can be selected and specified in step 118 , see FIG. 12. The contest results can be ordered or sorted in a step 120 , see FIG. 13. The contest can be named and saved in the library, step 122 .
[0146] Subsequently, the contest can be run with players P interacting with the appropriate plurality of game machines 12 a . . . n . Relative to FIG. 16B, contest results can be processed by the operator in a step 124 , see FIG. 14. Displayed contest data will have been sorted based on the previously specified orders of results, see step 120 , FIG. 16A. The operator will then have the option of printing current results, importing the results to another application (export to text capability) or, generating leaderboards, step 126 , see FIG. 15. The leaderboards can be downloaded to the various game machines and subsequently displayed, step 128 . Finally, in step 130 , contest winners can be identified.
[0147] It will be understood that other variations are possible without departing from the spirit and scope of the invention. For example, a game 12 a could incorporate a server. In this instance, the server in the game machine 12 a could be in communication with the server 22 via the network. Alternately, server 22 could be incorporated into the game machine 12 a and communicate with the remaining game machines 12 b, c . . . n via the network. Such communications could be with wired interconnects, such as switched phone lines or dedicated high speed lines. Alternately, communications could be wireless as would be understood by those of skill in the art.
[0148] It will also be understood that Labels, see FIG. 8 can automatically form the basis of selecting a group of games for a contest. Operator O can direct software S to sort games by their respective Label(s). Those games with the specified Label(s) can be automatically included in one or more contests.
[0149] The operator O can specify screens to select various classes of winners. For example, the top ten or twenty prior winners of a prior contest or contests can be automatically selected as eligible for a “winners” contest. In this fashion, participation can be automatically limited to a specified subset of available players.
[0150] From the foregoing, it will be observed that numerous variations and modifications may be effected without departing from the spirit and scope of the invention. It is to be understood that no limitation with respect to the specific apparatus illustrated herein is intended or should be inferred. It is, of course, intended to cover by the appended claims all such modifications as fall within the scope of the claims. | A system and method of organizing and administering contests or other promotions for physically dispersed currency, card, or ticket video games enable an organizer to conduct such contests or promotions from a single location. Software executable locally enables the organizer to define a contest, transmit contest or promotional information to the various video games, and stage the contest or promotion at a plurality of such games during a predetermined time interval. Contest results can be retrieved by the organizer at the location. The organizer can determine contest or promotion winners and transmit those results to the various video games. | 0 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. patent application Ser. No. 11/131,875, filed May 17, 2005.
[0002] This application is related to U.S. patent application Ser. No. 10/446,006, filed May 22, 2003 and U.S. patent application Ser. No. 10/871,557, filed Jun. 18, 2004.
FIELD OF THE INVENTION
[0003] This invention relates to the protection of property against high winds and, in particular, to a flexible protective barrier device for securing property against the force of winds, rain and from impact of foreign objects carried by localized atmospheric over-pressure.
BACKGROUND OF THE INVENTION
[0004] As is known by one skilled in the art of protecting buildings and the like from damage caused by missile-like objects that are occasioned by the heavy winds of hurricanes, tornadoes, or explosive over-pressures, there are commercially available variations of hurricane protective devices, often called shutters, that fasten immediately over the frangible area to be protected. These devices are typically expensive to purchase cumbersome, made from stiff, heavy material such as steel and aircraft quality aluminum alloy or occasionally reinforced plastic. Many need to be manually connected and then removed and stored at each threat of inclement weather. Many require unsightly and difficult-to-mount reinforcing bars at multiple locations. Further, these known shutters are usually opaque, preventing light from entering a shuttered area and preventing an inhabitant from seeing out. Likewise, it is desirable that police be able to see into buildings to check for inhabitants and to prevent looting which can be a problem in such circumstances.
[0005] Missiles, even small not potentially damaging missiles, striking these heretofore known shutters create a loud, often frightening bang that is disturbing to inhabitants being protected. Standardized testing requiring these protective devices to meet certain standards of strength and integrity has been introduced for various utilizations and locales. In order to qualify for use where testing requirements apply, the strength and integrity characteristics of these protective devices must be predictable and must be sufficient to meet mandated standards.
[0006] Additionally, it is beneficial to qualify for these standards even in situations in which standards do not apply. As a result of these standards, many undesirable aspects of the previously known shutters have been acerbated. They have become more cumbersome, more bulky, heavier, more expensive, more difficult to store, and remain generally opaque and noisy when impacted.
[0007] To incorporate sufficient strength to meet said requirements, weight and bulk become a problem over six feet in span. The useable span (usually height) of the heretofore known shutters that meet said standards may be limited to eight feet or less. This makes protecting large windows, for example, or groupings of windows, with the heretofore known devices cumbersome, expensive and impractical. Devices that are intended to be deployed in a roll down manner either manually, automatically, or simply by motor drive, have been difficult to strengthen sufficiently to pass the test requirements and require unsightly reinforcing bars every few feet.
[0008] Prior to the introduction of said standards, an ordinary consumer had very little useful knowledge of the strength and integrity of said shutters. It is believed shutters of the pre-standard era were very weak such that all would fail the present standardized testing. As the hurricane conditions can be very violent and destructive, the standards are not intended to require strength and integrity sufficient to protect in all circumstances. The standards simply provide a benchmark as to strength and integrity. The strength and integrity of the shutters can now be measured by standardized tests.
[0009] There are many patents that teach the utilization of knitted or woven fabric such as netting, tarpaulins, drop cloths, blankets, sheets wrapping and the like for anchoring down recreational vehicles, nurseries, loose soil and the like. But none of these are intended for, nor are capable of withstanding the forces of the missile-like objects that are carried by the wind in hurricanes or explosive over-pressures.
[0010] Some protection devices have internal stiffness and rigidity that resists deflection, or bending. In rigid protection devices, it is stiffness that stops the missile short of the frangible surface being protected.
[0011] Other protection devices use fabric or netting material to cover a unit to be protected. Typically, the device completely covers the unit, and edges of the fabric are fastened to the ground. Examples of fabric employing devices are shown in the following patents: U.S. Pat. No. 3,862,876 issued to Graves, U.S. Pat. No. 4,283,888 and U.S. Pat. No. 4,397,122 issued to Cros, U.S. Pat. No. 4,858,395 issued to McQuirk, U.S. Pat. No. 3,949,527 issued to Double et al., U.S. Pat. No. 3,805,816 issued to Nolte, U.S. Pat. No. 5,522,184 issued to Oviedo-Reyes, U.S. Pat. No. 4,590,714 issued to Walker and U.S. Pat. No. 5,522,184 issued to Pineda. U.S. Pat. No. 5,522,184, for example, provides a netting that fits flush over the roof of a building and uses a complicated anchoring system to tie down the netting.
[0012] Typical of known flexible, fabric-employing protection devices is the characteristic of substantial rain and wind-permeability. For example, U.S. Pat. No. 5,579,794, issued to Sporta, discloses a wind-permeable perforate sheet that extends downwardly and outwardly from the top of the object to be protected at an acute angle so as to surround a substantial portion of each of the sides with an inclined wind-permeable planar surface.
[0013] U.S. Pat. No. 6,325,085 to Gower illustrates a barrier similar to the instant invention to be deployed inside a building or over individual windows. U.S. Pat. No. 6,176,050 to Gower teaches the use of the barrier material of this invention deployed over multi-story buildings. Both patents are incorporated herein by reference.
[0014] Thus, what is lacking in the art is an improved flexible protective barrier constructed from a mesh material with substantial rain and impact resistance that can be easily stored and deployed in combination with a flexible, inflatable, reinforcing cushion for protecting the frangible portion of a structure not only from objects carried by the wind but also from the force of the wind itself.
SUMMARY OF THE INVENTION
[0015] Therefore, it is an objective of this invention to teach the use of a flexible barrier synthetic textile that is able to satisfy stringent testing requirements. When used with a building, for example, the top edge of the fabric may be anchored to the eave of the roof and the bottom of the fabric may be attached to anchors imbedded in the foundation, ground or cement, so as to present a curtain adequately displaced from and in front of the structure of the building to be protected.
[0016] Knitted, woven or extruded material can be used if the material itself meets the criteria described later herein. The device provides a barrier that is substantially impermeable to rain and wind. Although air travels through the barrier, the barrier is approximately 95% closed, and the velocity of wind passing through the device is greatly reduced. For example, the velocity of a 100 mph wind is reduced by approximately 97% by passing through the wind abatement system of the present invention. The wind abatement system of the present invention substantially reduces the force of wind passing through the device and also provides a barrier against wind-borne missiles having diameters of approximately 3/16 inch in diameter or larger. Also, rain drops striking the barrier are reduced in velocity and dispersed into a mist which reduces the water damage to the structure.
[0017] Alternatively the material can be termed to be solid wherein the fabric is coated or the interstices of the fabric are filled by either close weaving, or use of a coating.
[0018] The inflatable cushion(s) between the fabric and the building provide displacement and pneumatic dissipation of the force of impact of debris on the fabric. This pneumatic plenum allows the flexible barrier system to be in direct contact with the structure being protected.
[0019] Another objective of this invention is to teach the use of very large areas with spans covering greater than 25 feet. Thus most window groupings, from a single window up to several stories of a building, could be readily protected. This invention is light in weight, easy to use, does not require reinforcing bars, can be constructed in varying degrees of transparency, can be weather tight, is economical, and is capable is dissipating far greater forces without damage than conventional stiff devices. Missiles striking this barrier make very little sound. Additionally, this invention is suitable to be configured with the necessary motor and mounting devices for automatic deployment.
[0020] Another objective of the invention is to permit the adaptation of the invention to meet a particular enclosure or object. For instance, the inflatable cushion(s) may be placed over a window, preferably a wind rated window, to provide the necessary spacing. Alternatively the inflatable cushion(s) may be placed over the mullions of a window thereby transferring wind loading directly to the inflatable cushion and thus to the structure of the mullion. Further, the inflatable cushion(s) may be placed along the edge of the window or on the structure abutting window. Similarly, the inflatable cushion(s) may be placed adjacent an object, such as a tiled wall, painting, statue, sculpture, or the like, to prevent wind, rain, and debris from impacting the object.
[0021] It is a further objective of this invention to teach a wind barrier that does not rely on rigidity but rather is very flexible, which gives several positive features including allowing for ease of storage as by deflating and rolling or folding. The fabric material in this barrier system is displaced from the structure being protected and this displacement is a function of the depth of the inflatable cushion. An impacting missile stretches the barrier until it decelerates to a stop or is deflected. The fabric material has a predetermined tensile strength and stretch that makes it suitable for this application. The known strength and stretch, together with the speed, weight and size of the impacting missile, all of which are given in test requirements, permit design calculation to ascertain barrier deflection at impact. The cushion is capable of a deflection, due to compression, commensurate with the stretch of the fabric to prevent rupture.
[0022] Thus greater energy from a missile can be safely dissipated than is possible with the prior art structures, and the energy which can be safely dissipated is calculable. In simple terms, the missile is slowed to a stop by elasticity as the barrier stretches and compression as the cushion deforms. The greater the impact, the greater the stretch and compression. Thus the building is not subjected to an abrupt harsh blow as the energy transfer is much gentler and less destructive that with the rigid devices.
[0023] It is yet another objective of this invention to teach the use of a screen-like fabric with interstices that permit the light to pass through and that is reasonably transparent, if desired. If transparency is not desirable, the fabric can be made sufficiently dense to minimize or eliminate the interstices. To assure a long life the material of the fabric preferably would be resistant to the ultra violet radiation, and to biological and chemical degradation such as are ordinarily found outdoors. This invention contemplates either coating the material or utilizing material with inherent resistance to withstand these elements. A synthetic material such as polypropylene has been found to be acceptable. Another example is a coated material of vinyl coated polyester. The coating may fill interstices to make a solid material. The fabrics may use natural or synthetic fibers and blends of fibers or blends of yarns, e.g., an open weave with steel reinforcing strands there through or Kevlar or other ballistic yarns. Materials intended to be used outdoors in trampolines, for example, are more likely candidates for use in this invention. Black colored polypropylene is most resistant to degradation from ultra violet radiation. Other colors and vinyl coated polyester are sufficiently resistant, particularity if the barrier is not intended to be stored in direct sunlight when not in use.
[0024] These same materials may be used to form the walls of the inflatable plenums or cushions. The cushions may be coated or laminated on the outside or inside surfaces to form air tight cells. The cushions may be made of extruded polymeric films. The desired amount of deformation, in the cushion, is a function of the elasticity of the material and the inflation pressure. The plenums may also be thin walled structures inserted into a sleeve of the barrier material which provides the requisite strength.
[0025] The preferred embodiment of the fabric allows air passage through it, albeit at substantially reduced rate. In one embodiment, upwind pressure of 1″ of mercury, which roughly translates into a 100 mph wind, forces air through at 250 cfm or approximately 3 mph. The amount of air passage depends on the interstice size and percentage of openness. If a weather tight and transparent barrier is desired, the polypropylene material may be laminated with a flexible clear plastic skin.
[0026] It is of importance that the material affords sufficient impact protection to meet the regulatory agencies' requirements in order for this to be a viable alternative to other hurricane protective mechanisms. While stiff structures, such as panels of metal, are easily tested for impact requirement and have certain defined standards, fabrics on the other hand, are flexible and react differently from stiff structures. Hence the testing thereof is not easily quantified as the stiffer materials.
[0027] However, certain empirical relationships exist so that correlation can be made to compare the two mediums. Typically, the current impact test of certain locales requires a wood 2×4 stud be shot at the barrier exerting a total force of approximately 351 foot pounds, or 61.3 psi, over its frontal (impacting) surface. This impact and resultant force relate to the Mullen Burst test commonly used by manufacturers to measure the bursting strength of their fabrics. Thus the impact test heretofore used on rigid devices will work equally well on this flexible device.
[0028] The preferred embodiment of this invention would use a textile of the type typically used in trampolines which would burst at least 675 psi or a total of 2,531.25 pounds over the same 3.75 square inch frontal surface of the nominal 2×4 test missile wherein stretch characteristics of the material are known. The strength and stretch characteristics of the material are also known. The strength of this fabric is more than eleven (11) times the 351 foot pounds of strength required to withstand the above-described 2×4 missile test as presently required by said regulatory agencies. Stronger fabrics are available. Others are available in various strengths, colors and patterns.
[0029] The use of flexible fabric distanced out from the frangible area as a protective barrier allows extended deceleration. When the strength and stretch properties of the fabric are known and allowed for, as well as, these same properties in the inflated cushion, the extended deceleration becomes controlled. By mounting the protective barrier material some distance from the frangible surface, i.e., the thickness of the inflated cushion, a distance that is calculable, the missile can be decelerated to a stop prior to contacting the frangible surface. And the pounds per square inch of impact force are spread throughout the inner surface of the cushion. In other words, in any situation where the missile must stop prior to impacting the frangible surface being protected, it is desirable to decelerate the missile through an extended, controlled deceleration. This invention does precisely that. Since the use of a flexible material as a protective barrier affords an extended deceleration, very strong impacts can be withstood.
[0030] A further objective of this invention is to teach a barrier made from fabric to protect the frangible portions of a building and the like from the force of wind, or over pressure, and impact from water or other liquids and wind-borne debris by displacing the barrier out from and in front of the frangible area with inflatable cushions. The barrier is mounted on the building by attaching two opposing edges to anchors located so as to position the barrier as described. For example, one edge of the fabric can be anchored to the overhang of the roof or other high structure and the opposite edge of the span to the ground or low structure. The lower anchors can be attached to the foundation of the building or the ground by embedding in cement or other ground attachment such as tie downs or stakes and the like and providing grommets, rings or other attachments in the fabric to accept a clamp, cable, rope, and the like.
[0031] Another objective of this invention is to teach an inflatable structure placed between any opening in a structure and may be spaced from the structure a greater distance than the thickness of the cushion to allow for some deceleration before the cushion is compressed.
[0032] Still another objective of this invention is to teach the use of a retainer for deploying and securing the two opposing edges of a wind barrier material to retainer channels located so as to form a structure envelope about the openings with the barrier spanning the opening.
[0033] The curtain-like barrier of this invention is characterized as a barrier with strength and simplicity that is unattainable with the heretofore known barriers. Impact by a missile does not cause a large bang, and is not disturbing. It is easy to install, requires low maintenance and has low acquisition cost. There is much flexibility with storage. It can either be left in place or rolled much as a shade, or slid out of the way much as a curtain, so as not to interfere with the aesthetics of the building. It can also be fully removed and stored out of the way, or swung up to form a canopy when not in use as a protective barrier. It is preferable but not essential, that the material selected to be used in the netting fabric of this invention be inherently resistant to elements encountered in the outdoors or can be coated with coatings that afford resistance to these elements. The inflatable cushions can be separate from the netting or attached by interweaving, fasteners or pockets in the netting. The cushions may be stored with the netting or removed for storage elsewhere.
[0034] Another objective of this invention is to teach the use of valves in the inflatable cushions whereby they can be deflated for storage and inflated once the barrier is in place on the building.
[0035] Other objectives and advantages of this invention will become apparent from the following description taken in conjunction with the accompanying drawings wherein are set forth, by the way of illustration and example, certain embodiments of this invention. The drawings constitute a part of this specification and include exemplary embodiments of the present invention and illustrate various objects and features thereof.
BRIEF DESCRIPTION OF THE DRAWINGS
[0036] FIG. 1 is a partial view in perspective and schematic illustrating this invention partially deployed and attached to a building;
[0037] FIG. 2 is a partial cross section and side view illustrating the protective barrier and inflated cushion in place;
[0038] FIG. 3 is a perspective of the barrier showing holders for the cushions;
[0039] FIG. 4 is a detailed showing of a mechanism for attaching the retainers to the barrier;
[0040] FIG. 5 is a detailed view of another mechanism for attaching the retainers to the barrier;
[0041] FIG. 6 is a diagrammatic and schematic view illustrating the channel;
[0042] FIG. 7 is a perspective of a protective barrier for individual openings or small groups of openings; and
[0043] FIG. 8 is a perspective of a single window with an inflatable barrier in place.
DETAILED DESCRIPTION
[0044] This barrier 10 is made up of a flexible material 11 that has known qualities of strength, stretch and deformation and is sufficiently strong to withstand applicable impact testing and one or more inflatable plenums or cushions 12 . The barrier 10 does not derive its strength from stiffness or rigidity but rather from its bursting strength and stretch, with the latter acting like a spring to gradually decelerate any impacting missile. Wind speed may become a significant factor in larger spans.
[0045] There are many desirable characteristics of this barrier 10 , such as resistance to weathering, light weight, ease of installation, deployment and storage, economy. Additionally, there are several methods of deploying and storing this barrier. While this invention is shown in its preferred embodiment as being utilized to protect the windows and overhang roof, shown in FIG. 2 , of a structure, it is to be understood that this item has utility for other items requiring protection and is applicable to other types of structures, as shown in FIG. 8 . Where appropriate, the barrier and inflatable plenums can be deployed horizontally, as well as, the vertical as shown in FIGS. 1-2 .
[0046] Reference is now made to FIGS. 1-6 which partially show a building structure 100 including windows 110 intended to be protected from the onslaught of winds and debris typically occasioned during a hurricane. According to this invention the top of a curtain panel or material 11 , made from a textile woven of a suitable fiber, (other weaves or knits may be used) is attached to roof 16 and the bottom thereof is attached to the foundation 200 . A suitable material is polypropylene formed in a monofilament and woven into geotextile (style 20458) manufactured by Synthetic Industries of Gainesville, Ga. The fabric is woven in a basket (plain) weave as in the preferred embodiment in interstices are substantially equal to 0.6 millimeters which approximates the interstices of commercially available residential window screening.
[0047] The selection of interstices size and configuration is dependent on the amount of transparency and air passage desired and the limitation that the maximum size must be sufficiently small to prevent objects that are potentially damaging on impact from passing there through. The above-mentioned regulations, set in place by Miami-Dade County, Florida, have determined that the smallest diameter missile (wind blown debris) with which they are concerned is 3/16 inch in diameter. Therefore to satisfy the Dade County Regulations the interstices must be small enough to prevent 3/16 inch diameter missiles from passing there through. Other regulations may set other minimum missile diameter sizes, and the interstice size would vary accordingly if new standards were to be met. The parameters of the test and the fabric are fully discussed in U.S. Pat. No. 6,176,050.
[0048] The cushions 12 have conventional inflation-deflation valves 116 , such as those used in tires or sports equipment. The valves may include a safety valve which will open when a pre-selected internal pressure is exceeded. This will prevent rupture of the cushion. The inflation pressure of the cushions 12 can be adjusted to compensate for the impact pressure of the debris or test missile. A higher inflation pressure would decrease the amount of deflection of the material. In this manner, the improved barrier 10 would not require the spacing necessary with the material, per se. For example, a cushion having a depth of 2 feet may be used in spans from 8 feet to 40 feet and beyond. This permits attachment of the bottom of the barrier to the protected structure, as shown in FIG. 8 , rather than being displaced away from the building.
[0049] The top of the barrier 10 is secured to the roof 101 , facia 102 , or under the eave 103 . The bottom of the barrier would be secured to the foundation 200 of the building by fasteners 119 . The longitudinal sides 13 , 14 of the barrier are mounted in retainers 104 , 105 . The retainers 104 , 105 , as shown in FIG. 6 , are elongated box-shaped metal sections permanently attached to the building. The retainers may be installed in sections or as a seamless whole. The top of the retainers 104 , 105 have a flared opening 106 , 107 to facilitate the feeding of the barrier 10 into the retainers as the barrier 10 is unrolled into position.
[0050] The base 108 of the retainers is bolted or otherwise fixed to the structure 100 . The top wall 114 is parallel to the base. The outer wall 109 has a height that provides the spacing of the material 11 from the building 100 to permit the inflatable cushions to be deployed. The outer wall 109 of the opposite retainers 104 , 105 enclose the longitudinal edges of the barrier to prevent wind entry between the barrier and the building. The inner wall 110 has a longitudinal groove 111 through which the longitudinal selvage edge of the material 11 slides. The groove 111 terminates in an enlarged channel 112 of a size and shape to permit the pins 113 to move.
[0051] The pins 113 , shown in FIGS. 4 and 5 , are tapered from the central position toward each end. The pins may be attached to the longitudinal selvage by tabs 120 or hemmed into the selvage. As the barrier is deployed each pin enters the flared end of the retainers and slides down the channel. Since the slot is narrower than the diameter of the pins, the pins are captured in the channels. Other arrangements can include a cable attached to the longitudinal edges of the material.
[0052] Once the minimum space between the barrier and the structure being protected is established, the fabric must be anchored in a suitable manner so as to absorb the loads without being torn from its support. While various hardware devices may be used to anchor the fabric in place, general criteria include stainless steel bolts with 0.5 inch diameter and 1,000 lbs. max. bolt loading; 0.375 inch diameter and 625 lbs. max. bolt loading; with minimum pull-out force for steel 20× bolt loading; concrete 3,000 psi, spaced to achieve 1,100 lbs./linear foot; wood 2,400 lbs/linear inch of engaged thread; ground 8 inch helix ground anchor with 9,900 lbs. holding force in class 5 soil. These criteria are merely exemplary and not limiting. Other anchoring hardware may be used to install protective barrier of this invention.
[0053] As shown in FIGS. 1 and 2 the protective barrier 10 may be unrolled from a spindle 15 that is attached to the roof 101 or the eaves 103 of the roof by suitable threaded bolts or screws. The spindle attaching method allows for ease of installation as the installer can wrap the material around the spindle as necessary to adjust the material to the span and then attach the spindle to the building. Additionally, the use of a spindle 15 allows the edge if the barrier to be securely fastened overhead in a simple and economical method. Other methods are available in appropriate situations. The lower edge is fastened by anchors 118 set in recesses formed into the foundation to bury or partially bury eyebolts.
[0054] The material 11 may also be fabricated with a top and bottom selvage or hem or can utilize a reinforcing tape such as “Polytape” that is made from a polypropylene material. The selvage or tape may include commercially available grommets or rings to accept the tie-down hardware. The side margins may also have a selvage or other reinforcement with either grommets or ties for fastening to anchors placed in the wall of the structure.
[0055] The material, as shown in FIG. 3 , may have one or more belts 117 for containing the cushions in alignment with the material 11 . The belts may be of the same material or an elastic fabric. The belts 117 may be formed as loops with intermediate portions attached to the barrier by interweaving, adhesives or other fasteners. The loops would accommodate the width of the cushions. Alternatively or in addition, pockets may be fashioned in the top and bottom to enclose the ends of the cushions. The cushions or plenums may be completely surrounded by the fabric, as shown in FIG. 7 .
[0056] The multiple story installation may be deployed simply by attaching the upper edge of the barrier to the bolts on the building and feeding the barrier into the top of the retainers then allowing the barrier to fall toward the ground. Once the lower edge becomes free, it can then be attached to a set of lower fasteners located at the corresponding vertical height on the building or the ground. The barrier can be winced down by a hand crank or motorized winch (not shown) attached by a line to the bottom selvage of the barrier. Thin metal, polymeric or wooden battens 115 may be placed across the width of the barrier at spaced intervals to control deployment evenly. Once the barrier is in place, the cushions 12 are inflated to the desired pressure. To store the barrier, the cushions are deflated and either removed or rolled up with the material 11 .
[0057] The inflatable wind barrier may be deployed for individual openings such as windows and doors rather than covering major surfaces of a building, as shown in FIG. 8 . FIG. 7 illustrates a plenum 12 encompassed by the material 11 . The material 11 has flaps 131 , 132 extending outwardly from the sleeve 130 . Each flap terminates in a selvage 135 , as shown. Grommets 133 are attached through the selvage 135 providing apertures 134 to connect to anchors along the periphery of the opening. Top and bottom flaps may also be provided. Other attachment devices, such as hooks, may be used in place of the grommets.
[0058] The cushions or plenums 12 may be inflated by pumps supplying high volume low pressure inflation, HVLP, for example home vacuum cleaners through a valve. The valve may include a means for sealing of the opening similar to a tire valve, inflatable dinghy valve, or conventional air cushion valve.
[0059] FIG. 8 illustrates a single frangible opening, such as a window 201 , in a larger structure. The structure has a set of fasteners 202 mounted about the periphery of the window. Connected to these fasteners are the edges of the barrier material 11 . The edges may have selvages and grommets 203 as mentioned above. Plenums 204 are located between the barrier and the window and are held in place by the fabric of the barrier. The plenums provide the spacing necessary for the fabric to decelerate debris, such as solids and liquids, before striking the frangible portion of the window. However, even if the frangible portion is broken, the barrier remains intact providing protection to the interior of the structure.
[0060] The inflatable cushion(s) permit adaptation of the barrier to meet the design of a particular enclosure or object. For instance, the inflatable cushion(s) may be placed directly over a window, preferably a wind rated window, to provide the necessary spacing of the fabric from the glass. Alternatively the inflatable cushion(s) may be placed over the mullions of a window thereby transferring wind loading directly to the inflatable cushion and thus to the structure of the mullion. Further, the inflatable cushion(s) may be placed along the edge of the window which is stronger than the center, or on the structure abutting window such as the frame or actual structure abutting the window. Similarly, the inflatable cushion(s) may be placed adjacent an object, such as a tiled wall, painting, statue, sculpture, or the like, to prevent wind, rain, and debris from impacting the object.
[0061] Although this invention has been shown and described with respect to detailed embodiments thereof, it will be appreciated and understood by those skilled in the art that various changes in form and detail thereof may be made without departing from the spirit and scope of the claimed invention. | A flexible hurricane shutter or barrier to protect buildings from over pressure has inflatable cushions held in place by a fabric material capable of withstanding winds in excess of 100 mph. The barrier can be stored on site in a rolled fashion. Retainers are mounted on a building to guide and secure the longitudinal edges of the fabric to permit ease of deployment. The retainers may be spaced apart over one side of a building and the barrier may be deployed over an entire surface of a multi-story building by raising and lowering the fabric. Inflatable cushions are held between the fabric and the building. The inflated cushions reinforce the material and distribute the force of impact throughout the surface of the cushions and act as spacers to both hold the fabric off the structure and focus the forces onto stranger portions of the structure. | 4 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a lightweight, collapsible reel for supporting cable, conduit or tubing wound therearound and especially to a reel collapsible to a thickness no greater than approximately the thickness of the two side by side circular end flanges of the reel. The components of the reel are especially adapted for fabrication of synthetic resin material which results in an extremely lightweight reel that retains its load bearing properties and characteristics after repeated in-field use of individual reels.
Collapsible reels for supporting products such as elongated stretches of a cable, conduit or tubing wound around the core of the reel are known but have not heretofore gained widespread recognition in the field. Although deficiencies in marketing of past collapsible reels may have been a contributing factor in limited customer demand for prior reels, the inability of such reels to fully collapse and the excessive weight of the reels even when collapsed no doubt has been a limiting deterrent to widespread adoption and use.
2. Description of the Prior Art
Brown, in U.S. Pat. No. 3,791,606, illustrates a cable spool said to be collapsible but as illustrated in FIG. 4 of the patent drawings, folding of the central bar or leg segments 13 results in collapse of the reel such that there is still a space between opposing flanges 5 that substantially exceeds twice the width of one of the flanges 5 . Thus, Brown in the '606 patent does not disclose or suggest a collapsible lay flat reel. Brown teaches the provision of a spool in which the end flanges are movable toward one another but opposed margins of the foldable leg segments form a V when folded which limits collapse of the reel flanges.
Similarly, in Culp U.S. Pat. No. 5,649,677, the patentee provides a collapsible spool having a plurality of foldable arms 16 which fold into a state of maximum collapse, as illustrated in FIG. 8 . The overall thickness of the reel when collapsed is substantially greater than twice the thickness of one of the end flanges.
SUMMARY OF THE INVENTION
The present invention provides a lightweight, collapsible reel for cable, conduit or tubing in which a pair of opposed, relatively thin, generally circular, coaxially end flanges of substantially equal diameter are interconnected by at least three foldable cable, conduit or tubing support units. The reel, when fully collapsed, is no thicker than twice the thickness of each individual end flange. The support units, which each include a pair of hingedly interconnected end-to-end leg segments that cooperate in their fully extended, straight-line positions, to present a generally triangular cage internal of the space between the flanges for wrapping of cable, conduit, tubing or the like around the support units.
The end flanges and support units are designed and especially adapted to be individually molded as one-piece from synthetic resin material. Preferably, the flanges in the leg segments of the support units are molded of a synthetic resin material in prefabricated molds utilizing a resin such as polypropylene containing a conventional blowing agent so that a thin, relatively tough, abrasion resistant outer skin is formed from compaction of the resin at the surface of the part while the lower density resin produced by the blowing agent serves as an internal support for the skin.
In order to minimize the overall weight of the reel without sacrifice of its utility and strength characteristics, each of the unitary flanges has an inner relatively flat face, and an outer cellular face defining a plurality of weight saving spaces. In a preferred embodiment, the outer portion of each of the flanges includes an outer annular band of end-to-end rectangular pockets, an intermediate annular section of web defining trapezoidal spaces, and an innermost central section of generally polygonal areas.
The leg segments of the support units are preferably molded to define a series of elongated, side by side ribs which increase the beam strength of the individual segments while saving weight. The flanges are provided with a series of elongated recesses located to complementally receive the rib portions of respective leg segments of the support units. When the reel is collapsed by folding of the support units, the rib portions of the leg segments of each support unit, which face outwardly relatively, are fully received in respective recesses in the flanges so that the inner faces of the flanges move into interengaging, side by side relationship. The result is a reel when collapsed that is no thicker than the thickness of the side by side flanges.
The leg segments of respective support units are pivotally interconnected by a pin. Individual leg segments, which are all of identical construction, are all molded separately. Each of the ribbed leg segments has openings at opposite ends thereof. Pivot pins are inserted in the openings in one end of three leg segments. The three leg segments with the inserted pins, are then placed in a mold for a respective end flange with the pivot pins located 120° apart in spaced relationship as required for formation of the triangular cable, conduit or tubing cage to be defined by the support units. The leg segments with the inserted pins are located in the mold such that the ribbed surfaces face inwardly of the mold cavity. The mold also incorporates cavity defining surfaces for the cellular outer face of each of the molded flanges. By molding the individual leg segments along with the flange itself, the ribs of the leg segments form indentations or recesses in the inner surfaces of the flange so that the leg segments which are pivotally connected to the flange are inherently complementally received in the formed recesses. It is to be understood in this respect that a mold release agent is applied to the ribbed surfaces of the leg segments that are pivotally joined to a respective flange so that upon removal of the molded part from the mold, the leg segments that have been molded in place may readily be pivoted to their open, outwardly extended positions.
Upon completion of two molded flanges with incorporated leg segments, the leg segments of both flanges are extended outwardly and pivot pins inserted within aligned holes in what becomes end-to-end leg segments of respective support units.
The end flanges are provided with central openings which are coaxial in the completed reel so that a guide rod or pipe may be inserted through the aligned openings to guide or support the reel as a cable, conduit or tubing is unwound from the expanded reel.
An important advantage of the present collapsible reel is the fact that manufacture of the reel of synthetic resin material as explained permits recycling of the reel at the end of its useful life, which in most instances should be at least the order of fifty cycles of use. Another advantage is the minimal thickness of a fully collapsed reel, which is ⅙th to {fraction (1/7)}th that of a conventional reel. The no more than 2× flange thickness of each collapsed reel results in significant savings in return transportation costs of empty reels in collapsed condition from a space standpoint, in that a significantly larger number of reels may be transported in the space that would have been taken up in the transport vehicle by conventional reels. In addition, minimization of warehousing space required for empty reels provides significant cost savings. The collapsed reels are much easier to handle and maneuver because of the decreased weight as compared with conventional plywood reels.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an isometric view of a collapsible reel constructed in accordance with the preferred concepts of this invention and showing the reel with cable, conduit or tubing wound therearound and supported by a conventional reel stand;
FIG. 2 is an expanded isometric view of the collapsible reel;
FIG. 3 is an isometric view of the collapsible reel minus the cable, conduit or tubing shown in FIG. 1 and illustrated without support of a reel stand;
FIG. 4A is a generally schematic elevational view on a reduced scale of the collapsible reel in its expanded condition;
FIG. 4B is a fragmentary, cross-sectional view through the expanded collapsible reel of FIG. 4A and taken on line 4 B— 4 B of FIG. 7 through one of the three circumferentially spaced, foldable cable, conduit or tubing support units pivotally interconnecting the circular end flanges of the reel;
FIG. 5A is a generally schematic elevational view on a reduced scale of the collapsible reel in a partially collapsed condition;
FIG. 5B is a fragmentary, cross-sectional view taken on the same line as FIG. 4B and illustrating the support unit as depicted in FIG. 4B in its partially collapsed condition;
FIG. 6A is a generally schematic elevational view on a reduced scale of the reel in its fully collapsed condition with the circular flanges of the reel in side by side, substantially interengaging relationship;
FIG. 6B is a fragmentary, cross-sectional view through the reel in it filly collapsed condition;
FIG. 7 is an end elevational view of one of the end flanges as molded with the cable, conduit or tubing support units molded in the positions thereof recessed in face;
FIG. 8 is an isometric view of one of the three tubing support units that pivotally interconnect the end flanges of the reel;
FIG. 9 is an expanded fragmentary cross-sectional view of one of the leg segments of a support unit and taken on the line 9 — 9 of FIG. 7 ; and
FIG. 10 is an enlarged fragmentary isometric view of a portion of one of the end flanges and showing one of the leg segments of a support unit telescoped in recesses for the leg segments in the flange.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The collapsible reel, broadly designated by the numeral 10 in the drawings, is especially adapted in its expanded condition, as shown in FIG. 1 of the drawings to support cable, conduit or tubing 12 or the like wrapped around the central cage defining structure, designated by the numeral 14 in FIG. 2 . Reel 10 includes two opposed, relatively thin, identical, generally circular, oppositely oriented, coaxially positioned end flanges 16 and 18 .
For simplicity, in view of the identical nature of flanges 16 and 18 , the same component parts of each of the flanges 16 and 18 are given the same number in the drawings. Thus, as is apparent from FIGS. 1 and 2 , each of the circular end flanges 16 and 18 has an inner, relatively flat face 20 provided with a circular guide rod or pipe opening 22 in the center thereof.
Three foldable cable, conduit or tubing support units 24 are hingedly connected to opposed inner faces 20 of end flanges 16 and 18 . Each support unit 24 includes a pair of identical leg segments 26 and 28 which are joined end-to-end by respective pivot pins 30 as best shown in FIG. 8 . The leg segments 26 and 28 are of identical construction and are preferably molded in one-piece as detailed hereunder. Each leg segment 26 and 28 has a plurality of elongated, transversely spaced ribs 32 which are integral with a planar body portion 34 , as is to be noted from the cross-sectional view of FIG. 9 . As is evident from that view, the two outer most rib portions 32 a are of lesser height, the two innermost rib portions 32 b are of greatest height and the rib portions 32 c between respective outer most rib portions 32 a and innermost rib portions 32 b are of intermediate height. Ribs 32 a , 32 b and 32 c are of heights selected so that in the extended condition of reel 10 with the leg segments 26 and 28 or each of the support units 24 being in linear, aligned relationship, as shown for example, in FIGS. 3 and 4A , the outer margins of ribs 32 a , 32 b and 32 c collectively, essentially define an imaginary cylinder. For example, in the case of an illustrative reel 10 , having a diameter of 30″, the outer margins of ribs 32 a , 32 b and 32 c of support units 24 may for example lie in imaginary cylinder having a radius of about 5″.
The ends of leg segments 26 and 28 which are an end-to-end relationship as shown in FIG. 8 , have interlocking cylindrical portions 36 provided with cross openings 38 therein for receipt of pivot pins 30 . It is to be further observed that the leg segments 26 and 28 of each support unit 24 are moveable from the straight-line disposition as shown in FIGS. 4A–4B to the filly folded positions shown in FIGS. 6A and 6B as the leg segments 26 and 28 pivot about pins 30 . Cooperable detents (not shown) may be provided on the ends of leg segments 26 and 28 which interengage in the extended linearly aligned disposition of leg segments 26 and 28 of support units 24 for retaining leg segments 26 and 28 filly extended until it is desired to fold support units 24 to collapse reel 10 .
The extremity of each of the ribs 32 b of leg segments 26 and 28 remote from cylindrical portions 36 has a circular end surface 32 b ′ while the extremities of ribs 32 a and 32 c of each leg segment 26 and 28 have integral, semi-circular end caps 32 a ′ and 32 c ′. The end caps 32 a ′ and 32 c ′, and the ends of ribs 32 b terminating in circular surfaces 32 b ′ of each of the leg segments 26 and 28 are provided with a series of aligned coaxial pivot pin receiving openings 40 . The cross-openings 40 through end caps 32 a ′ and 32 c ′, and the end surfaces 32 b ′ of leg segments 26 and 28 respectively have aligned, coaxial pivot pin receiving openings 40 . The aligned openings 40 at the outer ends of each of leg segments 26 and 28 receive elongated pivot pins 42 , each of which projects outwardly beyond the outer surfaces of end caps 32 a ′, as shown in FIG. 2 .
Inner faces 20 of end flanges 16 and 18 are defined by relatively thin, planar panel portion 44 ( FIGS. 9 and 10 ) which nominally may be approximately ¼″ thick. In addition, all component portions of the flanges 16 and 18 are of the preferred ¼″ thickness. The ribs 32 a , 32 b and 32 c are all approximately ¼″ thick while planar bottom portion 34 of each of the leg segments 26 and 28 is preferably ⅛″ thick. The diameter of reel 10 as presented by flanges 16 and 18 may be varied, with one preferred dimension being about 30″. Each of the flanges 16 and 18 may, for example, be about 1½″ in depth front to back.
The wall structure of end flanges 16 and 18 includes outwardly facing cell defining component portions which project in opposite directions from respective panel portions 44 , include an outer, annular cellular band 46 made up of a plurality of end-to-end generally rectangular open pockets 48 defined by the outer annular rim portion 50 , and inner rim portion 52 and a series of circumferentially spaced, radially extending wall portions 54 . The pockets 48 are approximately 1¼″ deep.
A central outboard cellular section 56 of the flanges 16 and 18 , best shown in FIGS. 2 and 3 , surrounds a respective opening 22 in coaxially relationship thereto and has a plurality of individual web segments 58 that make up a number of circumferentially extending open polygonal areas 60 . Here again, each of the areas 60 is approximately 1¼″ deep.
An intermediate outboard cellular section 62 in each of the flanges 16 and 18 surrounds central cellular section 56 and has a series of generally radial, spaced webs 64 that cooperate with the inner rim portion 52 and web segments 58 to define a plurality of circumferentially extending open trapezoidal areas 66 . The areas 66 are also approximately 1¼″ deep.
In those instances where three foldable support units 24 are provided between and pivotally connected to flanges 16 and 18 , three radially extending and circumferentially spaced cavity areas 68 are provided in the wall structure panel portion 44 of each of the flanges 16 and 18 . The cavity areas 68 have a series of elongated, parallel, transversely spaced recesses for the respective ribs 32 a , 32 b and 32 c of leg segments 26 and 28 of supports units 24 when the support units 24 are in their fully collapsed condition. As is most evident from FIGS. 9 and 10 , each of the cavity areas 68 includes two elongated, outboard, unitary, transversely spaced, U-shaped recesses 68 a configured to complementally receive respective outboard ribs 32 a of a corresponding leg segment 26 and 28 . Similarly, two elongated, inboard, unitary, transversely spaced, U-shaped recesses 68 b are provided which complementally receive respective ribs 32 b of corresponding leg segments 26 and 28 of support units 24 . Two elongated, intermediate, unitary, transversely spaced, U-shaped recesses 68 c complementally receive the ribs 32 c of leg segments 26 and 28 of support units 24 .
When the support units 24 are unfolded to provide an extended reel as shown in FIG. 3 , the reel 10 is adapted to receive a cable, conduit or tubing 12 as shown in FIG. 1 . The imaginary cylinder defined by the outer margins of ribs 32 of the three support units 24 serves as a support for cable, conduit or tubing 12 which may be wound therearound in a pattern as shown in FIG. 1 . The reel 10 with the cable, conduit or tubing 12 thereon may be shipped as a unit and a plurality of the reels stacked one on top of the other with the outer faces of the reels interengaging as is conventional with standard wooden reels. At the site of use, the reel 10 may be positioned on a support such as stand 70 as depicted in FIG. 1 , in which a rod or pipe 72 passing through a line openings 22 in flanges 16 and 18 is typically received within a U-shaped open top saddle 72 a forming a part of stand 70 . The cable, conduit or tubing 12 may be pulled from reel 10 as it rotates about the axis of rod or pipe 72 . Alternatively, reel 10 may be supported for rotation upon the body of a mobile vehicle such as a truck.
Upon depletion of the supply of cable, conduit or tubing 12 carried by reel 10 , the reel 10 may be collapsed to the condition illustrated in FIG. 6A for shipment. The support units 24 may be folded about the axes of respective pivot pins 30 whereby ribs 32 a , 32 b and 32 c are received in corresponding recesses 68 a , 68 b and 68 c . It can be observed from FIG. 9 that the panel portion 44 of each of the flanges 16 and 18 has three radially extending, circumferentially spaced, rectangular indentations 74 in the faces 20 of panel portions 44 which are configured to complementally receive the planar bottom portion 34 of a respective leg segment 26 and 28 of support units 24 . As a consequence, when support units 24 are folded into their fully collapsed positions, the faces 20 of flanges 16 and 18 are in flat, fully conforming interengagement with essentially no space there between as shown schematically in FIGS. 6A and 6B .
It is also to be seen from FIGS. 8 and 10 that when the leg segments 26 and 28 of the support units 24 are brought into linear, aligned relationship as best shown in FIG. 8 , the extremities 32 a ″, 32 c ″and 32 b ″ of leg segments 26 and 28 move into abutting relationship while adjacent ends of the flat surfaces of respective planar bottom portions 34 complementally interengage, thereby preventing the leg segments 26 and 28 from swinging overcenter during pivoting about pivot pins 30 . The interengagable detents on adjacent ends of fully opened leg segments 26 and 28 cooperate to maintain the leg segments 26 and 28 in end-to-end aligned relationship.
A preferred procedure for manufacture of reel 10 involves pre-molding of a supply of leg segments 26 and 28 , which it is to be observed are of identical construction and configuration. The leg segments 26 and 28 may be molded of a suitable synthetic resin such as polypropylene whereby the leg segments 26 and 28 are solid throughout the thickness of the individual leg segments 26 and 28 , or in the alternative, leg segments 26 and 28 may be fabricated of a synthetic resin composition in which a resin such as polyproplyene contains an amount of a blowing agent that is compatible with the resin. If formed, for example, from polypropylene which includes a quantity of a blowing agent, during molding of the parts, gases generated by the blowing agent cause the outer surface of the part to become denser than the interior portions of the part, thereby defining a tough, homogeneous, substantially void-free outer skin layer. The thickness of the skin layer will nominally be of the order of 0.060″ to about 0.100″. The overall thickness of the wall structures of flanges 16 and 18 will nominally be about ¼″.
The outer rim portion 50 of each of the end flanges 16 and 18 which define the overall thickness of respective flanges 16 and 18 nominally or about 1½″. The leg segments 26 and 28 generally are about 1⅛″ thick overall. A fully collapsed reel 10 , as shown in FIGS. 6A and 6B , has a maximum folded thickness of only about 3″.
The faces of the three leg segments 26 or 28 of support units 24 which face outwardly to define cage 14 when reel 10 is unfolded, are sprayed with a mold release agent. The treated leg segments 26 or 28 with pins 42 in place in openings 40 are strategically placed in the mold for end flanges 16 or 18 with the outer surface of planar bottom portions 34 of leg segments 26 and 28 lying in a plane that is planar with the face 20 of the end flanges 16 or 18 to be molded.
Next, a synthetic resin, such as polypropylene which contains a blowing agent, is introduced into the mold for a respective end flange 16 or 18 . The polypropylene/blowing agent composition is then allowed to expand into the cavity of the mold defining an end flange 16 or 18 . As previously explained, expansion of the polypropylene by the blowing agent incorporated into the resin formulation causes a relatively tough, homogeneous, substantially void-free outer skin layer to be formed throughout the extent of the end flange 16 or 18 , which fully encloses the cellular synthetic resin interior of the part. It is believed that the density of the resin making up the interior of the formed flange decreases in a direction away from the outer skin toward the center of the part.
By forming each of the flanges 16 and 18 with the support units 24 in their normal folded positions thereof, support units 24 may readily be swung outwardly from the finished part because of the release agent that was applied to the surfaces of the leg segments 26 and 28 which face inwardly of the mold during the fabrication of a respective flange 16 or 18 . It is important to note in this respect that by molding of the leg segments 26 and 28 in place during forming of the end flanges 16 and 18 , the pivot pins 42 are also correctly molded in position. It would be difficult and more expensive to locate the pivot pins 42 in flanges 16 and 18 after molding of the flanges than is the case with molding of the pivot pins in place in flanges 16 or 18 .
In addition, molding of the end flanges 16 and 18 with a leg segment 26 and 28 positioned in the flange mold results in the outer surfaces of ribs 32 accurately forming complemental recesses for ribs 32 of each leg segment 26 and 28 when the support units 24 are folded to collapse the reel 10 and thereby bring the faces 20 of end flanges 16 and 18 into proximal interengaging relationship.
The synthetic resin used for molding of leg segments 26 and 28 of support units 24 should be of characteristics and properties such that the formed leg segment part is capable of withstanding and not be deformed by the elevated temperature environment within the interior of the mold(s) used to fabricate end flanges 16 and 18 .
Although polypropylene is the preferred resin for fabrication of reel 10 , other resins may be employed such as high-density polyethylene. Suitable blowing agents for the resin include thermally decomposable foaming agents such as sodium bicarbonate, azodicarbonamide and the like, an inert gas such carbon dioxide, nitrogen and the like, or an organic compound having a low boiling point such as butane and the like. Additives may also be incorporated in the resin to enhance the physical characteristics of the formed reel, such as glass fibers or the like, particularly in the skin layer of the formed components, and inorganic fillers such as talc, silica, and the like added as a nucleating agent for the forming foam cells. A conventional flexiblizer component may be added to the resin if desired.
Although the preferred reel 10 is constructed as illustrated and described having a cellular outer face in order to save weight and decrease the cost of the reel 10 , it is to be understood that if desired the wall structure of end flanges 16 and 18 may be essentially of solid construction except for the recesses receiving the ribs 32 of leg segments 26 and 28 . Similarly, support units 24 may be constructed as essentially flat components without the provision of ribs 32 . In these instances, the end flanges 16 and 18 , and support units 24 would desirably be molded of a synthetic resin having a blowing agent incorporated therein to produce end flanges and support units having a high strength to weight ratio.
When formed of the defined resin and constructed of the dimensions described, a 30″ diameter reel having a fully opened width approximating that of the diameter of flanges 16 and 18 will hold at least about 400 pounds of cable, conduit or tubing wound therearound. | A lightweight, collapsible, readily repairable, minimum thickness reel for cable, conduit, tubing or the like and the components of which are preferably molded of synthetic resin material. The end flanges of the reel each have a flat inner surface and a cellular outer surface for decreased weight. Molded, foldable ribbed tubing support units are interposed between the inner surfaces of the end flanges for receiving and supporting cable, conduit or tubing wound therearound when the support units are extended. The planar, inner surfaces of the end flanges have recesses for complementally receiving the rib portions of the leg segments of respective support units so that when the reel is in its collapsed condition the reel is not substantially thicker than the combined thickness of the side by side end flanges. The end flanges are molded of a synthetic resin material in a mold which receives pre-molded leg segments with a release agent thereon which results in concomitant forming of the recesses for the folding leg segments of the support units. A blowing agent may be incorporated in the resin in which the flanges are molded so that a relatively thin, tough, abrasion resistant skin is formed while the interior of the wall structure of the flange is of decreased density. | 1 |
This is a continuation of copending application Ser. No. 07/413,838 filed on Sep. 28, 1989 now abandoned.
BACKGROUND OF THE INVENTION
This invention relates to electrochemical cells.
Fuel cells are a type of electrochemical cell in which the cathodic and anodic reactants are fed to the cell from an external source during operation, rather than being permanently contained within the cell. The reactants contact electrodes which catalyze the reduction of the cathodic reactant and the oxidation of the anodic reactant; the electrodes themselves are not consumed in the reaction. The electrodes also collect the current generated as a result of the electrochemical oxidation and reduction reactions.
Metal-air cells are similar to fuel cells except that only the cathodic reactant is fed to the cell. The anodic reactant is a metal which forms a permanent part of the cell.
Carbon microfibers are fibers having diameters less than 1 micron. Microfibers having diameters less than 0.5 micron are referred to as fibrils.
SUMMARY OF THE INVENTION
In general, the invention features an improved electrochemical cell that includes a catalytic electrode on which an electrochemical reaction occurs into which is incorporated an amount of electrically conductive carbon microfibers having diameters less than or equal to 0.1 micron sufficient to enhance the electrical conductivity of the electrode.
In preferred embodiments, the electrochemical cell is a fuel cell (e.g., a hydrogen/oxygen fuel cell) or a metal-air cell (e.g., in which the metal is zinc).
Preferred microfibers have length to diameter ratios of at least 5. Even more preferred are carbon microfibers that are tubes having graphitic layers that are substantially parallel to the microfiber axis and diameters between 3.5 and 75 nanometers, inclusive, as described in Tennent, U.S. Pat. No. 4,663,230 ("Carbon Fibrils, Method for Producing Same and Compositions Containing Same"), Tennent et al., U.S. Ser. No. 871,676 filed Jun. 6, 1986 ("Novel Carbon Fibrils, Method for Producing Same and Compositions Containing Same"), Tennent et al., U.S. Ser. No. 871,675 filed Jun. 6, 1986 ("Novel Carbon Fibrils, Method for Producing Same and Encapsulated Catalyst"), Snyder et al., U.S. Ser. No. 149,573 filed Jan. 28, 1988 ("Carbon Fibrils"), Mandeville et al., U.S. Ser. No. 285,817 filed Dec. 16, 1988 ("Fibrils"), and McCarthy et al., U.S. Ser. No. 351,967 filed May 15, 1989 ("Surface Treatment of Carbon Microfibers"), all of which are assigned to the same assignee as the present application and are hereby incorporated by reference. One aspect of substantial parallelism is that the projection of the graphite layers on the microfiber axis extends for a relatively long distance in terms of the external diameter of the microfiber (e.g., at least two microfiber diameters, preferably at least five diameters), as described in Snyder et al., U.S. Ser. No. 149,573. These microfibers preferably are also substantially free of a continuous thermal carbon overcoat (i.e. pyrolytically deposited carbon resulting from thermal cracking of the gas feed used to prepare the microfibers). These microfibers also are preferably in the form of aggregates in which individual microfibers are randomly entangled with each other or oriented substantially parallel to each other.
Incorporating small diameter carbon microfibers in one o both of the catalytic electrodes enables the electrode to collect current efficiently. The microfibers also increase the surface area of the electrode.
Other features and advantages of the invention will be apparent from the following description of the preferred embodiments thereof, and from the claims.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
We now describe preferred embodiments of the invention.
Carbon microfibers having diameters less than or equal to 0.1 μm are suitable for incorporation in the catalytic electrodes of a wide variety of fuel cells and metal air cells. Examples of such cells are described in Handbook of Batteries and Fuel Cells, ed. David Linden, ch. 1, p. 10. They include zinc/oxygen (air) cells and hydrogen/oxygen cells. The particular material for the catalytic electrode is chosen based upon the reactants, as one of ordinary skill in the art will readily appreciate. In the case of the zinc/oxygen and hydrogen/oxygen cells, the preferred catalytic material is platinum. The cells are prepared using conventional fabrication techniques.
The carbon microfibers exhibit high electronic conductivity, good corrosion resistance in alkaline and acidic environments, and high accessible surface area. In the fuel cell, they act as a support for the catalytic material (holding it in place and making it accessible to the gaseous reactant) and as a current collector. In the latter application, they increase the electrical conductivity of the electrode by forming an effective electrically conductive network throughout the catalytic electrode material. Preferred microfibers are carbon fibrils having small diameters (preferably between about 3.5 and 75 nanometers), length to diameter ratios of at least 5, and graphitic layers that are substantially parallel to the fibril axis that are also substantially free of a continuous thermal carbon overcoat, as described in Tennent, U.S. Pat. No. 4,663,230; Tennent et al., U.S. Ser. No. 871,676; Tennent et al., U.S. Ser. No. 871,675; Snyder et al., U.S. Ser. No. 149,573; and Mandeville et al., U.S. Ser. No. 285,817. The fibrils may also be treated to introduce oxygen-containing functional groups onto the fibril surface, as described in McCarthy et al., U.S. Ser. No. 351,967, or milled, e.g., by mechanical milling (using a ball or stirred ball mill) or by chemical milling (using chemical reagents such as those described in the aforementioned McCarthy application) to decrease the size of fibril aggregates and the lengths of individual fibers.
When produced in useful quantities, the fibrils are in the form of aggregates of individual fibrils. For example, the process described in Snyder et al., U.S. Ser. No. 149,573 yields aggregates of randomly entangled fibrils resembling bird nests. A second type of aggregate consists of clusters of individual fibrils in which the fibrils are oriented substantially parallel to each other, giving the aggregate the appearance of combed yarn. The lengths and diameters of fibrils in each cluster are essentially uniform, although they may vary from cluster to cluster. These aggregates, and a method for making ,them, are described in Moy, U.S. Ser. No. 07/413,837 entitled "Fibril Aggregates and Method for Making Same" filed concurrently with the present application and assigned to the same assignee as the present application which is hereby incorporated by reference in its entirety.
The substantially parallel graphitic layers of the individual fibrils and small diameters are desirable because they enhance electrical conductivity. The lack of a continuous thermal carbon overcoat leads to enhanced electrical conductivity and oxidation resistance.
Other embodiments are within the following claims. | An improved electrochemical cell that includes a catalytic electrode on which an electrochemical reaction occurs into which is incorporated an amount of electrically conductive carbon microfibers having diameters less than or equal to 0.1 micron sufficient to enhance the electrical conductivity of the electrode. | 2 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] Embodiments of the present invention relate to a coated board product and a method of producing the same.
[0003] 2. Description of Related Art
[0004] In the field of producing paper products, one ongoing goal is to improve the quality of board products, especially boxboard, and the economy of producing the same.
[0005] Board is required to have a certain surface quality for ensuring a desired gloss and print quality, and a stiffness and tear resistance for securing the functionality of a package. Since board is produced in large quantities in a board mill, the efficient use of raw material is also important. However, these demands are somewhat contradictory to each other. Board can be provided with a sufficient gloss by calendering the board by compressing it in a nip, often moistened and heated in a certain manner. The surface fibers and coating of board are preferably pressed smooth by this compression, yet without compacting the middle ply of board. The compaction of a middle ply undermines board stiffness and reduces tear resistance. The compaction of a middle ply is often referred to as a loss of bulk. In this case, bulk is understood as being an inverse value to density and a loss thereof is thus equal to a densifying compaction of paper or board.
[0006] Since the process of making paper and board is highly raw material intensive, even a minor saving in raw material provides a major advantage over competitors. In this respect, a saving of just one percent can be considered a major competitive edge and the investment restitution time is short. Saving raw material is also desirable for environmental reasons. By virtue of a reduced weight structure, the multiplicative effects of the board of this invention cover the product's entire life span, the reduced consumption of raw material resulting in a lighter container which ultimately creates savings also in shipping operations and in the way of a reduced amount of waste.
[0007] Packing boards are often coated or multi-ply structured. Basic board consists typically of three plies of fiber, wherein the top and back plies are made of bleached pulp. The filler ply consists often of mechanical pulp, typically groundwood (GW), but in many cases also pressure groundwood (PGW) and chemithermo-mechanical pulp (CTMP), or the filler ply can also be made by using broke. The face of board is generally coated twice and the back once. Coating and sizing are used for providing desired properties. A typical basis weight range for boxboards is 180-350 g/m 2 . The necessary basis weight depends on a required stiffness of the container, a lighter board being sufficient for small boxes. Successful conservation of board bulk in surface treatment to produce thereby board of a higher stiffness results in savings of raw material and energy by enabling the use of board of a lesser basis weight. Typical applications for board include cigarette packages, pharmaceutical packages, postcards, cardboard covers for books, various food packages.
[0008] Boxboards are often smoothed with a Yankee cylinder prior to coating, which provides a good bulk and stiffness, the surface properties being also good, the drying shrinkage along the edges being likewise small, yet the use of a Yankee cylinder is limited by speed restraint, space demand for equipment and the enormous size of a Yankee cylinder in a high-speed machine. Another typical treatment method involves a wet-stack calender, the drawbacks of which include problems regarding runnability and a controlled application of water and, in addition, extra costs are incurred by the necessity of drying the board before and after a calendering process.
[0009] A machine calender is often used together with other calenders, the machine calender referring to a hard calender with no elasticity in its rolls. The use of a machine calender as the sole surface treatment method is not advisable. A soft calender refers to a soft-nip calender, wherein the calender roll has a surface which is elastic, the surface having possibly a hardness in the same order as the surface hardness of wood, yet being elastic.
BRIEF SUMMARY OF THE INVENTION
[0010] The above and other needs are met by the present invention which, in one embodiment, provides a method of making a boxboard product having a smooth printing surface, a high gloss and stiffness in the boxboard with a lesser-than-before consumption of material, and avoiding bottlenecks and improving runnability in the production process. In one embodiment, the coated container board of the invention comprises two or more plies of fiber, wherein the outside plies consist of bleached chemical pulp and the inner plies of mechanical pulp or chemithermo-mechanical pulp or broke.
[0011] According to the invention, boxboard is treated with a long-nip calender prior to coating or during its coating process in order to upgrade the board qualities over what is known before and, in addition, the production runnability is improved and the production method is not subject to a speed restraint the same way as a Yankee cylinder. A long-nip calender suitable for making a board of the invention has been described, for example, in U.S. Pat. No. 6,164,198 also assigned to the assignee of the present invention.
[0012] A calender suitable for the surface treatment of a board of the invention includes a fixed support element, around which is a tubular jacket. A heated counter-element is disposed on the other side of the tubular jacket from the support element, such that a web passes through between said counter-element and the tubular jacket. The fixed support element is provided with load elements, applying the jacket against the heated counter-element and thereby enabling a calendering process between the jacket and the counter-element. The jacket has its opposite ends secured to end walls mounted rotatably relative to the support element, the rotary motion of the end walls being delivered by a separate drive motor, which is independent of a motion of the fibrous web in order to avoid overheating of the jacket.
[0013] A method of the invention for conditioning the surface of coated or uncoated board with a surface conditioning device is in turn characterized in that the method comprises feeding a fibrous web through a long nip established by a roll and a counter-roll, the former being in the form of a tubular-shaped flexible jacket. Across the extent of the nip the jacket deflects and thereby presses into contact with the counter-roll over a long stretch. The board treated with the method is lighter than currently available boards, while stiffness and surface properties are equal to those of currently available boards.
[0014] The solution enables a running speed substantially higher than what is accomplished with a Yankee-cylinder equipped board-machine. In addition, the runnability is better, this also contributing to improved quality and reducing waste.
[0015] Web speed in the calender may be higher than 600 m/min, preferably higher than 800 m/min, and still more preferably 1000 m/min, yet lower than 4000 m/min. Thus, the calender does not restrict the speed of a board machine. The above-mentioned heated roll has a temperature of 150-350° C., preferably higher than 170° C., most preferably about 200-250° C. Linear pressure in the nip is within the range of 100-500 kN/m, preferably less than 400 kN/m, most preferably about 50-300 kN/m. Maximum pressure in the nip is 3-15 MPa, preferably less than 13 MPa, most preferably about 0.5-8 MPa.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING(S)
[0016] Having thus described the invention in general terms, reference will now be made to the accompanying drawings, which are not necessarily drawn to scale, and wherein:
[0017] FIG. 1 is a sectional view of a long-nip calender, provided with a long nip between an enclosed shoe calender and a counter-roll;
[0018] FIG. 1A is a partial enlargement of FIG. 1 ;
[0019] FIG. 2A is a partial sectional view of the device shown in FIG. 1 , along the roll axis and depicting a drive mechanism; and
[0020] FIG. 2B shows the operation of press shoes in a longitudinal section.
DETAILED DESCRIPTION OF THE INVENTION
[0021] The present inventions now will be described more fully hereinafter with reference to the accompanying drawings, in which some, but not all embodiments of the inventions are shown. Indeed, these inventions may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will satisfy applicable legal requirements. Like numbers refer to like elements throughout.
[0022] In FIG. 1 , a board web 80 travels through an extended and heated nip 1 . The nip 1 is established by an enclosed shoe roll 10 present under the web 80 . Above the web 80 is a heatable counter-roll 22 . The enclosed shoe roll 10 comprises a flexible jacket 12 impervious to liquid. The jacket consists for example of fiber-reinforced polyurethane. The stationary fixed support element 14 carries at least one load shoe 18 . Between the load shoe 18 and the support element is an actuator 20 , such as a hydraulic cylinder, for urging the concave load shoe 18 and thereby also the flexible jacket 12 against the counter-roll 22 . Thus, the jacket 12 is forced out of its normal unloaded position 11 in a direction away from the center of the enclosed shoe roll. The jacket 12 is fastened at both ends thereof to end walls 24 , 26 , thus creating a sealed compartment 13 (see FIG. 2 ). As shown also in FIG. 1 , at least one detector device 99 is mounted in communication with the web 80 for detecting web breaks. The detector device 99 is connected to a control device 98 for controlling the operation of a calendering process in dependence of the web being broken or not.
[0023] As shown in FIG. 1 , the heatable counter-roll 22 is accompanied by a disengagement mechanism, comprising a lever 95 pivotable by a hydraulic cylinder assembly 94 and provided with a pivot point 96 for pivoting the lever thereon. The disengagement mechanism presses the counter-roll 22 to an engagement with the nip 1 and disengages it from the nip 1 .
[0024] Between the load shoe 18 and the jacket 12 is supplied a pressurized oil, which develops a hydrostatic pressure throughout the nip and presses the jacket to an engagement with the counter-roll 22 over the entire extent of the nip 1 . At the same time, the oil protects the jacket from being damaged by lumps and a temperature rise.
[0025] In FIG. 2A it is shown that the end walls 24 , 26 are rotatably mounted on stub shafts 16 , 17 of the support element 14 (The end walls are preferably not integral but divided into a static part and a rotating part as shown in FIG. 2B ). On one end of the stub shaft, a cylindrical shaft 32 is arranged rotatably via bearings 34 . A support column 36 is arranged to the cylindrical shaft via self-aligning bearings 38 , which allow spherical movement to allow the deformation/bending of the support element 14 when heavily loaded. One of the end walls 24 is fixedly attached to the cylindrical shaft. A drive transmission 40 is fixedly attached to the cylindrical shaft outside the end wall, in the shown embodiment a cog wheel. The cog wheel is connected to a transmission 42 and in turn a drive 44 . A cog wheel 46 is fixedly attached to the cylindrical shaft inside the end wall. A drive shaft 48 is arranged inside the jacket and parallel to the support element 14 . The drive shaft 48 is supported by bearings 50 arranged in bearing houses 52 attached to the support element. At each end of the drive shaft, cog wheels 54 are arranged. Preferably these cog wheels have a prolonged toothed portion to allow axial movement of the intermeshing cog wheel which is attached to the end wall. A further cog wheel 56 is fixedly attached to the second end wall 26 inside the jacket. Both cog wheels inside the jacket mesh with the corresponding cog wheel on the drive shaft. The second end wall 26 is rotatably arranged on the second stub shaft 17 . The second stub shaft is in turn fixedly attached to a second support column 58 .
[0026] The operation is as follows. During normal operation, the driven heated roll 22 is in interaction with the fibrous web and the flexible jacket 12 by a desired pressure being exerted by the load shoe 18 , thereby causing a friction based drive of both the fibrous web and the flexible jacket. Accordingly, during normal operation the forces exerted in the nip provide for rotation of the enclosed shoe roll.
[0027] Only in specific occasions, it will normally be desirable to operate the independent drive of the enclosed shoe roll 10 , for example when starting up the calender. If the calender should be started without first speeding up the flexible jacket 12 , this would inevitably cause damage to the flexible jacket due to overheating. Furthermore, it would also be deteriorating for the fibrous web, since at the moment of start it would develop exceptional tension forces in the fibrous web. Accordingly, the independent drive arrangement of the enclosed shoe roll is to be used for instance at the start-up of the calendering surface. At the start, the nip gap is not closed, but the roll 22 has been moved out of contact with the nip 1 . Before moving the heated counter-roll 22 into the nip, the drive arrangement 44 of the enclosed shoe roll 10 is activated to accelerate the first end wall 24 via transmissions. The rotation of the end wall causes the inner first cog wheel 46 to rotate, and subsequently the drive shaft 48 . The drive shaft transmits the rotation to the second end wall 26 via the second inner cog wheel 56 . The both end walls are thus accelerated and rotate at the same speed until a desired peripheral speed is obtained, which is normally equal to the speed of the fibrous web. The nip is closed by activating the hydraulic piston 94 to pivot the lever 95 and thereby moving the counter-roll 22 into the nip and subsequently the load shoe 18 is urged against the heated roll 22 by its actuators 20 . Once the calender functions in the desired manner, the drive arrangement of the enclosed shoe roll can be deactivated and the press roll driven in a conventional manner by friction within the nip 1 .
[0028] In FIG. 2B there is shown an alternative embodiment of the drive arrangement for an enclosed shoe roll. This embodiment uses friction for the transmission of rotational forces.
[0029] FIG. 2B also shows a design of arranging the support element and the end walls. The end walls are divided into inner parts 24 A, 26 A connected non-rotatably to the support element 14 , a rotational part 24 B, 26 B, and a bearing assembly 24 C, 26 C therebetween. The support element 14 is at its ends arranged with self-aligning bearings 23 , 25 to allow a deflection of the support element 14 .
[0030] In the figure there is shown a drive 44 having a shaft 19 B. On the shaft 19 B is mounted a disc 19 having a rubber layer at its peripheral end 19 A. The outer ends of the flexible jacket 12 are fixedly attached between an annular ring 15 , acting as a replaceable force transmitting device, and the periphery of each end wall. The ring 15 is fixedly attached to the end wall. On the inside of the rotational part 24 B, 26 B of each end wall there is fixedly attached a cog wheel 46 , 56 . The drive arrangement 44 , 19 is movable in and out of contact with the force transmitting device 15 . When it is desired to accelerate the enclosed shoe roll 10 , the drive arrangement is moved such that the rubber layer 19 A comes into frictional engagement with the force transmitting device 15 . The cog wheel 46 and the drive shaft 48 transmit the rotation of the end wall 24 to the other end wall 26 by the cog wheels 54 , 55 and 56 , which at the same time function as a synchronizing device. Hence, both end walls 24 , 26 are operated as described in reference to FIG. 2A . FIG. 2B further illustrates in a schematic view one functional embodiment of the load shoe 18 . Generally, the load shoe 18 is not disposed diametrically relative to the drive shaft, but perpendicularly as in FIG. 2A .
[0031] Tests conducted by the assignee indicated that, in test batches manufactured by a long-nip calender as described above, the board could be provided with a ratio of bulk and smoothness better than in currently available types of board. Thus, according to measurements, the goals of the invention are achieved.
[0032] Shoe calenders can be driven at high speeds and, furthermore, by the application of an elevated temperature, e.g. about 250° C., and by taking into account a long dwell time in the calendering zone, the resulting gloss finish will be equal to what is achieved in a slower solution using a Yankee cylinder. In addition, the board is provided with improved bulk. In addition to aspects contributing directly to board quality, the results include savings of production space in a mill, the elimination of a production limiting Yankee cylinder, and the provision of a more manageable, more easily controlled system.
[0033] In view of producing board of the invention, surface moistening can be provided prior to calendering. However, the inventive board can also be produced without surface moistening.
[0034] Conducted tests showed that better surface properties were obtained for board with equal bulk. Test runs were performed on board which was calendered with the above-described long-nip calender without smoothing it with a Yankee cylinder:
Methods Measured For The Same Grade Of Board Precalendering Conditions Board Properties Linear Added Bendtsen PPS Temper- pressure water Bulk roughness roughness Hunter ature ° C. kN/m g/m 2 cm 3 /g ml/min μm gloss Yankee reference — — — 1.83 22 1.4 35 Shoe calender 200 100 4 1.84 41 1.5 33 Shoe calender 200 200 4 1.82 25 1.3 32 Shoe calender 250 100 4 1.82 16 1.2 33 Shoe calender 250 200 4 1.82 17 1.2 32
In the test run, reference board and pilot-calendered board were coated twice in a blade coating station, the total amount of coating being about 24 g/m 2 . The products received no final calendering.
[0035] Hence, without affecting bulk, the result showed less roughness and more gloss than what was achieved with the Yankee reference. Based on experience, the interpretation of test results represents a progressive step, regarding for example the quality and production economy of boxboard. In general, pilot tests provide results are somewhat less indicative than those achieved in the ultimate environment, so even on the basis of these preliminary tests, it is possible to draw a conclusion that the method is capable of producing board that is better than before and at the same time more easily and economically producible. In addition, the method is applicable to considerably higher speeds than a Yankee cylinder.
[0036] Many modifications and other embodiments of the inventions set forth herein will come to mind to one skilled in the art to which these inventions pertain having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. Therefore, it is to be understood that the inventions are not to be limited to the specific embodiments disclosed and that modifications and other embodiments are intended to be included within the scope of the appended claims. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation. | A method of forming a coated boxboard product is provided. A boxboard product is formed without being processed by a Yankee dryer, and further comprises a plurality of fiber plies, including outermost plies forming the top and back sides and comprised of bleached chemical pulp, and medial plies disposed between the outermost plies and comprised of groundwood, pressure groundwood, chemithermo-mechanical pulp, recycled pulp, and/or broke. The boxboard product is precalendered with a surface conditioning device and then coated such that the coated boxboard product has a density of between about 500 kg/m 3 and about 1000 kg/m 3 , and a basis weight of between about 150 g/m 2 and about 400 g/m 2 , and the top side has a PPS-s10 roughness of between about 0.5 μm and about 2.0 μm and a Hunter gloss of between about 35% and about 80%. | 3 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application contains subject matter which is common to our pending application Ser. No. 07/176,075, filed Mar. 31, 1988, which was a continuation of application Ser. No. 06/766,846, filed Aug. 16, 1985, and now abandoned, and this application contains subject matter which is common to our co-pending application Ser. No. 07/202,338, filed June 6, 1988, which was a continuation of application Ser. No. 06/915,140, filed Oct. 3, 1986 and now U.S. Pat. No. 4,777,789, issued Oct. 18, 1988.
BACKGROUND OF THE INVENTION
The present invention relates generally to yarns, fabrics and protective garments knitted of such yarns and, more particularly, to an improved yarn which may be knitted into an improved, more comfortable, more flexible protective garment such as a glove.
Prior to the present invention, technological developments of cut resistant yarns for protective garments have followed essentially a two-pronged approach. The first approach was in connection with the use of Kevlar, which is a Dupont trademark for an aramid fiber, with the Kevlar fiber to be used in yarns for protective garments. By way of example and not by way of limitation, aramid fibers have been used to form yarns, with the yarns thereafter knitted to make protective garments, including protective gloves, as exemplified by Byrnes U.S. Pat. No. 3,883,898. In addition to the aramid yarn, aramid fibers have been used in combination with other materials such as wire to form a protective garment, such as a protective glove, with an increased/or cut-resistance. Examples of this concept may be found in Byrnes U.S. Pat. No. 4,004,295 and Byrnes et al. U.S. Pat. No. 4,384,449. This latter-most Brynes patent describes a particular yarn configuration, namely, a four-piece yarn configuration including a core and a covering. The core is composed of two parallel strands, one wire and one aramid fiber, and the covering is composed of two strand spirally-wrapped around the core, one clockwise and one counterclockwise, both of aramid fiber. This approach was expanded upon in Bettcher U.S. Pat. No. 4,470,251 where the yarn is made up of five pieces; three parallel strands comprising the core, and two wrappings comprising the cover. The Bettcher patent generally describes the core as comprising two wires and one aramid fiber, and the two wrappings with the first, or inner wrapping, being a high-strength synthetic fiber such as aramid and an outer wrapping preferably comprising three strands of nylon. This Bettcher patent further describes yet another version of the yarn, namely, a seven piece yarn with generally the same core as the five piece yarn. The first wrapping (closest to the core) is preferably an aramid. The next outermost wrapping is also an aramid, the next outermost wrapping is a three strand nylon, and the outermost wrapping is a three strand nylon.
In our prior applications, we disclosed the use of extended-chain polyethylene, such as the fiber manufactured by Allied-Signal, Inc., under the trademark Spectra in combination with other fibers and wire and in various configurations, for the purpose of an improved cut resistant or slash resistant yarn and garment. We explained the use of extended use polyethylene as avoiding numerous limitations and problems which occurred with the use of aramid fiber, such as, but not limited to, the fact that the polyethylene fiber has a substantially greater tensile strength than the comparable aramid fiber, the fact that polyethylene fiber is resistant to ultraviolet light and does not result in undesirable color change, as contrasted to aramid fiber, that the polyethylene fiber has increased abrasion resistance comparable to aramid, has only two-thirds of the density, has greater chemical resistance, and is inert, non-absorptive, non-allergenic and stable.
Unfortunately, there are certain limitations when extended-chain polyethylene fibers are utilized in a yarn for a protective garment. One of the most substantial limitations is that the extended-chain polyethylene fiber has an extremely limited heat resistance and, thus, when gloves knitted of yarns using extended-chain polyethylene are utilized, for example, in the food industry, the extended chain polyethylene fibers can not withstand the high temperature used for laundering and drying the gloves.
We overcame some but not all of these problems in a composite wire-fiber yarn and glove knitted therefrom, in the configuration described in our aforementioned U.S. Pat. No. 4,777,789, which illustrates various configurations of yarn in FIGS. 1, 2 and 5, the yarn including both wire and fiber, and we described how fibers, other than aramid and extended-chain polyethylene, may be used.
However, in many industries it is not desirable to utilize yarns and protective garments such as gloves which contain wire. As previously indicated, the wire may break and injure the hand of the wearer. In addition, gloves or garments made of yarn which contains wire will be electrically conductive, which is unsuitable for certain purposes. Wire, of course, is also thermally conductive.
Thus the yarns containing wire and either extended-chain polyethylenes, or aramids, have numerous limitations.
SUMMARY OF THE INVENTION
The present invention relates to a new and improved yarn and protective garment, such as a glove, formed of the yarn. This invention is based on our discovery that a cut-resistant or slash resistant yarn suitable for industrial use, can now be made from fibers which are free of wire, free of extended-chain polyethylene and free of aramid, while providing substantially the same cut resistance or slash resistance as the yarns and protective garments described in our prior applications and in the prior art referred to above.
The yarn and glove, according to the present invention, have numerous advantages over the prior art yarns and gloves as heretofore described, while maintaining substantial cut resistance and slash resistance, and the yarn, according to the present invention, may be formed on a conventional covering machine, may be utilized in conventional knitting or weaving machines and is of substantially lower cost than yarns which include the extended-chain polyethylene or aramid fibers.
BRIEF DESCRIPTION OF THE DRAWINGS
The various benefits and advantages of the present invention will be more apparent upon reading the following detailed description of the invention taken in conjunction with the drawings.
In the drawings, wherein like reference numerals identify corresponding components:
FIGS. 1 through 4 are illustrations of yarns in accordance with the principles of the present invention; and
FIG. 5 is an illustration of a protective garment, namely, a glove, made from a yarn according to the principles of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
Referring first to FIG. 1, a yarn 10 is illustrated according to the principles of the present invention, the yarn including a core and a covering. The core is illustrated as having tWo strands 12, 14. The strands are illustrated as being placed parallel to each other, although it is within the spirit of the present invention that the core strands may be wrapped, twisted or braided together. The core strands include a first fiber strand 12 and a second fiber strand 14. The core strand 12 may be formed of fiberglass, and the core strand 14 may be formed of fiberglass, nylon, polyester, polycotton, asbestos, wool or regular (i.e., non-extended chain) polyethylene.
Surrounding the core is a covering comprising first and second strands 16, 18, wrapped in opposite directions relative to each other around the core. The covering strands may likewise be of fiberglass, nylon, polycotton, asbestos, wool, regular polyethylene or polyester.
With respect to the details of the fibers, the fiberglass may be either E-glass or S-glass, either continuous filament or spun and having a denier between about 300 and about 2,000. Fiberglass fibers of this type are manufactured both by Corning and by PPG and are characterized by various properties such as relatively high tenacity, of about 12 to about 20 grams per denier, and by resistance to most acids and alkalies, by being unaffected by bleaches and solvents, and by resistance to environmental conditions such as mildew and sunlight and highly resistant to abrasion and to aging.
The fiber strand which is not made of fiberglass fiber may be nylon 6 or nylon 6,6 or polyester or one of the other fibers referred to above. The preferred denier range may be from about 400 to about 1,500 and the fiber may be filament or spun. Preferably, when nylon is used, it will be a pre-shrunk or low-shrink nylon. When a polyester fiber is utilized, it is characterized by good resistance to most acids except sulfuric acid and good resistance to alkalies except strong alkalies at boiling temperature. Furthermore, polyester exhibits excellent resistance to bleaches and solvents and excellent resistance to mildew, aging and abrasion. Polyester has good resistance to sunlight, but prolonged exposure to sunlight may cause some loss in strength. Nylon, of course, resists weak acids but is degraded by strong oxidizing agents, and nylon is substantially inert in alkalies, nylon generally can be bleached and dyed, and has excellent resistance to mildew, aging and abrasion. Nylon has good resistance to sunlight, although prolonged exposure to sunlight can cause some deterioration.
At this point, it may be helpful to explain some of the benefits of the yarn heretofore described when compared to the yarn of the prior art. By prior art, we are referring to the yarns using aramids plus wire or extended-chain polyethylenes plus wire as described previously in this patent application and in the prior art referred to herein, and as heretofore commercialized for use in cut resistant gloves or cut resistant garments.
There are certain well-known shortcomings when aramid is utilized. Since it is necessary to launder cut resistant gloves, especially if the gloves are being worn in meat processing industries, it must be recognized that aramids have essentially no resistance to bleach. Equally significant and limiting is that aramids do not resist abrasion. A glove, knitted of the yarn of the present invention, which is free of aramid and free of wire, has equivalent cut resistance to a glove knitted of the yarn of wire and aramid of the same total denier plus exhibits resistance to bleaches and substantially higher abrasion resistance.
When comparing a glove knitted from the yarn of the present invention to a glove knitted from yarn of extended-chain polyethylene and wire, according to the aforementioned prior patents, patent applications and commercially available products the glove of the present invention has at least equivalent cut resistance to gloves including wire and extended chain polyethylene of the same denier, and the glove of the present invention can withstand the heat necessary for laundering. The extended-chain polyethylene yarns typically have a maximum temperature or heat limit of approximately 2201/2 F. after which degradation and/or decomposition take place.
There are several additional benefits of the glove knitted from the yarn of the present invention as compared to gloves made of a yarn comprising aramid and wire and a glove made of a yarn comprising extended-chain polyethylene and wire. For example, wire tends to kink or knuckle and fracture during knitting and during laundering. In addition, when a glove containing wire is slashed with a knife, the wire can be nicked or cut, thus, creating additional wire ends. All of these wire ends can scratch or puncture the skin of the wearer of the glove. If the wire breaks prior to or during the knitting, there can be jamming of the knitting equipment and the resulting waste of yarn and partially-knitted gloves.
The yarn, according to the principles of the present invention, being free of wire, does not have the aforementioned problems, and, in addition, the yarn is softer for the hand, providing better feel and control for the wearer of a glove knitted from such a yarn and is more pliable in the knitting machines.
Perhaps one of the greatest attributes of the yarn of the present invention, as contrasted to the prior art yarn, is that the raw material price of a yarn, according to the principles of the present invention, is about one-fifth to one-sixth of the price of the raw materials for an aramid-wire yarn or an extended-chain polyethylene-wire yarn with the same denier and the same cut or slash resistance.
According to the principles of the present invention, a preferred fiberglass heretofore used is E-glass with a denier of about 650 in the core. The preferred range of denier of the fiberglass is from about 300 to about 2000.
Referring next to FIG. 2, a yarn 20 is illustrated comprising a core and covering. The core is illustrated as comprising three strands 22, 23, 24, which may be parallel, braided or twisted. At least one of the strands is preferably formed of fiberglass. Each of the other two strands may be fiberglass, nylon, polyester or other fiber as heretofore described excluding, of course, aramid and extended chain polyethylene. The covering for the core includes at least two strands 26, 28, wrapped about the core in opposite directions relative to each other such as a first wrap in a clockwise direction and a second wrap in a counterclockwise direction. The covering strands 26, 28 may be fiberglass, nylon or polyester, or the other fibers referred to above. Thus, for the purposes of comparison, the yarn of FIG. 1 may be thought of as comprised of four pieces or four plies or four ends while the yarn of FIG. 2 may be thought of as including five pieces or five plies.
Referring next to FIG. 3, yet another form of the yarn of the present invention is illustrated, this also being a five piece or five ply yarn 30. The yarn 30 includes a core and a covering, the core including two strands 32, 34, at least one of which is fiberglass, and the covering including three strands 36, 37 and 38, two of which are wrapped in the same direction around the core, and the third being wrapped around the core in a direction opposite to the other covering strands. Thus, for the purpose of illustration, the covering comprising strands 36, 37 and 38 includes an innermost covering strand 36 wrapped in a first direction about the core, a second covering strand 37 wrapped around both the core and the first covering strand 36, in a direction opposite to the direction of covering strand 36, and an outermost covering strand 38, wrapped about the covering strand 37 in a direction opposite to the direction of wrapping of covering strand 37 and identical to the direction of the wrapping of covering strand 36.
Referring next to FIG. 4, a yarn 40 is illustrated as a six piece or six ply yarn. The yarn 40 includes a core and a covering, the core including two strands 42, 44, at least one of which is fiberglass, and the covering including four strands 46, 47, 48 and 49. The covering strands are wrapped about the core, the covering strands are sequentially applied to the core, and each strand is wrapped in the direction opposite to the direction of the immediately preceding cover strand. Thus, in the illustrated embodiment, a first covering strand 46 is wrapped in a first direction about the core, a second covering strand 47 is wrapped about the core in a direction opposite to the direction of the wrapping of cover strand 46, and, of course, covering strand 47 is also wrapped around portions of the covering strand 46. Thereafter, a third covering strand 48 is wrapped around the core in the same direction as covering strand 46 and the third covering strand 48 will, of course, cover not only the core but also covering strands 46 and 47. Lastly, a fourth covering strand 49 is wrapped about the core in the direction opposite to the direction of wrap of covering strand 48 and, hence, in the same direction of wrap as covering strand 47. Covering strand 49 is the outermost wrap and therefore encircles not only the core but all the preceding covering strands.
The yarn, according to the principles of the present invention, may be formed on a standard hollow spindle covering machine with the coverings or wrappings being at the rate of 4-12 turns per inch, with 8 turns per inch being preferred. The yarn according to any of the embodiments of the present invention may be knit into a glove 50 on a conventional knitting machine such as, but not limited to, a Shima Seiki machine. The cut resistant yarn of the present invention may also be woven or knitted to form other protective garments.
The fibers used in the yarn of the present invention should typically have a denier in the range of about 185 to about 2000, with a range of 375 to about 1000 being preferred for the core and a range of 500 to 1000 being preferred for the covering. By way of comparison, if a four ply yarn is provided according to the principles of the present invention, the two core strands may each have a denier of about 650 and the two covering strands may each have a denier of about 1000. Thus the denier of the composite yarn is just over 3500 since denier are not additive because of the wrapping of the covering on the core. A glove knitted of such a yarn has equivalent cut resistance to a yarn made of a core and covering, the core including wire of about 0.0045 inch diameter and a fiber of aramid or extended chain polyethylene and the covering including two wrappings of nylon or extended chain polyethylene or aramid, or combinations thereof, with an equivalent total denier. The preferred total denier of the yarn should generally be in the range of about 3000 to about 6000.
For ease of reference it is pointed out that fibers such as fiberglass, aramids and extended chain polyethylene typically have a tenacity greater than 10 grams per denier while the other fibers referred to herein have a tenacity less than 10 grams per denier.
The foregoing is a complete description of the present invention. Various changes and modifications may be made without departing from the spirit and scope of the invention and, hence, the invention should be limited only by the following claims. | An improved yarn, fabric and protective garment made from such yarn, where the yarn, fabric and garment exhibit increased cut resistance, flexibility, pliability and softness. The yarn is non-metallic and includes a core made of fiber and a covering wrapped around the core. At least one of the strands is fiberglass, the non-fiberglass strands are preferably nylon or polyester. | 3 |
This application is a continuation-in-part of Ser. No. 722,918, filed Sept. 13, 1976, now abandoned.
BACKGROUND OF THE INVENTION
The present invention relates to a process and apparatus for producing molded articles formed from thermosetting epoxy resin mixtures.
Apparatus for the processing of thermosettable epoxy resin mixtures used heretofore consisted of a heated mold, generally having two separable parts, a locking device for sealing the mold, a pressure hose and valve element, and a pressure vessel. Liquid mixtures of epoxy resins were premixed in an ordinary vacuum mixer and consisted of resin, hardener, mineral fillers, short fiberglass filaments having a length of 1 mm or above, and accelerator. The mixture was introduced at room temperature into the pressure vessel and was injected therefrom at a pressure of 2 atmospheres or above by means of the pressure hose into the mold which was generally preheated to 150° C. or above. The resultant temperature rise of more than 140° C. accelerates the reaction of the resin mixture so that curing progressed sufficiently in less than 35 minutes for the molded piece to be rigid enough to be removed from the mold.
A drawback of this process was that the compressed air which filled upper portions of the pressure vessel penetrated the upper layer of the liquid therein which, in the case of an affected surface area of 2000 sq.cm. and an average viscosity of the molding resin compound of 15,000 cP, resulted in air penetrating the liquid to a depth of approximately 20 mm. The consequent inclusion of bubbles in the molded articles obtained from this gas-saturated layer of molding compound could not be avoided. In electrical components, where the molded articles were to be employed as e.g. support insulators for high voltage applications, the ultimate electrical strength of such articles was impaired. Additionally the presence of voids in the molded articles also led to partial discharges or arcing when electrical fields were applied.
In order to achieve satisfactory crosslinking with short fiberglass filament-filled resin mixtures; the resin binders must be subjected, prior to final mixing to a heat setting with pure epoxy resin, which complicates the preparation process.
SUMMARY OF THE INVENTION
The present invention is intended to overcome the foregoing disadvantages and to provide uniform, fiberglass-reinforced, void-free, homogeneous molded products.
It is one object of the invention to provide a process for the production of molded articles from epoxy resin admixtures which avoids the formation of voids in such articles.
Another object of the invention is the provision of a process for the production of molded articles from epoxy resin admixtures which facilitate the incorporation of mineral fillers in the admixture.
Yet another object of the invention is the provision of a process for the production of movable articles from epoxy resins which improves the storability of premixtures of the molding composition.
Still another object of the invention is the provision of a process for the production of molded articles from epoxy resin which are reinforced with fiberglass and are less susceptible to contamination.
Further objects of the invention involve the provision of apparatus adopted to permit the carrying out of the process of the invention.
Other objects and advantages of the invention will become readily apparent to persons skilled in the art from the ensuring description of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
In order that the invention may be more fully comprehended it will now be described, by way of example, with reference to the accompanying drawings in which:
FIG. 1 is a side elevational view, partly in cross section showing apparatus embodying the features of the invention;
FIG. 2 is an end elevational view of the apparatus of FIG. 1 taken along line A--A thereof;
FIG. 3 is an elevational view of one half of a mixing pipe in a partially assembled state;
FIG. 4 is an elevational view of a mixing pipe in its assembled state formed from segments as shown in FIG. 3;
FIG. 5 is a side elevational view, partly broken away, of one form of premixer utilizable with the apparatus of this invention;
FIG. 6 is a schematic illustration of a complete molding system;
FIG. 7 is a fragmentary side elevational view, partly in cross-section of certain components of the overall molding system including the mixing tube, valve mold and movable carriage for the valve mixing tube;
FIG. 8 is a perspective view of a mechanism for positioning of a reinforcing element within the mold;
FIG. 9 illustrates a suitable fiber glass reinforcing element; and
FIG. 10 is a longitudinal section through an injection mold for a drive-shaft f.e. for a motor vehicle.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Before explaining the present invention in detail, it is to be understood that the invention is not limited in its application to the details of construction and arrangement of parts illustrated in the accompanying drawings since the invention is capable of other embodiments and of being practiced or carried out in various ways. Also, it is to be understood that the phraselogy and terminology employed is for the purpose of description and not of limitation.
Referring to the drawings in which like parts are similarly designated there is shown a mold 1 mounted in a frame which includes wall elements 3 and 4 and side heating plates 2 and 2a. The frame is adapted to maintain therewithin a vacuum pressure as will become clear. One wall of the frame is provided with an inlet member 5 within which, by means of flange member 6, there is slidably mounted hollow cylinder or piston rod 7 and a piston 8, such piston and hollow piston rod constituting, and being movable as, an assembly so as to permit pressured engagement of an orifice 9 at the end of piston rod 7 against the mold 1 for introduction of molding material thereinto, as will become clear.
A controllable cut-off or valve member 10 is situated in close proximity to a hose 27 which is connected at one end (not shown) with a source of molding feed material. Member 10 is designed to serve as a hose squeezer valve and includes, as a contact base for the exerting of compression onto the hose 27 an arcuate guide element 12. The external contour of the hose 27 is that of an equilateral hyperbola. The configuration of the guide element 12 makes it possible to coact with the somewhat complementary shape of the hose 27 so as to apply a gradually effective pressure thereon and thus effectuate relief of the compression chamber within the hollow cylinder 7 which is under the pressure of the resinous molding material feed thereto.
Referring particularly to FIGS. 2, 8 and 9 there is mounted on top of mold 1 a clamping device C adapted to position within the mold a reinforcing element 13 such as a fiberglass fabric (FIGS. 8, 9). The clamping device includes a block 14 having a longitudinally extending slot 15 therein dimensioned to receive one position of the reinforcing element. The block is given a longitudinal bore within which there is rotatably carried a slotted pin member 16 which is in turn provided with a handle element H. As will be appreciated, rotation of handle H will serve to concomitantly rotate pin member 16 and stretch or prestress the reinforcing element 13, which is secured at its opposed end within an insert element 15'. Insert element 15' thus assists in pretensioning the reinforcing element 13, enforcing the molded article.
In the upper portion of the frame there is shown a venting valve 17, a heated inspection glass 18, and a vacuum connection fitting 19. A vacuum line 20 is shown diagramatically in FIG. 1 with a pressure gauge 21, check valve 22, vacuum pump 23, and cold trap 24 cooled by means of Peltier elements 25. The trap 24 may thus be provided with series-connected glass plates which are cooled by the Peltier elements 25. Consequently, the gases supplied by the vacuum pump are cooled at the heat exchanger surface by at least 10° C. Only purified amounts of residual gas without harmful substances are capable of expansion.
FIG. 3 depicts one half of a segmented two-part mixing pipe 26 having an interchageable connecting piece, 27, support rings 28, and static mixing elements 29 inserted between the support rings. A pressure connection member 30 is shown positioned within the end of the mixing pipe remote from connecting piece 27.
FIG. 4 shows the two halves of the mixing pipe joined by screws 29', a pressure connection member 31 for a first premixed protion of a molding composition, a pressure connection member 32 for a second premixed portion of the molding composition and a connecting flange 33 for the mounting of the cut-off element 10 (FIG. 1), as well as a pressure-sensing element 34 for the control and regulation of pressure-dependent feeder pumps to be described.
In FIG. 5 there is shown one form of premixer 35 which may be employed to premix portions of the molding composition prior to introduction into the mixing pipe 26. The premixer comprises a container or mixing tank 36 having a suction pipe 37 and a discharge pipe 38. A stirrer member 39 is mounted for rotation within mixing tank 36 and is driven by electric-motor 40. The premixer includes a cover 41 which can be closed during the degassing of the feed material. In order to more efficiently degas the material, there is connected by means of flanges to suction and discharge pipes 37, 38 a circulating-feeder pipe 42 having a screw conveyor 43 rotatably mounted therein and drivable by an electric-motor 44 independently of stirrer member 39. By means of the screw conveyor 43 there is performed in addition to an intensive cross-linking of the portions of the molding composition to be premixed, also the degassing of the material to be mixed in a thin layer, e.g., as a liquid film having a thickness of from 0.2 to 0.6 mm. This thin layer is produced as the result of a vacuum formed at the break-off edges of a tapered shell 45 which is rotatable with the stirrer member 39. The duration of the degassing step for epoxy resin or hardener mixtures that are liquid at room temperature may be controlled by differences in the speeds for the drive motors 40 and 44, precisely as a function of the viscosity state of the material to be mixed. It is likewise possible to provide a heating jacket 69 for mixing tank 36 and to circulate a liquid or gaseous heat transfer medium therein in order to achieve a predetermined viscosity for the feed material.
FIG. 6 illustrates a molding system having two storage tanks designed as premixing tanks 36 each of which is provided with a stirring device 39 as well as with a feeder pipe 42 equipped with an associated screw conveyor which is series-connected between the tanks 36 and mixing pipe 26. Two feeder pumps, screw conveyors 73, 74 are actuated by means of motors 70, 71 which are hydromotors. The hydromotors are supplied with a liquid pumping medium by a vane or radial piston pump 46 which is actuated in turn by an electric motor 47. A pressure regulating device 48 of conventional type is interposed in the hydraulic circuit for the purpose of maintaining the pressure in the drive network of the two hydromotors 70, 71 at a relatively constant level.
The screw of the two screw conveyors 73, 74 preferably have an adjustable clearance between the flanks of the screws as described in the copending parent application Ser. No. 723,386, now U.S. Pat. No. 4,078,653, disclosure of which is incorporated herein by reference. Their drive and throughput may be controlled, for instance by a temperature indicating controller such as the Model MIC which is manufactured by Foxbor.
Referring further to FIG. 6 it will be seen that a conduit 41a leads from each of the screw conveyors 73, 74 into a common mixing pipe 26 (FIG. 4) which is provided with static mixing elements 29 (FIG. 3) in order to mix the two premixed portions of the molding composition that are charged separately.
The mixing tube 26 is desirably enclosed within a protective tube 39 which is capable of functioning as an electric heating element in order that the mixture within the mixing tube be protected during casting against excessive shear. At the outlet end of the mixing tube 26, there is connected a feeder line (FIG. 1) such as hose 27 which is cooperable with a controllable shutoff device 10 (FIG. 1) as previously described. The controllable shutoff device 10 (FIG. 1) is provided with a turnable control element 50. FIG. 6 further shows a drive mechanism for pressure-tight connection of supplyline 27 to the mold 1, identified generally by reference numeral 51. Such drive mechanism preferably includes a hollow cylinder or piston rod 7, a cylinder 52 and a piston 8, which drive mechanism is actuated via a hydraulic line 53. The hollow cylinder or piston rod 7 (FIG. 1) is connected to piston 8 designed to be cooperable with the inlet member 5 (cylinder 52) in the mold frame as shown in FIG. 1.
The apparatus illustrated in FIG. 6 comprises furthermore a pressure switch 54, a control valve 55, a locking device 56, an auxiliary switch 57 and a timer 58. The hydraulic fluid, usually hydraulic oil, is stored in a tank 59. The tanks 36 are each provided with a connecting pipe 60 for connection to a source of vacuum (not shown) in order to reduce the pressure within such tanks to the desired level.
FIG. 7 depicts a convenient arrangement of the cut-off valve assembly 10 relative to mixing tube 26 and mold 1. As shown piston rod 7 is connected to the cut-off valve assembly 10, the lower portion of the valve assembly being configured as or mounted fixedly upon a sliding carriage 62 which is adapted to travel along guide rail 63. The guide rail may be formed so as to constitute an integral portion of base plate 64. Thus when pump 46 supplies pressure through line 61 to the rear of piston 8 the valve assembly 10 is moved along the guide rail so as to bring orifice 9 into engagement with the mold for the injection of molding material into the mold.
The heat-settable epoxy resin selected to produce the molded articles which are desirably reinforced with glass fabric are subdivided into two portions one of which, namely a hardener, filler and resin, is introduced into one of storage tanks 36, and the other portion comprising resin, filler, and accelerator, is introduced into the other storage tank 36. The reinforcing resin binder, for instance, the glass fabric is pretensioned in the hollow mold such as by the device shown in FIG. 8.
For the filler, one can use a ground mineral talc marketed by Norwegian Talc A/S under the tradename "Microdol" which possesses an average grain diameter of 20 microns. Microdol talc is a double carbonate of calcium and magnesium. This filler is distributed in the two premixed portions introduced to tanks 36 in such a way that the two premixtures are of substantially identical viscosity at room temperature.
Through this arrangement, the mold occupancy time can be reduced drastically in that the reinforcing fiberglass fabric is extended during casting through the effect of a constant initial pretensioning force so that the glass fabric is wetted faster and more effectively by the mixture of epoxy resin. Given a maximum cycle of 15 minutes, it is thus possible to remove from the cavity a perfect, fiberglass reinforced molded article so as to dispense, in most instances, with a post cure insofar as the temperature of the hollow mold has been set at least at 140° C.
The tensioning device is associated with the hollow mold 1 and maintains the fiberglass fabric during casting uniformly under a tensile force of about 20 Newton/sq.mm. or higher in the center of the two-part mold cavity.
Subdivision of the molding composition into more than two premix portions is, of course, possible by the installing of additional storage tanks 36. Following the feeding of the two premix portions into their respective storage tanks, the tanks are closed and are subjected at room temperature to a pressure below 50, preferably 10, Torr, with the result that air which may be present between the feed material particles is removed by suction and the remaining material is practically completely degassed. Degassing can occur in stages with intermediate waiting times at the various pressure levels, or else can be carried out continuously in one single stage from ambient pressure directly to the desired vacuum. Degassing at the lowermost pressure occurs at the most for one minute.
The premix portions of the molding composition which have been degassed in this manner are delivered by means of the two pulsation-free screws 73, 74 into the heated mixing tube 26. In said mixing tube the two premix compositions are blended completely, heated, and brought into a liquid-pasty state. Subsequently, the resinous molding composition ready for casting is forced via the feeder line, e.g. the hose 27 (FIG. 1) to valve 10 which, in the operating position illustrated in FIG. 1 is forced against the hollow mold 1 for injection molding so that the molding mixture can reach, via the nozzle 9 and the feeder duct 25, the interior or cavity of the mold 1.
Continuous automatic filling of the mold 1 is guaranteed by the fact that the screw conveyors 73, 74 are actuated by the hydro-motors 70, 71. From the central hydraulic power supply comprising the vane or radial piston pump 46, additional pressure medium is fed through hydraulic line 61 connected in parallel to the rear of piston 8 whereupon, as illustrated in FIG. 1, the piston is forced into its front extreme position and in the process also carrying with it piston rod 7 and orifice 9 into the casting position. This pressure on piston 8 continues during injection molding so that the nozzle 9 is maintained under high pressure against the mold 1. This applied pressure is greater by at least 5 atm. than the resin filling pressure required to compensate for the pressure drop in the mold cavity. The pressure switch 54 which is designed to be adjustable with respect to the pressure limiting valve, controls during the casting cycle the injection pressure and the locking pressure of the hydraulic fluid for the nozzle 9. Following the attaining of a predetermined pressure, pressure switch 54 transmits a sequential signal for the opening of cut-off valve 10 by means of control element 50. The valve 10 opens and thereby permits flow of the resinous material via the nozzle 9 and the feeder duct 25 into the cavity of the mold 1. The amount of molding resin, the filling rate, the molding temperature, and the filling pressure are provided at desired levels by the piston pump 46 as a function of the cross-sectional area of the feed material flow opening in valve 10, by the reversible electrical control device with the control element 50, and a result of the circuit state of the pressure switch 54.
The pressure regulating valve 48 of the pump 46 controls the amount of the pressure medium, usually oil, as a function of the power consumption of hydromotors 70, 71 with the maximum pressure being regulated at the pressure regulator 48.
The controlled closing of valve cut-off member 10 is brought about by timer 58 and auxiliary switch 57, which are incorporated in the electrical circuit which includes pressure switch 54. Timer 58 determines also the activation of the control element 50 which closes cut-off valve 10 and, as a result, also the delivery by the hydromotors 70,71 of molding composition into the mold 1. After the closing of cut-off valve 10, the hydromotors remain stopped while the amount of pressure applied is maintained. Should the applied pressure drop below the rated value, the hydromotors and screw conveyors will resume rotation.
At a predetermined time lag, a signal is transmitted for opening the electrically locked locking device 56 and for energizing the circuit permitting the actuating of control valve 55 for retracting piston 8 (FIG. 1) by means of the oil pressure from the pump 46.
By means of the molding system described and by means of the locking-unit-actuated two-part mold 1 with a vacuum chamber, one achieves as a function of the parameters of quantity, pressure, filling rate, and temperature a controlled processing of thermosetting resin admixtures reinforced by glass fabrics and enriched, in addition, with mineral fillers, with the amount of the injection molding compound being practically constant and with the avoidance of any inclusions of air or gas.
The epoxy resins or resin systems employed in the practice of this invention may be the conventional materials well known in the art. See for example, U.S. Pat. Nos. 3,433,893 and 3,619,447. A particularly useful epoxy resin is prepared from bisphence A and diglycidyl ether, which is sold under the designation of XB 2719 by the Ciba-Geigy Corporation. The usual additives such as resin hardeners, fillers, accelerators, etc. may also be employed in conjunction with the epoxy resins.
The present invention provides, among other purposes for the efficient manufacture of molded articles which are to be subjected to high stress; for example, flywheels which, as lightweight power storage elements rotate at circumferential velocities of 120 m/sec. and more and in which, accordingly, the material is exposed to high centrifugal forces upon braking and accelerating. Another use is in connection with the manufacture of fiberglass-reinforced, glass frames.
A further use of this process is in the manufacturing of pressure tubes or torsion-stiff hollow shafts, especially drive-shafts for motor cars.
FIG. 10 shows an injection mold 81 with a wound core 82 and two flange armatures 83 for the vacuum injection molding of driving shafts. A dense, compound-material without porosity for driving shafts is manufactured by winding on the core 82 on which are mounted the two flanges 83 on a lath in crosswinding a filament of 0.05 mm diameter in several layers with a pretension of 0.05% in a dense manner. According to the mechanical characteristics which are necessary the filament to be wound can be a spun graphite-, ceramic-, glass- or polymere fibre-material, such as carbonfibres. Before bringing a core 82 wound in this manner in an injection mold it has to be warmed up to 140° C. whereas the parts of the injection mold 81 in which the core 82 is embedded must have a temperature of at least 5° more i.e. at least 145° C. The injection in the closed injection mold is done under an over-pressure of 0.5 bar or more. An epoxy resin of the vinyl modified type with a hardener and an accelerator is injected. A driving shaft made according to this process with 100 parts of weight of resin on the base of BPA-Diglycidyl ether, 80 parts of weight of a hardener on the base of phthalico-acid-anhydride, 10 parts of weight of a hardener on the base of methyltetrahydrophthalico-acid-anhydride, 0.1 parts of weight accelerator on the base of benzyl dimethylamin and 400 parts of weight filament of S-glass. The time for formation was 15 minutes at 140° C.
A material examination of the after-harded driving shaft gave a filament tensioning modul of 42×10 3 MN/m2. The dense and homogenous mixture of the material was very resistant to atmospheric and chemical corrosion.
An auxiliary flange 84 and a screw 85 both fixed to the core 82 serve to keep the core 82 in place in the mold 81 and to allow to take after opening the mold 81 the core 82 out of the molded piece i.e. the driving hollow shaft. | This invention provides process and apparatus for the injection molding of epoxy resin molding compositions. The constituent materials of the epoxy resin feed mixture are separated into at least two groups in at least two separate chambers. Each of the chambers is subjected to a vacuum of from about 50 to 100 Torr in order to degassify the feed material and thereby avoid the formation of voids in the final molded product. The degassified molding materials are then fed under pressure to a mixing tube which may be heated. The mixing tube is connected by means of a valve having a discharge orifice alignable with the entry passage of a mold. The mixing tube, valve and orifice are movable toward the mold so that the orifice engages the mold and is maintained in engagement therewith at a greater pressure than the pressure exerted on the molding composition fed to the mixing tube and mold. | 1 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to clock generators for digital electronic circuits and, more particularly, to apparatus and a method for generating a clock signal which is tuned to a reference frequency.
2. Prior Art
The subject of clock generation for digital electronic circuits is covered in section 7.4 "Clock Generation" of a book by Carver Mead and Lynn Conway entitled Introduction to VLSI Systems, Addison-Wesley, October 1980, pages 233-236. Previously, the reference clock for operation of subsystems was obtained from a master clock signal, obtained from a crystal or other resonant circuit. For a self-contained VLSI system on an integrated circuit chip, it is often essential that clock signals be generated on the chip. The book recommends that, instead of dealing with electronic oscillator circuits, it is better to take a more basic approach beginning with an understanding of what clock signals are used for. A fundamental principle is stated, which is that the role of the clock in a synchronous system is to connect a sequence of desired events with time. The interval between clock transitions must be sufficient to permit the activities planned for that interval to occur. A clock signal then is more like a set of timers than an oscillator.
Timers can be built as a chain of inverter circuits. Clock generation circuits that use timers are elaborations on a ring oscillator circuit, which has an odd number of signal inversions around the ring. The ring oscillator has a period that is an odd sub-multiple of the delay time twice around the ring. To avoid having the ring oscillate at a harmonic, clock signals are suppressed during initialization by using a gate in series with the ring to inhibit operation until an initializing signal is provided.
SUMMARY OF THE INVENTION
It is an object of the invention to provide a time reference signal which is tuned to a variable system reference signal, such as the spindle index pulse of a magnetic disc drive.
In accordance with this and other objects of the invention, a tuned ring oscillator is provided which includes a ring oscillator circuit having a plurality of inverters connected in series in a ring and forming a ring oscillator.
According to one aspect of the invention, the output signal of the ring oscillator circuit is fed to a programmable frequency divider in which the frequency of the ring oscillator is divided down to provide a coarse frequency control for an output clock pulse.
The ring oscillator is interrupted for a predetermined period of time by having a control gate in series with the ring oscillator to inhibit operation of the oscillator ring. A control signal for the control gate is provided as the output signal of a programmable delay line, which has input terminals for receiving control signals from, for example, a microprocessor controller. The variable delay provided by the programmable delay line provides fine adjustment to the period of the output clock pulse.
A comparator circuit is provided for comparing the frequency of the output clock pulse with the frequency of a system reference pulse, for example, in the spindle index pulse of a rotating memory system comprising a magnetic disk drive.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings, which are incorporated in and form a part of this specification, illustrate embodiments of the invention and, together with the description, serve to explain the principles of the invention:
FIG. 1 is a circuit diagram of a prior art ring oscillator.
FIG. 2 is a logic circuit diagram of a tuned ring oscillator circuit according to the invention.
FIGS. 3A and 3B are respective sets of waveform diagrams at various terminals in the circuit of FIG. 2 for a short delay interval and for a longer delay interval.
FIGS. 4A and 4B are contiguous logical circuit diagrams of a clock rate timer which performs a comparison between the frequency of the tuned ring oscillator and the frequency of a reference pulse.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Reference will now be made in detail to the preferred embodiments of the invention, examples of which are illustrated in the accompanying drawings. While the invention will be described in conjunction with the preferred embodiments, it will be understood that they are not intended to limit the invention to those embodiments. On the contrary, the invention is intended to cover alternatives, modifications and equivalents, which may be included within the spirit and scope of the invention as defined by the appended claims.
FIG. 1 shows a prior art ring oscillator circuit 10. This simple version of a ring oscillator circuit includes an inverted-input AND gate 12, or inverter, which has an initializing signal present at a signal line 14 connected to one of the input terminals. The output signal for this circuit is provided at a terminal 16. The output signal is fed back through a delay device 18 to another input terminal of the inverted-input AND gate 12, as shown.
FIG. 2 shows a tuned ring oscillator circuit 20 according to the invention. A ring oscillator circuit 22 is formed by a 2-input inverted-input AND gate 24. The output terminal of the AND gate 24 is connected to the input terminal of an inverter 26. The output terminal of the inverter 26 is connected to the input terminal of a second inverter 28. The output terminal of the second inverter 28 is fed back on signal line 30 to one of the inverting input terminals of the inverting AND gate 24. This forms the ring oscillator circuit 22.
The inverting-input AND gate 24 functions as an inverter and also provides a means for interrupting the ring oscillator 22 for a predetermined time by inhibiting propagation of an oscillating signal through the oscillator ring 22. The AND gate 24 is disabled when a logical high signal level appears at the other input terminal to the inverting-input AND gate 24 on a signal line 32.
The output signal of the ring oscillator 22 which appears on signal line 30 is designated the Minor Clock signal. The signal appearing on the signal line 32 at the second input to the AND gate 24 is the inverted Clock Enable signal (-CLKENA). The Minor Clock signal is also connected to the clock input (CLK) of a programmable divider 40 which is programmed by, for example, a key pad 42 which provides appropriate binary input signals to the programming terminals A, B, C, D of the programmable divider 40. An inverted Carry Out CO is an active low signal. The programmable divider 40 divides down the Minor Clock output signal of the ring oscillator 22. Each period of the Minor Clock signal represents a clock increment of between 4 and 16 nanoseconds. The output of the programmable divider 40 is obtained as a Major Clock signal on a signal line 44 from the output terminal QD of the programmable divider 40. The Carry Out signal is fed back on a signal line 46 to the inverted load terminal L. The Carry Out signal is also fed on a signal line 48 to one inverting input terminal of an inverting-input AND gate 50. The other input terminal of the inverting-input AND gate 50 is fed on the signal line 52 with the Minor Clock output of the ring oscillator 22. The output signal of the AND gate 50 is passed through a series of inverter pairs 52,53; 54,55; 56,57, which are connected in series as shown. These two-gate pairs form a delay line having delay increments of two gate delay times. The output signals from the AND gate 50 and each of the gate pairs is provided to the respective input terminals of respective transmission gates 58,59,60,61. These transmission gates are controlled by respective control signals at respective control terminals. These transmission gates 58,59,60,61 provide taps for the delay line formed of the inverter pairs 52-57. The output signals of the transmission gates 58,59,60,61 are tied together and connected to a signal line 62.
A NOR gate 70 has the Carry Out signal connected to one input terminal and the output signal from the transmission gates on line 62 connected to its other input terminal. The input signals to the NOR gate 70 are combined to provide the clock enable signal on signal line 32.
FIG. 3A shows the signal waveforms for the Major Clock, the Minor Clock, the inverted clock enable signal, and the negative carry out signal for the circuit of FIG. 2 when a small time delay from the delay time formed by the inverters 52,57 is obtained. The period of the Major Clock signal is thereby extended for a short period of time.
FIG. 3B shows the Major Clock, the Minor Clock, the inverted clock enable, and the inverted carry out signals obtained for a long clock delay from the delay line 52-57. The inverted enable signal is maintained at a high level in the long clock delay configuration which inhibits the ring oscillator circuit 22 for a longer period of time. This extends the period of the major clock by adding the delay line of the programmable delay line 52-57 each time that the programmable divider circuit 40 overflows. The taps on the delay line 52,57 are programmable with each tap representing one-half to two nanoseconds. In this way, the period of the major clock output signal from the programmable divider 40 on the signal line 44 is incremented in very small increments.
FIGS. 4A and 4B show contiguous logical circuit diagrams of a clock rate timer system 100 for comparing the frequency of an input clock signal (DRAM -- Clk or SCSI -- Clk) obtained from the tuned ring oscillator circuit 20 with the frequency of a reference pulse (Index -- Edge). The logic circuits are formed from standard cells and building blocks provided from the AT&T 1.25 micron CMOS Library. The DRAM -- Clk operates typically at frequencies in the range of 10-24 Mhz and is provided at an input terminal 102. The SCSI -- Clk typically operates at 20 Mhz and is provided at an input terminal 104. The Index -- Edge is provided at an input terminal 106 and is derived from the edge of the spindle index pulse for a rotating memory system comprising a magnetic disc drive system. The frequency of the Index -- Edge pulse is typically 1/60th of a second.
Generally, the function of the clock rate timer system 100 shown in FIGS. 4A and 4B is to provide a time period equal to 16 periods of the Index -- Edge pulse during which the time period DRAM -- Clk or SCSI -- Clk signals are counted to determine the frequency of the ring oscillator. These pulses are counted in a modular ripple counter provided by a series of 24 counter modules, typically indicated as 110. The outputs of the counter modules are provided as the uP -- Data -- Out (7:0) on signal bus 112. The respective signal lines of the bus 112 are connected to respective terminals 114. These terminals provide the information bits to a microprocessor (not shown) which compares the count of the ripple counter during the 16 periods of the Index -- Edge signal. If the count from the ripple counter is not within the range acceptable to the microprocessor, the control signals from the microprocessor to the ring counter 20 are changed. The 24 bits from the ripple counter to the microprocessor are provided as three multiplexed groups of 8 bits at terminals 114. The drawing notation for FIG. 4B for a ripple counter module 110 is that each of the blocks 110 represents an I, where I=1 to 23, module. The modules are arranged and interconnected to provide a ripple counter. Each of the modules 110 include a D flip-flop 120 having its QN terminal connected to its D input terminal to function as a divide-by-two circuit. An input signal CNT -- (I-1) is provided from a previous stage (I-1) as the input signal on the clock terminal CK for the Ith module. Each Q output of the D flip-flop 120 is provided through a transmission gate 122 to the output bus 112. The transmission gate 122 and similar transmission gates for the other modules of the ripple counter are controlled by the counter read signals Rd(2:0) and its inverted signal Rd -- (2:0). Both the Rd -- (2:0) signals and the non-inverted versions are obtained from signals presented on respective input terminals 130,132,134. These signals represent the three groups of multiplexed 8 bit blocks for the 24 bit output data word from the ripple counter. The inverted version of these three input signals are derived from Rd -- High, Rd -- Mid, and Rd -- Low using the respective inverters 136,138,140. This circuit configuration allows selected 8 bit blocks of information from the ripple counter to be read out onto the microprocessor data bus 112.
Note that the ripple counter contains 24 divide-by-two stages. The first stage of the ripple counter is the CNT -- O stage 150 which is also a D flip-flop divider. The inverted output signal QN of the D flip-flop 150 is fed to the clock terminal of the first stage 120 of the ripple counter. The input signal to the clock CK terminal of the first stage 150 is obtained on a signal line 160 from the output terminal of a selector stage 162. The selector 162 selects either the DRAM -- Clk signal or the SCSI -- Clk signals as determined by a selector D flip-flop 164 having its Q and QN inputs respectively coupled to the inputs of the selector 162. The D flip-flop 164 is switched to select one of the clocks by the bit 2 line of the 3-bit data selection signal present on a signal line 166. The clock signal presented to the CK terminal of the flip-flop 164 is obtained on a signal line 168 from a write control terminal 170 Wr -- Control.
Selection of the operating mode of the clock rate timer circuit 100 is obtained using a control signal obtained from the microprocessor. That signal is the UP -- Data -- In(2:0) signal, which is provided on three signal lines coupled to terminals 169.
A counter for counting the Index -- Edge pulses, that is the Indx -- (0) signal, is provided at terminal 106 to a signal line 180 and to the clock CK terminal of a first D flip-flop 182, which is the first divide-by-two stage of a five stage index counter for counting index pulses. Similar to the ripple counter 110, the five-stage index counter comprises five D flip-flop stages 183, as indicated in the drawing with appropriate connections being made for the four other stages. The output of the five-stage counter is the INDX(5) signal which is provided on a signal line 182.
The five-stage index pulse counter is activated by a Run signal provided on a signal line 186 connected to the negative clear CDN terminal of the first stage 182. The run signal is provided on signal 186 from the Q output terminal of a run flip-flop stage 190. The run flip-flop stage 190 has a clock signal provided at its clock terminal CK from the Wr -- Control terminal 170. An input signal to the D terminal of the run flip-flop 190 is obtained from the zero bit of the uP -- Data -- In (2:0) signals.
A Time Index flip-flop 200 is alternatively provided such that the next edge of the Index -- Edge signal sets the run flip-flop 190 and starts the ripple index counter for counting the index pulses into operation. The index counter for the index pulses counts typically to 16.
When the index counter counts to 16 a signal present on signal line 184 at the output of the ripple counter is propagated through a selector 210 and two inverting stages 212,214 to a signal line 216. This signal is called the Stop signal which resets the alternate time index flip-flop 200 and the run flip-flop 190 to zero output signal levels. Note that for the circuit 210 when the time index pulse, the run pulse and the index -- (5) pulse are all true, the stop signal on line 216 is also in a true state.
The run signal present on signal line 186 also is connected to the D input of a first stage Syn0 214 of a D flip-flop 214, the Q output of which is coupled through a signal line 220 to the D input of a second D flip-flop Syn 1 222. An edge D flip-flop 224 is provided also. Both the Syn 0, the Syn 1, and the edge flip-flop 224 all have their respective clock terminals CK connected to the output terminal of the selector 162 which selects either the DRAM -- Clk or the SCSI -- Clk clock signals. The clock signal is provided on a signal line 160 to the clock CK terminal of the first stage of CNT -- 0 stage of the ripple counter. The synchronized signal provided by the second stage of 222 of the synchronizer and the edge flip-flop 224 both provide respective inputs to an AND gate 226. The output of the AND gate 226 provides a preset signal on a signal line 228 to the PO terminals respectively of all of the stages of the ripple counter, as indicated, to get all stages to a 1 level.
The status of the Q output signals of the time index flip-flop 200, the run flip-flop 190, and the clock select flip-flop 164 are provided through respective transmission gates 230,232,234 on a signal bus 236 to the microprocessor data bus 112 and from thence to the respective output terminals 114 to the microprocessor.
The clock rate timer circuit shown in FIGS. 4A and 4B permits the microprocessor to control the frequency of the ring oscillator 20 as shown in FIG. 2. This is accomplished by the index ripple counter counting 16 index pulses to provide a count period for the clock pulse ripple counter. This permits the frequency of the ring oscillator 20 to be synchronized to the index pulse and tends to remove long term variations caused by temperature changes, voltage changes, and variations in semiconductor process parameters.
The foregoing descriptions of specific embodiments of the present invention have been presented for purposes of illustration and description. They are not intended to be exhaustive or to limit the invention to the precise forms disclosed, and obviously many modifications and variations are possible in light of the above teaching. The embodiments were chosen and described in order to best explain the principles of the invention and its practical application, to thereby enable others skilled in the art to best utilize the invention and various embodiments with various modifications as are suited to the particular use contemplated. It is intended that the scope of the invention be defined by the claims appended hereto and their equivalents. | An oscillator circuit is tuned to the frequency of reference pulses, for example, the spindle index pulses of a rotating magnetic storage system. A ring oscillator circuit includes a series transmission gate. The transmission gate is controlled by the output signal from a programmable delay line to interrupt operation of the ring oscillator and, in effect, provide fine tuning of the ring oscillator frequency in programmed steps. The output signal of the ring oscillator is divided down in a programmable divider, which provides a coarse frequency adjustment for an output pulse signal provided by the divider. Output signals from the divider are also provided as inputs to the programmable delay line. The frequency of the output pulse signal is compared to the frequency of the reference pulses to generate control signals for the programmable delay line. The control signals are generated by a microprocessor. | 8 |
BACKGROUND OF THE INVENTION
This invention relates to a transdermal drug delivery patch, in particular, a patch useful for the transdermal delivery of nicotine. The patch is useful in that it delivers an amount of nicotine which achieves a physiological effect, curbing the urge to smoke tobacco, and thus easing the physiological symptoms of nicotine withdrawal.
A long felt need has existed in the medical art for a transdermal nicotine patch. In the past, nicotine has been administered orally, for example by chewing a resin gum containing nicotine such as that sold commercially under the trade name NICORETTE.
Several transdermal nicotine products have recently been disclosed. One such transdermal delivery device is disclosed by Lohmann & Co. GmbH in WO 8801-516A, filed Aug. 28, 1986. Lohmann describes a controlled release transdermal delivery system with an active substance, e.g., nicotine, in a depot formed by a reservoir contained between an adhesive layer and a backing layer. A dispersion device is connected to the depot which is spatially defined from the matrix.
Von Tilly, Ger. Offen. DE No. 3,438,284 similarly discloses a nicotine-reservoir containing transdermal preparation which is alleged to deliver approximately 20 to 30 mg/day from a 10/20 cm 2 patch.
Rose, et al. "Transdermal nicotine reduces cigarette craving and nicotine preference", Clin. Pharmacol. Ther., Vol. 38, No. 4, pp 450-456 (Oct., 1985) discloses that transdermal nicotine base (8 mg) applied in 30 percent aqueous solution under a polyethylene patch was helpful in reducing the urge to smoke tobacco.
It has been determined that a relatively constant nicotine blood level may help to curb the urge to smoke. Hence, one objective of the invention is to provide a transdermal nicotine patch which will deliver nicotine transdermally over an extended period of time, e.g., 16 to 24 hours. A further objective is to provide a transdermal nicotine patch which causes a minimum of local pruritis or discomfort where applied and worn on the skin.
These objectives, as well as others, will become more readily apparent from the following detailed description taken in conjunction with the drawings wherein:
FIG. 1 is a cross-sectional schematic view of a transdermal nicotine patch in an adhesive matrix form;
FIG. 2 is a cross-sectional view of an alternative embodiment of a transdermal nicotine patch, i.e., a polymeric matrix patch; and
FIG. 3 is a cross-sectional view of a second alternative embodiment of a transdermal nicotine patch, i.e., a reservoir patch.
During testing of the transdermal nicotine patch described herein, it was discovered that nicotine delivered transdermally causes severe pruritis with practically no local erythema or inflammation. This pruritic reaction appears to be a pharmacological response to nicotine rather than a component of a general inflammatory reaction, since little if any erythema or inflammation are observed.
SUMMARY OF THE INVENTION
A transdermal nicotine patch is disclosed, comprising (a) an amount of nicotine or a salt or solvate thereof effective for treating the symptoms associated with tobacco smoking cessation, said nicotine to be transdermally delivered to a patient in need of such treatment and (b) an effective amount of a topical antipruritic. A preferred antipruritic is bisabolol, in an amount ranging from about 0.10 to about 2 percent of the total weight of the nicotine, antipruritic and carrier.
The transdermal patch may comprise an adhesive matrix, a reservoir or a polymeric matrix for containing the nicotine and/or antipruritic, and the transdermal patch preferably further comprises an easily removed release liner to protect the patch prior to application, and may further comprise a rate-limiting membrane.
The invention further includes a method of treating the urge to smoke tobacco and/or nicotine withdrawal, which method comprises transdermally delivering to a patient in need of such treatment an effective amount of nicotine in combination with the topical or transdermal use of an antipruritic such as bisabolol.
DETAILED DESCRIPTION
The invention described herein involves in its preferred embodiment the incorporation in a transdermal device for administering nicotine and at least one antipruritic compound useful for reducing or eliminating itching caused by the transdermal penetration of nicotine.
The active ingredient in the patch described herein is nicotine or a pharmacologically and pharmaceutically acceptable salt or solvate thereof. Typical salts and solvates include the hydrochloride, dihydrochloride, sulfate, tartrate, bitartarate, zinc chloride double salt monohydrate and salicylate. The concentration of nicotine in the patch generally ranges from about 5 to about 40 percent of the total weight of the nicotine, antipruritic and carrier (e.g., the weight of the adhesive matrix, the polymeric matrix or the contents of the reservoir, but not including the weight of the backing material, release liner or rate controlling membrane) on a (w/w) basis. The preferred active ingredient is nicotine free base, and the preferred concentration of active ingredient is about 10 to about 20%.
The antipruritic used in the transdermal nicotine patch is included to counter the pruritic effects experienced when delivering nicotine transdermally. As such, it is referred to herein as the antipruritic, rather than as the "active ingredient" even though it is clearly "active" in the sense that it reduces itching. The antipruritic is without pharmacological effect with respect to the nicotine withdrawal symptoms that are being treated.
One such preferred antipruritic compound is bisabolol, also known as 2-(4-methyl-3-cyclohexenyl)-6-methyl-5-hepten-2-ol, and more preferably α(-)bisabolol. Such a compound has not previously been used to effectuate the transdermal delivery of drugs, and in particular, nicotine, although it has been used as a cosmetic adjuvant. It is commercially available from BASF Wyandotte Corp., Parsippany, N.J. α(-)bisabolol is present in an amount ranging from about 0.10 to about 2%, more preferably about 0.1 to about 1% of the total weight of the nicotine, antipruritic and carrier.
Examples of topical antipruritics effective in reducing itching during transdermal nicotine delivery other than bisabolol, mentioned above, are oil of chamomile, chamazulene, allantoin, D-panthenol glycyrrhetenic acid, corticosteroids, antihistamines, and combinations thereof. ANTIPHLOGISTICUM "ARO", commercially available from Novarom GmbH, Holzminder, Germany, comprising a combination of 18-β-glycyrrhetenic acid and D-panthenol, is a particularly useful combination.
Other ingredients useful in preparing the carrier for the transdermal nicotine patches described herein include conventional adhesives, solvents, co-solvents, plasticizers, polymeric matrices, stabilizers, thickeners, preservatives, etc.
Examples of pharmaceutically acceptable pressure sensitive adhesives useful in delivery devices for nicotine include acrylic, silicone, vinyl acetate and synthetic or natural rubber adhesives as well as other adhesives useful in transdermal drug delivery. The adhesives may be used alone or in combination to prepare an adhesive drug matrix or may be applied to the skin-contacting surface of a polymeric matrix or reservoir patch to adhere said patch to the skin. Examples of adhesives are acrylic adhesives such as RA 2484, RA 2333, RA 2397, R 363 and R 362 from Monsanto Co. Other acrylic adhesives, such as Durotak, manufactured by Morton Thiokol, Inc., and Neocryl XA5210bby Polyvinyl Chemicals, Ltd. may be utilized. Vinyl acetate adhesives include Flexcryl-1614, 1617, 1618 and 1625 from Air Products. Numerous silicone based adhesives may be used, such as Q72929, Q27406, X72920 and 355, each manufactured by Dow-Corning. Natural and synthetic rubbers include polyisobutylenes, neoprenes, polybutadienes and polyisoprenes.
Polymeric matrix-forming agents include pharmaceutically acceptable polymers such as polyvinyl alcohol, polyvinylpyrolidones, gelatin and partially hydrolyzed polyvinyl alcohols.
Examples of solvents useful for effecting the transdermal delivery of nicotine include aqueous and organic solvents. As used herein the term solvent differs from the term co-solvent only in the most general sense. A co-solvent is a liquid which generally is a non-solvent, in which the active ingredient becomes soluble upon the addition of a small amount of a true solvent. Water is a typical solvent used in the transdermal nicotine patch. Polar organic solvents, such as ethanol, may also be useful.
Co-solvents useful in the transdermal nicotine patch include, for example, mineral oil, silicone-based liquids, and low molecular weight polyisobutylenes.
Suitable preservatives, antioxidants and chelating agents can be included in the transdermal nicotine patch, such as butylated hydroxyanisole (BHA), butylated hydroxytoluene (BHT), sodium metabisulfate, a-tocopherol, maleic acid, ethylenediaminetetraacetic acid (EDTA), and cysteine hydrochloride.
Components useful for imparting the desired wear and pharmacokinetic characteristics to the transdermal nicotine patch include, for example, polymeric matrix-forming materials added to facilitate curing of the adhesives, for example Aerotex Resin 3730 (American Cyanamid) and a thickener may be added to adjust the viscosity of the polymer mixture to the desired viscosity for coating on a backing material. The thickener can be an acrylic polymer thickener such as AMSCO 6038A (Unocal), methyl cellulose and hydroxypropylmethyl cellulose. Plasticizers may be added to impart softness and flexibility to the adhesive, a typical plasticizer being glycerin. Stabiliziers, added to prevent degradation by heat and light and to improve aging characteristics, include polyvinylpyrolidone. Examples of formulations are shown below in Table 1. Formulae 1-3 are adhesive formulations, Formula 4 is a reservoir formulation, and Formula 5 is a polymeric matrix formulation.
TABLE 1__________________________________________________________________________EXAMPLES OF FORMULATIONSINGREDIENT FUNCTION FORMULA 1 FORMULA 2 FORMULA 3 FORMULA 4 FORMULA__________________________________________________________________________ 5Acrylic Pressure Adhesive 71.5% -- -- -- --Sensitive AdhesiveSilicone Pressure Adhesive -- 52.5% -- -- --Sensitive AdhesivePolyisobutylene Pressure Adhesive -- -- 87% -- --Sensitive AdhesiveMineral Oil Co-solvent -- -- -- 12.45% --Silicone Medical Fluid Co-solvent -- -- -- 80% --Glycerin Plasticizer -- -- -- -- 11.5%Polyvinyl Alcohol Polymeric matrix -- -- -- -- 25.3%Polyvinylpyrrolidone Stabilizer -- -- -- -- 3.1%Nicotine Free Base Active Drug 20% 40% 10% 5% 30%Water Solvent 4% -- -- -- 17.6%Butylated Hydroxyanisole Anti-oxidant 2.5% 2.5% 2.5% 2.5% 2.5%α(-)Bisabolol Anti-pruritic 1% 5% 0.5% 0.5% 10%Acrylic Polymer Thickener Thickener 1% -- -- -- -- 100% 100% 100% 100% 100%__________________________________________________________________________
The transdermal nicotine patch described herein can be in any conventional patch form, such as a polymeric matrix type, a reservoir type or an adhesive type, with the adhesive type being preferred.
As shown in each of the Figures, an impermeable backing layer 10 is typically included to render the contents of the patch impervious to the outside environment during use. Suitable components for use as an impermeable backing material include such materials as foam, metal foil, polyester, low density polyethylene, copolymers of vinyl chloride and polyvinylidene chloride (e.g. Saran), and laminates thereof. A preferred backing material is a metallized plastic such as metallized polypropylene.
A protective release liner 17, also shown in each of the figures, is typically included. The release liner is removed prior to application and use; it is typically present to protect the patch, e.g. by preventing dirt from sticking to the patch adhesive during shipment and storage. Examples of materials suitable for release liners are polyethylene and polyethylene-coated paper, preferably silicon-coated to facilitate removal.
The patch shown in cross-section in FIG. 1 exemplifies an adhesive/nicotine/antipruritic combination 11 applied to the backing layer during manufacture. The combination 11 may also include therein other components such as a polymeric matrix-forming material.
The patch exemplified in FIG. 2 illustrates elements of a matrix-type patch, wherein distinct portions of the patch contain the active ingredient and the adhesive; the matrix 19 comprises the nicotine or salt or solvate thereof and an antipruritic compound, which is separated from the backing layer 10 by a paper foil baseplate 18 and an absorbant pad 13. The baseplate 18 prevents the migration of the active into the absorbant pad 13, while the pad absorbs moisture from the adhesive, which in turn absorbs moisture from the skin. The adhesive 16 is peripheral to the matrix and keeps the matrix in contact with the skin surface. The patch preferably also comprises a release liner covering the adhesive, the drug matrix and the baseplate.
FIG. 3 shows a cross-section of a reservoir type patch wherein a reservoir 12 is formed, which reservoir contains the nicotine/antipruritic combination and may also contain one or more additional components such as preservatives or thickeners. A rate-controlling membrane 14 may be included to effect controlled release of the nicotine/antipruritic from the patch. Alternatively, the nicotine may be contained in a distinct section of the patch such as reservoir 12, and the antipruritic may be contained in a separate layer 15 when it is not desirable to mix the two components.
Materials suitable for rate-controlling membranes include ethylene-vinyl acetate (EVA) copolymer membranes (e.g. 1-20% vinyl acetate), polyvinylalcohol (PVA) gels and silicone films.
The adhesive, polymeric and reservoir patches are all made by methods well known in the art.
The transdermal nicotine patch is used by simply removing the protective layer to expose the adhesive surface, and applying the patch to the skin of a patient in need of such treatment so that the patch adheres to the skin.
Transdermal delivery of an effective amount of nicotine thereby occurs over an extended period of time. The patch described herein provides adequate serum levels of nicotine which are useful for a period of from about 4 to about 24 hours, after which the patch is replaced. Preferably the patch is used for about 12 to 24 hours and then replaced.
Effectiveness of the antipruritic in the transdermal nicotine patch is measured in terms of reduced itching as noted from the data below in Table 2. An adhesive-type transdermal nicotine patch comprising nicotine and bisabolol was used to test itching in patients. The concentration of antipruritic and nicotine was varied, and the number of patients complaining of itching was evaluated, along with the severity of the itching experienced.
TABLE 2__________________________________________________________________________ Number of SevereControl Patch Adverse Reactions Reactions Requiring% Nicotine % α(-)Bisabolol Number Tested (i.e. Itching) Removal of Patch__________________________________________________________________________40% 0 12 12/12.sup.a 1220% 0 12 5/12.sup.a 110% 0 12 7/12.sup.a 0Test Patches20% 5% 12 7/12 120% 10% 12 7/12 120% 0.5% 12 4/12.sup.b 020% 1% 12 6/12.sup.b 010% 10% 12 5/12 110% 5% 12 4/12 0__________________________________________________________________________ Notes .sup.a Itch duration was long, until the patch was removed. .sup.b Itch duration in those experiencing side effects was generally low not longer than 10 minutes.
As is seen from Table 2 above, the formulations containing 0.5 to 1 percent α(-)bisabolol caused fewer itching side effects than those without the antipruritic, and also fewer side effects than those patches which contain 5 to 10 percent of the antipruritic. Additionally, severity of the itching side effect is greatly reduced in the formulations containing 0.5 to 1 percent antipruritic. Hence it is concluded that a transdermal nicotine patch containing α(-)bisabolol is effective in treating nicotine withdrawal symptoms with a minimum of adverse itching side effects.
While certain specific embodiments of the transdermal nicotine patch have been described herein, numerous modifications are possible and within the scope of the invention. Consequently, interpretation of the claims is not to be limited thereby. | A transdermal nicotine patch comprising an antipruritic to counteract pruritis observed with the transdermal administration of nicotine is disclosed. The patch can be any conventional patch type, e.g., reservoir, adhesive or polymeric matrix. | 0 |
TECHNICAL FIELD
[0001] This invention generally relates to aircraft auxiliary power units (APUs), and more particularly, this invention relates to a method and system for accurate oil quantity determination and indication for an APU.
BACKGROUND
[0002] The primary purpose of an aircraft APU is to provide power to start the main engines. Turbine engines must be accelerated to a high rotational speed to provide sufficient air compression for self-sustaining operation. Smaller jet engines are usually started by an electric motor, while larger engines are usually started by an air turbine motor. Before the engines are to be turned, the APU is started. Once the APU is running, it provides the power to start the aircraft's main engines.
[0003] APUs are also used to run accessories while the engines are shut down. This allows the cabin to be comfortable while the passengers are boarding before the aircraft's engines are started. Electrical power is used to run systems for preflight checks. Some APUs are also connected to a hydraulic pump, allowing crews to operate hydraulic equipment prior to main engine start up. This function can also be used, on some aircraft, as a backup in flight in case of the loss of main engine power or hydraulic pressure.
[0004] APUs fitted to extended-range twin-engine operations (ETOPS) aircraft are an important backup system, as they supply backup electricity, compressed air and hydraulic power in the highly unlikely, yet postulated event of a loss of main engine power or a failed main engine generator. As such, operators flying ETOPS legs are required to track and record oil consumption rates to ensure the APU is always serviced with sufficient oil for the duration of the flight mission. To support that need, APU controllers will display oil quantity on a flight deck display.
[0005] Certain control systems have the capability of displaying quantity in discrete units, e.g., quarts or liters, or volume; however, displaying a consistent and accurate oil quantity while the APU is running is problematic. This is because these systems inadequately account for APU startup or shutdown gulp. To acquire a consistent oil quantity measurement with sufficient accuracy to permit ETOPS operation requires the aircraft maintenance operators to shut down the APU. Unfortunately, shutting down the APU is not preferred due to the increased time, work and inconvenience to restart the APU, e.g., hook up ground power, get a ground cart, etc. Therefore, aircraft manufacturers and operators are consistently looking for improved APU oil quantity measurement systems to support maintenance activities and reduce aircraft downtime.
[0006] Accordingly, it is desirable to provide methods and systems to determine and indicate an accurate oil quantity of an APU, particularly as the APU is running. Furthermore, other desirable features and characteristics of the present invention will become apparent from the subsequent detailed description and the appended claims, taken in conjunction with the accompanying drawings and the foregoing technical field and background.
SUMMARY
[0007] An APU oil quantity indication system and method establishes oil gulp on APU start up, during operation and at shutdown. As a result, it is possible to determine and indicate APU oil quantity whether the APU is running or off. Furthermore, stable oil quantity indication is possible during engine transients such as startup and rolldown after shutdown.
[0008] In one of the herein described embodiments, an APU oil gulp value may be established at APU startup and shutdown, respectively. The gulp value is combined with a continuous oil quantity indication to provide a stable oil quantity indication under all operating conditions, including transient conditions.
[0009] In still another embodiment, a method of and system for determining and indicating APU oil quantity includes establishing an APU oil gulp value at various phases of APU operation. An APU oil quantity is determined by combining the oil gulp value with a continuous oil quantity value. The method may further include indicating the APU oil quantity value.
DESCRIPTION OF THE DRAWINGS
[0010] The exemplary embodiments will hereinafter be described in conjunction with the following drawing figures, wherein like numerals denote like elements, and wherein:
[0011] FIG. 1 is a functional block diagram of an APU lubrication system including an APU oil quantity indication system in accordance with various embodiments;
[0012] FIG. 2 is a functional block diagram of an APU control unit including an oil quantity indication system in accordance with various embodiments; and
[0013] FIG. 3 graphic depiction of APU oil quantity.
DETAILED DESCRIPTION
[0014] The following detailed description is merely exemplary in nature and is not intended to limit the application and uses. Furthermore, there is no intention to be bound by any expressed or implied theory presented in the preceding technical field, background, brief summary or the following detailed description. It should be understood that throughout the drawings, corresponding reference numerals indicate like or corresponding parts and features. As used herein, the term system or module may refer to any combination or collection of mechanical and electrical hardware, software, firmware, electronic control component, processing logic, and/or processor device, individually or in any combination, including without limitation: application specific integrated circuit (ASIC), an electronic circuit, a processor (shared, dedicated, or group), memory that executes one or more software or firmware programs, a combinational logic circuit, and/or other suitable components that provide the described functionality.
[0015] Embodiments of the invention may be described herein in terms of functional and/or logical block components and various processing steps. It should be appreciated that such block components may be realized by any number, combination or collection of mechanical and electrical hardware, software, and/or firmware components configured to perform the specified functions. For example, an embodiment of the invention may employ various combinations of electrical components, e.g., sensors, integrated circuit components, memory elements, digital signal processing elements, logic elements, look-up tables, or the like, which may carry out a variety of functions under the control of one or more microprocessors or other control devices. In addition, those skilled in the art will appreciate that embodiments of the present invention may be practiced in conjunction with any number of mechanical and/or electronic systems, and that the systems described herein are merely exemplary embodiment of the invention.
[0016] For the sake of brevity, conventional components and techniques and other functional aspects of the systems (and the individual operating components of the systems) may not be described in detail herein. Furthermore, the connecting lines shown in the various figures contained herein are intended to represent example functional relationships and/or physical couplings between the various elements. It should be noted that many alternative or additional functional relationships or physical connections may be present in an embodiment of the invention.
[0017] FIG. 1 provides a simplified depiction of an APU 10 that includes a turbine engine 12 and a lubrication system 14 . The turbine engine 12 may be coupled to drive various equipment such as generators, pneumatic compressors, hydraulic pumps and the like generically indicated as drive 16 . The lubrication system 14 provides lubricating oil 18 from a sump 20 to the turbine engine 12 and the drive 16 . Lubricating oil 18 may be drawn from the sump 20 by a pump 22 and is communicated to the turbine engine 12 and the drive 16 via a cooler/filter 24 . From the turbine engine 12 and the drive 16 , oil may be returned to the sump 20 via scavenge pump 26 and a cooler/filter 28 .
[0018] The lubrication system 14 includes an oil quantity sensor that provides an oil raw quantity indication in the form of an oil quantity value. For illustrative purposes, an oil quantity sensor 30 is shown disposed in association with the sump 20 . Oil quantity sensing during operation of an APU is known, and any suitable sensor arrangement may be used to provide the oil raw quantity indication. Suitable oil quantity sensing arrangements include capacitive or linear variable differential transformer oil quantity sensors that generate an oil quantity value that is proportional to oil quantity in discrete units such as quarts or liters or in volume.
[0019] FIG. 2 illustrates an APU controller 32 that includes oil quantity sensor 30 and gulp value logic 34 . The output of the sensor 30 , as noted, is a raw oil quantity value 40 . The output of the gulp value logic 34 is a gulp value 42 determined at various stages of APU operation. The raw oil quantity value 40 and the gulp value 42 are combined, e.g., summed, at combining logic 36 to provide an indicated oil quantity value 38 . The indicated oil quantity value 38 may be in quarts, liters, volume or any other suitable set of units.
[0020] In accordance with various embodiments of the invention, the gulp value logic 34 calculates an engine gulp on APU start, while running and at shutdown providing, for example, first, second and third gulp values. For purposes of discussion, and with reference to FIG. 2 , these values may be designated 42 ST , 42 L and 42 SD . Combining the appropriate gulp value for the given operating state with the continuous raw oil quantity value 40 results in an oil quantity indication 38 that is substantially the same value when the APU is off, starting, running or rolling down after shut down, and which furthermore is an accurate indication of actual APU oil quantity.
[0021] When the APU is started, the gulp logic 34 determines a start up gulp value, 42 ST , as a difference between the last oil quantity value 38 and the raw oil quantity value 40 at start up. This value is then combined, e.g., added, into the continuously updated raw oil quantity value 40 . In this regard, the gulp logic 34 will store or reference the last oil quantity value 38 , e.g., as determined at shut down of the APU 10 , and use this value to determine a startup gulp value, 42 ST corresponding to initial APU 10 startup. During start up and until the APU 10 has reached governed operational speed, the gulp logic 34 will periodically determine the gulp value 42 ST as a difference between the last oil quantity value 38 and the raw oil quantity value 40 . With the gulp value 42 ST continuously updated and added back to the raw oil quantity 40 , a smooth and consistent oil quantity display is achieved as the APU goes from off to governed speed.
[0022] Once the APU 10 achieves governed operating speed, i.e., the turbine engine 12 reaches its normal continuous operating speed, the gulp logic 34 latches the gulp value, 42 L , to prevent the gulp term from continuing to increase as the APU 10 consumes oil, i.e. the oil quantity display would not show the effects of oil consumption. Moreover, because it is expected that the APU 10 will consume some amount of oil during operation, the APU controller 32 will latch the oil quantity 38 at APU shutdown and use this oil quantity to calculate the gulp term, 42 SD , during shutdown. This will result in smooth and consistent oil quantity display as the APU 10 goes from governed speed to off.
[0023] FIG. 3 graphically depicts the values 38 , 40 and 42 ST , 42 L and 42 SD in accordance with there herein described embodiments and operation of the gulp logic 34 . In addition, the speed 46 of the APU turbine engine 12 is depicted to highlight the several states of APU 10 operation. The vertical black line is intended to represent a break in time so that the graphs may better represent the effect of oil consumption due to normal operation.
[0024] At initial APU 10 start up, raw oil quantity indication 40 illustrates a sharp drop corresponding to start up gulp. Correspondingly, the gulp value 42 ST rises based upon the calculated difference between the oil quantity value, 38 , and the raw oil quantity value, 40 . Once the APU reaches governed operation, the gulp value, 42 L , is latched. With constant gulp value 42 L , the indicated oil quantity 38 decreases with time corresponding to oil consumption during use. After the APU 10 has completed its preparation to shutdown, the gulp value is unlatched and a shutdown gulp value, 42 SD is established during APU 10 shutdown.
[0025] The gulp logic 34 may be modified to allow the gulp value 42 SD to increase during APU shutdown to account for the effects of reduced scavenge efficiency. Such a modification may improve the stability of the indicated oil quantity 38 during shutdown processes. Suitable logic would be required to account for an aborted shutdown process. The gulp logic 34 may additionally compensate for temperature expansion, and may further bracket all gulp values, i.e., truncate the gulp value at low and high limits, to prevent anomalous results due to data errors or other transient conditions. The skilled person will further appreciate that filtering and other data smoothing techniques may also be employed.
[0026] In general, there is likely to be some variance between indicated oil quantity value 38 when the engine is running and just post engine shutdown. The quantity of oil that returns to the sump 20 , and thus reflected in the raw oil quantity value 40 , is dependent on oil temperature, age of the oil, de-oil capability, and other factors. If these factors are not accounted for, there may be an indicated oil quantity with some variation. FIG. 3 shows this condition in which more oil returns to the sump than was gulped on startup and some acceptable variation in indicated oil quantity 38 at shutdown, especially as the variation is greatly reduced as compared to existing systems and methodologies.
[0027] While at least one exemplary embodiment has been presented in the foregoing detailed description, it should be appreciated that a vast number of variations exist. It should also be appreciated that the exemplary embodiment or exemplary embodiments are only examples, and are not intended to limit the scope, applicability, or configuration of the disclosure in any way. Rather, the foregoing detailed description will provide those skilled in the art with a convenient road map for implementing the exemplary embodiment or exemplary embodiments. It should be understood that various changes can be made in the function and arrangement of elements without departing from the scope of the disclosure as set forth in the appended claims and the legal equivalents thereof. | An auxiliary power unit (APU) oil quantity indication system and method provides a stable and accurate oil quantity indication during startup, mission duration and shutdown. The system determines a gulp value at various stages of operation, which is combined with a raw oil quantity indication to provide an indicated oil quantity. | 5 |
This application claims priority to GB Application No. 1101213.5 filed 25 Jan. 2011, the entire contents of which are incorporated herein by reference.
FIELD OF THE INVENTION
The present invention is relates to encoding methods for encoding an image according to a predetermined encoding format. In particular the present invention is concerned with such encoding methods when the predetermined encoding format encodes the image in blocks of pixels, each block of pixels being encoded as a set of encoded pixel colours comprising a base colour and a set of luminance offsets with respect to that base colour.
BACKGROUND OF THE INVENTION
Various encoding formats for encoding an image are known. The particular techniques embodied by these formats vary depending on the relative importance of various factors in the resulting encoded image, such as whether the encoding should be lossless, the desired data size of the resulting encoding image and the overall quality of the encoded image. A widely used and well known set of encoding formats for images are those defined by the JPEG group. However, predetermined encoding formats such as JPEG are not suitable for all applications, in particular those in which random access to areas of pixels in the encoded image is required. This may for example be the case when the encoded image provides a compressed texture to be used in graphics applications. This is because encoding formats such as JPEG rely on techniques which encode blocks of pixels within an image with respect to previous blocks within the same image. Whilst this enables a higher degree of data compression, this approach requires the image to be decoded as a whole and hence such encoding formats are not suitable for applications such as texture rendering, which require random access to subsections of a given image.
Consequently, it is known to encode images according to predetermined encoding formats which do allow such random access. Typically, in such encoding formats, the image is encoded in blocks of pixels (e.g. 4×4) representing the smallest units of the image which can be individually encoded and decoded. One known technique in such encoding formats is to represent the block of pixels by a base colour and a set of luminance offsets with respect to that base colour. In other words, for each block encoded in this manner, only one colour is defined for all of the pixels, with the luminance of each pixel being given as an offset from that base colour. This generally produces an acceptable image quality, because the human eye is less sensitive to local chrominance variation than to local luminance variation.
However, a problem associated with generating encoded images according to such encoding formats (of which the ETC format (Ericsson Texture Compression) is one example) is the processing time required to generate the compressed (encoded) images. For example, when using existing tools to create ETC compressed textures the processing time can be around 300 to 400 pixels per second, or 30 minutes to one hour for a typical texture, for the highest quality supported by those tools. This lengthy processing time results from the searching which is performed within the available encoding space to find the best combination of base colour and luminance offsets for each block of pixels. To produce the highest quality compressed textures the search is multi-dimensional and extensive, resulting in these long processing times. Such long processing times however are unacceptable when developing and testing graphics applications, since applications may include dozens or hundreds of textures, and developers need to be able to assess the quality of the compressed textures during development.
FIG. 1A schematically illustrates a block of 4×4 pixels 10 . Typically, when such a block of pixels is encoded according to encoding formats such as ETC, each block is in fact encoded in terms of two half-blocks adjacent to one another. As illustrated in FIG. 1A the block of pixels 10 may be divided by a vertical split into the two half-blocks. Equally, the same block of pixels may be divided into two half-blocks by means of a horizontal split.
The ETC encoding format defines eight tables of luminance offsets as illustrated in FIG. 1B . Hence, a base colour is defined for each half-block, and the eight pixels in that half-block are encoded by means of one three bit table number and eight two bit table entry numbers.
Two varieties of encoding are defined according to the ETC standard, namely absolute encoding and differential encoding, as illustrated in FIG. 1C . Each results in the block of pixels being encoded as a single 64 bit value. In absolute encoding, each half-block is independently encoded. The base colour for each half-block is encoded as a 12 bit (444) RGB value, and the encoding of the whole block is represented by 24 bits giving the R, G and B components of the base colours for the first and second half-blocks making up this block. This is followed by two three bit values giving the luminance offset table used for each half-block. The “diff” bit indicates whether this block has been encoded using absolute or differential encoding. The “flip” bit indicates whether the block has been split horizontally or vertically into half-blocks. Finally, the 16 individual pixels of the two half-blocks are each represented by two bits giving their corresponding entry in the selected table. The encoding format groups these as 16 MSBs and 16 LSBs.
The differential encoding is similarly defined, except that here the base colour of the second half-block is defined as an offset with respect to the first half-block. Hence, the first half-block base colour is given as a 15 bit (555) RGB value and the R, G and B offsets for the second half-block are each given as three bit offsets. This enables greater precision in defining the base colours, but only if the base colours of the half-blocks are close enough to one another to be represented by these three bit offsets. Otherwise the absolute encoding is used.
The 24 bits used to encode the base colours for the half-blocks correspond to a predetermined set of base colours which may be defined in the encoding. This predetermined set of base colours is schematically illustrated in FIG. 2A . Note that for clarity of illustration only a two dimensional representation is shown in which only the R and G components are shown (the B component in the third dimension being omitted). The base colour selected for the encoding of a given half-block is typically selected with reference to the average colour of the pixels in the half-block. Since the encoded pixels are encoded as luminance offsets with respect to a selected base colour, the diagonal lines (luminance lines) in FIG. 2A constrain where encoded pixels may lie in this colour space.
As illustrated in FIG. 2A , there is more than one way to choose the base colour from the predetermined set of base colours available for a given calculated average colour. Base colour 30 is the nearest base colour on the nearest luminance line, whilst base colour 40 is the geometrically nearest base colour.
FIG. 2B graphically illustrates the encoding of a given pixel value by means of a luminance offset from a base colour. The luminance offset (selected from a predefined table of luminance offsets) gives the position in this colour space of the compressed pixel colour relative to the base colour. The distance between the compressed pixel colour and the original pixel colour gives the encoding error for this pixel.
FIG. 3 shows the search range performed by an existing ETC compression algorithm for the base colour of each half-block of pixels. Having selected an initial base point (i.e. base colour) in dependence on the average colour of the pixels of the half-block, a search is performed in a volume of base points around that starting base point to see if an improved encoding can be found. In the high quality version of the compression, a 7×7×7 search volume is explored (represented as a 7×7 search area in the 2D representation shown). Amongst these the encoding which minimises the overall encoding error for the half-block is selected. It is the iterative process of calculating the best encoding for all eight possible tables for each of these 7×7×7 (i.e. 343) candidate base points which results in the lengthy processing procedure for existing compression tools.
Descriptions of some existing approaches to such image encoding/compression can be found in:
the presentation “iPACKMAN—High-Quality, Low Complexity Texture Compression for Mobile Phones” by Jacob Strom and Tomas Akenine-Moller (retrieved from http://www.graphicshardware.org/previous/www — 2005/presentations/strom-ipackman-gh05.ppt) which describes the ETC compression format;
in the full Khronos standard for the ETC format (available at http://www.khronos.org/registry/gles/extensions/OES/OES_compressed_ETC1_RGB8_texture.txt);
in the paper “Real Time DXT Compression”, J. M. P. van Waveren, May 2006 (http://cache-www.intel.com/cd/00/00/32/43/324337 — 324337.pdf); and
in a description of NVIDIA texture tools (retrieved on 12 Nov. 2010 from: http://code.google.com/p/nvidia-texture-tools/wiki/ApiDocumentation).
However, the above described lengthy processing times are prevalent in the prior art approaches and accordingly, it would be desirable to provide an improved technique for generating high quality encodings, which require less processing time.
SUMMARY OF THE INVENTION
Viewed from a first aspect, the present invention provides an encoding method of generating an encoding of an image according to a predetermined encoding format, wherein said predetermined encoding format encodes said image in blocks of pixels, each block of pixels being encoded as a set of encoded pixel colours comprising a base colour and a set of luminance offsets with respect to said base colour,
wherein said base colour is selected from a predetermined set of base colours defined in a predetermined colour space,
wherein said set of luminance offsets is encoded as a set of references to at least one predetermined table of luminance offset values,
and wherein said predetermined set of base colours and said luminance offset values define a set of luminance lines in said predetermined colour space, said encoded pixel colours lying on at least one of said luminance lines,
said method comprising the steps, performed for each block of pixels, of:
determining an average colour of colours of said block of pixels in said predetermined colour space;
selecting at least one luminance line in dependence on an offset in said colour space of said average colour from said at least one luminance line;
identifying a set of candidate base colours lying on said at least one luminance line; and
determining, using said set of candidate base colours and said luminance offset values, said set of encoded pixel colours, wherein said base colour and said set of luminance offsets are selected in dependence on an encoding error indicative of a sum distance in said colour space between said set of encoded pixel colours and said colours of said block of pixels.
When encoding an image according to a predetermined encoding format in which the image is encoded in blocks of pixels, each block of pixels being encoded as a set of encoded pixel colours comprising a base colour and a set of luminance offsets with respect to that base colour, the inventor of the present invention realised that an improved method could be provided by selecting the base colour for each block of pixels from a candidate set of base colours lying on at least one luminance line running through the predetermined colour space in which the encoding operates. Luminance lines in the predetermined colour space are defined by the predetermined set of base colours available for the encoding. Accordingly, according to the techniques of the present invention, for each block of pixels to be encoded, firstly the average colour of the pixels of that block of pixels is determined and then at least one luminance line is selected in dependence on an offset in the predetermined colour space of the average colour from the at least one luminance line. This at least one luminance line then provides a set of candidate base colours which are then used to determine the final encoding.
It has been found that rather than identifying a set of candidate base colours using, say, a set of base colours forming a cube approximately centred on the average colour of the block of pixels to be encoded (e.g. the 7×7×7 search volume illustrated in FIG. 3 ), an improved encoding method is provided if the candidate base colours are selected with reference to luminance lines running through the predetermined colour space.
This is due to the fact that an encoding format which encodes blocks of pixels as a base colour and set of luminance offsets with respect to that base colour provides far greater flexibility in setting luminance values than in setting chrominance values. Furthermore, since the encoded pixel colours are constrained to lie on one of the luminance lines running through the predetermined colour space (because each encoded pixel colour is represented as an offset along one of these luminance lines from a base colour which lies somewhere on the luminance line), identifying the best base colour to use for the encoding of a particular block of pixels is improved by performing this selection with reference to luminance lines rather than by using a spatial search around the average pixel colour of the block of pixels. This technique may be of particular benefit, for example, when the colours of the block of pixels are widely distributed in the predetermined colour space, meaning that the position of the average colour of the block of pixels is not particularly representative of the individual pixel colours. In such a situation, a luminance line may be is better suited to providing the candidate base colours than a predetermined search space around the average colour.
A further factor which makes the luminance line based approach more advantageous is that the luminance lines, which define lines of increasing luminance in the predetermined colour space, are not necessarily lines of constant chrominance, since the luminance can be increased or decreased beyond a point at which a component of the colour saturates. Seen graphically this represents the situation in which a luminance line meets the edge of the predetermined colour space. Hence, the luminance lines do not necessarily take a single straight path through the predetermined colour space. Consequently there may exist a luminance line which better matches a given set of pixel colours, whilst the average colour of those pixels on the other hand lies nearer to base colours which would only allow a poor encoding of the pixel colours. This may particularly be the case when the base colours which are closest to the average pixel colour in the predetermined colour space are significantly different from the individual pixel colours in terms of chrominance, since the predetermined encoding format only allows individual pixels to vary in terms of a luminance offset from the base colour and hence this chrominance difference may result in a large encoding error (between the encoded pixel colours and the original pixel colours).
It will be appreciated that there are various ways in which the offset can be defined, but in one embodiment said offset in said colour space is a distance of closest approach between said average colour and said at least one luminance line.
It will also be appreciated that there are various ways in which the encoding error can be defined, but in one embodiment said encoding error is calculated as a sum of squared distances between said set of encoded pixel colours and said colours of said block of pixels.
In one embodiment, said step of selecting said at least one luminance line comprises selecting three luminance lines with smallest values of said offset. The selection of three luminance lines is particularly appropriate in the context of a three dimensional predetermined colour space (e.g. RGB), since a given average colour position will be surrounded by three luminance lines. Which of these three luminance lines will prove to be most suitable for providing the base colour for the encoding will depend on the position of the colours of the pixels of the block of pixels with respect to each line.
In one embodiment, said step of selecting at least one luminance line comprises an iterative luminance line selection procedure, said iterative luminance line selection procedure comprising the steps of:
examining a neighbouring luminance line of an already-selected luminance line; and
if a total offset of said colours of said block of pixels from said neighbouring luminance line is not greater than a total offset of said colours of said block of pixels from said already-selected luminance line, selecting said neighbouring luminance line.
Accordingly, more than one luminance line may be selected by means of this iterative luminance line selection procedure. The proposal of this iterative luminance line selection procedure is based in the recognition that an initial luminance line selected in dependence on its offset in the predetermined colour space from the average colour of the block of pixels may not in fact provide the base colour which is the best encoding for the block of pixels. For example, because of the paths that the luminance lines take through predetermined colour space, a luminance line which most closely approaches the individual pixel colours may not be the same as the luminance line which most closely approaches the average colour of those pixels. Hence, the iterative luminance line selection procedure examines a neighbouring luminance line and compares the total offset of the colours of the block of pixels from that neighbouring luminance line with a total offset of the colours of the blocks of pixels from an already-selected luminance line, and if the neighbouring luminance line is shown to more closely approach the colours of the blocks of pixels (in terms of the total offset) then this neighbouring luminance line is also selected.
It will be recognised that there are various ways in which the total offsets could be calculated, but in one embodiment said total offsets are calculated as a sum of squared distances between said colours of said block of pixels and respective nearest points of each luminance line.
In one embodiment, said neighbouring luminance line is only examined if said neighbouring luminance line represents an increase in colour saturation from said already-selected luminance line. In considering the luminance lines in the predetermined colour space, it has been realised that the luminance line that lies closest to the colours of a block of pixels (for example in terms of a root mean squared (RMS) distance) is either the line closest to the average colour of the pixels or a line with a more saturated colour than this line. Hence when selecting further luminance lines as part of the iterative luminance line selection procedure it is advantageous to only consider selecting a neighbouring luminance line if its represents an increase in colour saturation from an already-selected luminance line.
In one embodiment, said neighbouring luminance line is only examined if said already-selected luminance line has a non-zero value of said total offset. It has been realised that some particular configurations of pixel colours may result in a zero value of the total offset between those pixel colours and a given luminance line. For example this may be the case if the pixel colours lie directly on one or more luminance lines, this for example being possible if the pixel colours lie on the fully colour saturated edge of the predetermined colour space. In this situation it is not necessary to examine neighbouring luminance lines.
In one embodiment, when a plurality of luminance lines is selected, said plurality of luminance lines is sorted by said total offset for each luminance line. Given that the encoding error for any given set of encoding pixel colours must be at least the total offset for the corresponding luminance line, it is advantageous when there is a plurality of luminance lines to sort those luminance lines in terms of their total offsets. On average, the luminance line with the smallest total offset is most likely to yield the lowest encoding error. However, it should be recognised that the line with the smallest total offset will not necessarily yield the lowest encoding error, since this will depend on the particular positions of the pixel colours with respect to the available base colours on that luminance line. For example, this may happen if the pixel colours happen to fall a relatively long way from the available base colours, then another luminance line may provide a smaller encoding error for this block of pixels.
In one embodiment, said step of determining said set of encoded pixel colours comprises an iterative luminance line consideration procedure, wherein said step of identifying a set of candidate base colours lying on said at least one luminance line and said step of determining said set of encoded pixel colours are performed for said plurality of luminance lines in order of increasing total offset. Having selected a plurality of luminance lines, the most procedurally efficient way of examining them is in order of increasing total offset.
In one embodiment, said step of determining said set of encoded pixel colours comprises an iterative encoding determination procedure comprising the steps, for each candidate base colour of said set of candidate base colours, of:
determining a candidate set of encoded pixel colours using said luminance offset values applied to said candidate base colour;
determining a candidate encoding error for said candidate set of encoded pixel colours indicative of a sum distance in said colour space between said colours of said block of pixels and said candidate set of encoded pixel colours;
if said candidate encoding error is lower than any previous candidate encoding errors determined for said block of pixels, setting said candidate encoding error as a best encoding error;
selecting as said base colour and said set of luminance offsets the candidate base colour and those luminance offset values which when applied to said candidate base colour give said best encoding error.
Accordingly, having determined a set of candidate base colours, each may be taken in turn to determine a candidate set of encoded pixel colours using the luminance offset values applied to that candidate base colour. On this basis a candidate encoding error may be determined indicative of a sum distance in the colour space between the colours of the block of pixels and the candidate set of encoded pixel colours. For each candidate encoding error thus determined, if it is found to be lower than any previous candidate encoding error it is set as the best encoding error. Thus as each candidate base colour is considered, track is kept of the best encoding error thus far found, and at the end of the process the base colour and set of luminance offsets which gave this best encoding error can be used as the chosen base colour and set of luminance offsets for this block of pixels.
In one embodiment, said at least one predetermined table of luminance offset values comprises a plurality of predetermined tables of luminance offset values, and said step of determining said candidate set of encoded pixel colours using said luminance offset values applied to said candidate base colour comprises iteratively determining said candidate set of encoded pixel colours using each table of said plurality of predetermined tables of luminance offset values.
Thus, when a plurality of predetermined tables of luminance offset values is provided, the step of determining the candidate set of encoded pixel colours using the luminance offset values applied to the candidate base colour may try each table of luminance offset values in turn to seek to find the best encoding error.
In one embodiment, said encoding error is determined cumulatively as a cumulative encoding error and, if said cumulative encoding error for a current table of luminance offset values under consideration exceeds said best encoding error, said determining said candidate set of encoded pixel colours using said current table of luminance offset values is terminated. Hence as each table of luminance offset values is considered, the encoding error can be determined cumulatively, and if this cumulative error exceeds a best encoding error previously found it is known that the final encoding error using this table can only exceed the best encoding error found so far, and processing time can be saved by terminating the calculation for this table of luminance offset values. This cumulative encoding error can be evaluated on a pixel-by-pixel basis and in one embodiment said cumulative encoding error is compared with said best encoding error on a pixel-by-pixel basis for said colours of said block of pixels. Hence, as soon as the calculation for a given pixel pushes the cumulative error beyond the best encoding error thus far found, consideration of this table of luminance offset values (as applied to the current base colour under consideration) can be terminated.
In one embodiment, before considering a next luminance line, if said total offset for said next luminance line exceeds said best encoding error said iterative luminance line consideration procedure is terminated and neither said next luminance line nor any further luminance lines in said plurality of luminance lines are considered. This is due to the fact that, as mentioned above, the encoding error using a base colour on a given luminance line must be at least as large as the total offset for that luminance line. Hence, during the iterative luminance line consideration procedure if it is found that the total offset for a next luminance line exceeds the best encoding error found so far, it can immediately be concluded that this next luminance line cannot improve on the best encoding error, nor can any further luminance lines, since these are sorted by total offset. As such, the best encoding error found so far cannot be improved on and the iterative luminance line consideration procedure can be immediately terminated.
In one embodiment, said blocks each comprise a set of 2 pixels by 4 pixels.
In one embodiment, at least one pair of adjacent blocks of said blocks of pixels is encoded in an interdependent fashion, a second block of said adjacent pair of blocks being encoded with reference to a first block of said adjacent pair of blocks. It may be found to be advantageous, in terms of encoding efficiency, for an adjacent pair of blocks to be encoded in an interdependent fashion. For example, if the base colours for two adjacent blocks of pixels are to be encoded using 24 bits, whilst each base colour could be encoded using 12 bits, greater precision for defining the base colours may be achieved by encoding one base colour using 15 bits (e.g. RGB 555 ), whilst the other base colour is defined as a set of 3-bit offsets with respect thereto. This is of course only possible if the difference between the base colours of the two blocks is sufficiently small to be represented in this set of 3-bit offsets.
In one embodiment, said pair of blocks are horizontally adjacent, whilst in another embodiment, said pair of blocks are vertically adjacent.
In one embodiment, the method further comprises determining for each block of pixels if said encoding error is lower when that block of pixels in encoded in said interdependent fashion or when that block of pixels in encoded in an independent fashion without reference to another block of pixels. The encoding fashion which gives the lowest encoding error for that block of pixels may then be selected.
In one embodiment, the method further comprises iteratively determining for each block of pixels said encoding error for all encoding fashions and selecting the encoding fashion which gives an overall lowest value of said encoding error. Hence, on a block-by-block basis, each permutation of independent/interdependent encoding and horizontal/vertical splitting may be tested to determine which permutation gives the best encoding. It may also be determined, for each variety of the interdependent encoding, whether a lower encoding error is produced if (giving the pair of blocks the arbitrary labels first and second) the first block is dependent on the second block, or vice versa.
In one embodiment calculations of distances in said colour space are perception-weighted according to human sensitivity to each colour component of said colour space. Because of the differences in sensitivity of the human eye to different colour components, a perceived improvement in the quality of the encoding can be gained by factoring this phenomenon in to the distance calculations.
In one embodiment said encoding error is calculated as a peak signal to noise ratio. This may also be judged to give an improved quality of encoding.
In one embodiment said image is a texture image. Texture images need to be randomly accessed by graphics applications and hence a block-wise encoding is particularly suitable.
In one embodiment said predetermined encoding format is an ETC format.
Viewed from a second aspect, the present invention provides a computer program product storing in a non-transient fashion a computer program configured cause a computer to carry out the encoding method of the first aspect.
Viewed from a third aspect, the present invention provides an encoding apparatus configured to generate an encoding of an image according to a predetermined encoding format, wherein said predetermined encoding format encodes said image in blocks of pixels, each block of pixels being encoded as a set of encoded pixel colours comprising a base colour and a set of luminance offsets with respect to said base colour,
wherein said base colour is selected from a predetermined set of base colours defined in a predetermined colour space,
wherein said set of luminance offsets is encoded as a set of references to at least one predetermined table of luminance offset values,
and wherein said predetermined set of base colours and said luminance offset values define a set of luminance lines in said predetermined colour space, said encoded pixel colours lying on at least one of said luminance lines,
said apparatus, configured to act on each block of pixels, comprising:
an average colour determination unit configured to determine an average colour of said block of pixels in said predetermined colour space;
a luminance line selection unit configured to select at least one luminance line in dependence on an offset in said colour space of said average colour from said at least one luminance line;
a candidate base colour identifier configured to identify a set of candidate base colours lying on said at least one luminance line; and
a determination unit configured to determine, using said set of candidate base colours and said luminance offset values, said set of encoded pixel colours, wherein said base colour and said set of luminance offsets are selected in dependence on an encoding error indicative of a sum distance in said colour space between said set of encoded pixel colours and said colours of said block of pixels.
Viewed from a fourth aspect the present invention provides encoding apparatus means for generating an encoding of an image according to a predetermined encoding format, wherein said predetermined encoding format encodes said image in blocks of pixels, each block of pixels being encoded as a set of encoded pixel colours comprising a base colour and a set of luminance offsets with respect to said base colour,
wherein said base colour is selected from a predetermined set of base colours defined in a predetermined colour space,
wherein said set of luminance offsets is encoded as a set of references to at least one predetermined table of luminance offset values,
and wherein said predetermined set of base colours and said luminance offset values define a set of luminance lines in said predetermined colour space, said encoded pixel colours lying on at least one of said luminance lines,
said apparatus means, configured to act on each block of pixels, comprising:
average colour determination means for determining an average colour of said block of pixels in said predetermined colour space;
luminance line selection means for selecting at least one luminance line in dependence on an offset in said colour space of said average colour from said at least one luminance line;
candidate base colour identification means for identifying a set of candidate base colours lying on said at least one luminance line; and
determination means for determining, using said set of candidate base colours and said luminance offset values, said set of encoded pixel colours, wherein said base colour and said set of luminance offsets are selected in dependence on an encoding error indicative of a sum distance in said colour space between said set of encoded pixel colours and said colours of said block of pixels.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will be described further, by way of example only, with reference to embodiments thereof as illustrated in the accompanying drawings, in which:
FIG. 1A schematically illustrates a block of pixels to be encoded, which is divided vertically into two half-blocks;
FIG. 1B shows the set of eight predetermined luminance offset tables defined by the ETC format;
FIG. 1C shows the breakdown of the 64 bit encoding of each block of pixels according to the ETC format, both for absolute encoding and for differential encoding;
FIG. 2A shows a set of pixel colours, the average colour of those pixels, and the predetermined set of possible base colours in a predetermined colour space;
FIG. 2B illustrates the encoding of a compressed pixel colour by a base colour and a luminance offset compared with an original pixel colour;
FIG. 3 shows a search area (volume) within which candidate base points are considered according to a prior art encoding method;
FIG. 4A illustrates the nearest luminance line to an average pixel colour and the best luminance line with respect to the original pixel colours;
FIG. 4B illustrates a set of luminance lines indicating the direction of increasing colour saturation;
FIG. 5A schematically illustrates a series of steps taken in one embodiment to determine the best encoding for a given block of pixels;
FIG. 5B illustrates the steps involved in the differential calculation used in the process shown in FIG. 5A ;
FIG. 6 schematically illustrates a series of steps taken in one embodiment when determining a candidate set of luminance lines;
FIG. 7 schematically illustrates a series of steps taken in one embodiment when performing an iterative luminance line consideration procedure;
FIG. 8 schematically illustrates a series of steps taken in one embodiment in an iterative encoding determination procedure when considering a set of candidate base colours on a luminance line; and
FIG. 9 schematically illustrates a general purpose computing device which may be used to implement various embodiments.
DESCRIPTION OF EMBODIMENTS
FIG. 4A illustrates a set of eight pixel colours from a block of pixels (specifically from a half-block of 2×4 pixels), which illustrates why the vicinity of the average pixel colour may not contain the best base colour for encoding these pixel colours. Due to the fact that the original pixel colours are spread across two groups, one relatively close to the origin and one at high R/low G, the average pixel colour falls somewhere between these two groups at a middle R/low G value. NB it should be appreciated that whilst FIGS. 4A and 4B are shown for a two dimensional colour space (RG) this is only for clarity of illustration and the predetermined colour space will more commonly be three dimensional (RGB). It can be seen from FIG. 4A that the nearest base colour (on the “nearest luminance line”) to the average pixel colour can only be expected to provide a set of encoded pixel colours with a relatively large encoding error. Whilst the group of pixels on the left do not deviate greatly from the luminance line on which this base colour lies, and hence could be encoded reasonably well with a relatively large negative luminance offset, the group of pixel colours on the right remain at a significant distance from this luminance line and hence can only be encoded with a relatively large encoding error. By contrast, it can be seen that the best base colour lies on a luminance line (“best luminance line”) which runs closer to both the left hand group of pixels and the right hand group of pixels.
It has in particular been recognised by the inventor of the present invention, that an improvement in the encoding error that can be achieved for a given group of pixel colours by selecting a luminance line which is not the closest luminance line to the average pixel colour of those pixels can only occur (if it will happen at all) for luminance lines which represent an increase in colour saturation with respect to the luminance line nearest to the average pixel colour. The progression of increasing colour saturation of luminance lines is shown in FIG. 4B . Referring back to FIG. 4A , the “best luminance line” is at higher colour saturation than the “nearest luminance line”. Consequently, embodiments of the present invention propose an iterative luminance line selection procedure, wherein luminance lines of increasing colour saturation are iteratively considered (as will be described in more detail below).
The overall encoding procedure of one embodiment of the present invention is schematically set out in FIG. 5A . Each block of 4×4 pixels is treated according to the steps set out in FIG. 5A . Firstly, in steps 100 - 135 , a number of differential encoding calculations are performed. These comprise dividing the 4×4 block into two 2×4 half-blocks and determining an encoding of one half-block with respect to the other. The division of the block into two half-blocks can be either horizontal or vertical and each half-block can be treated as the “first” half-block with respect to which the “second” half-block is differentially encoded. Firstly, at step 100 the block is divided vertically and the left half-block is set as the “first block” and the right half-block is set as the “second block”. Then at step 105 the differential calculation is performed to determine the encoding error for this permutation. The differential calculation at step 105 is carried out as illustrated in the FIG. 5B . Here, at step 160 firstly the best unrestricted differential encoding is calculated for the first half-block. Then at step 165 the best differential encoding of the second half-block relative to the first half-block is determined. Finally, at step 170 the overall encoding error for the block is determined based on the difference (in the colour space) between the original and the compressed pixel values.
Returning to FIG. 5A , the process carried out in steps 100 and 105 is then repeated in steps 110 and 115 , except that now the right hand half-block is set as the “first block” and the left hand half-block is set as the “second block”. Similarly, in steps 120 , 125 , 130 and 135 , the same procedure is carried out, but now splitting the block horizontally into an upper half-block and a lower half-block, and the differential calculation is carried out for the upper half-block with respect to the lower half-block and then reversed, i.e. for the lower half-block with respect to the upper half-block.
The differential encoding permutations have thus all been considered, and at step 140 the best absolute encoding is determined with respect to a horizontal split into two half-blocks, whilst at step 145 the best absolute encoding with respect to a vertical split into two half-blocks is calculated. Finally at step 150 the best overall encoding giving the lowest encoding error for the block as a whole is selected as the chosen encoding for this block. The detail of how the best encoding for each half-block is determined will now be described with reference to FIGS. 6 , 7 and 8 .
Each encoding procedure begins with the process illustrated in FIG. 6 of selecting a set of candidate luminance lines to be used for the encoding. Firstly, at step 200 , the average pixel colour of the half-block is determined. Then, at step 205 the three encodable luminance lines closest to the average pixel colour are selected. These three luminance lines surround the average pixel colour in the three dimensional RGB space used for the encoding. Then at step 210 , for each of these luminance lines the sum of squares distance of the colours of the pixels to the nearest point on that luminance line (the “total offset”) is calculated and each luminance line is added to a candidate set of luminance lines. Within this candidate set of luminance lines each of the three initially selected luminance lines are flagged as “parent” lines and the set is sorted with respect to the sum of squares distance calculated for each. Next, an iterative luminance line selection procedure is carried out beginning at step 215 .
At step 215 a luminance line which is flagged as a “parent” line in the candidate list is selected. Then, at step 220 it is determined if this “parent” line has any neighbouring “daughter” lines which are at higher colour saturation than the parent. Note that in 3D colour space there are generally two neighbouring daughter luminance lines with higher saturation for each parent. Note also that a neighbouring daughter line which has already been examined (via a different parent) will generally not be re-considered. If such neighbouring daughter luminance lines exist, then at step 225 , a daughter luminance line is selected and the sum of squares distance from the colours of the pixels of the half-block to this daughter luminance line is calculated. Then at step 230 it is determined if this sum of squares distance is not greater than the sum of squares distance for the parent luminance line of this daughter. If this is true, then at step 235 this daughter line is added to the candidate set of lines sorted by the sum of squares distance. Finally at step 240 it is determined if the sum of squares is non-zero and if it is, then this daughter is also flagged as a parent in the candidate list.
Having added this daughter to the candidate set of lines, at step 250 it is determined if there is another daughter line of the current parent under consideration, and if there is the flow returns to step 225 to process that daughter line. If however there is not another daughter line of the current parent, or if at step 220 (described above) it is determined that the current parent under consideration does not have any neighbouring daughter luminance lines with higher saturation, then the flow proceeds to step 255 where it is determined if there is another luminance line in the candidate set of lines which is flagged as a parent and has not yet been processed. If there is, then the flow returns to step 215 to begin processing that parent line. If there are no other unprocessed parent lines in the candidate set then the flow proceeds to step 260 at which point the candidate line generation process is completed.
With a candidate set of luminance lines selected according to the procedure described in FIG. 6 , the set of candidate luminance lines can then be considered to determine which gives the base colour which results in the best encoding for this half-block. This procedure is carried out in one embodiment according to the steps schematically illustrated in FIG. 7 . Firstly, from the candidate set of luminance lines sorted according to their total offset (i.e. the sum of squares distance of the colours of the pixels of the half-block to the nearest point on that luminance line), the line with the lowest offset is selected at step 300 . Then, at step 305 the best encoding available for this line (i.e. using the set of base colours and luminance offsets which define this line) is determined. More detail of this will be described below with reference to FIG. 8 . Having determined the best encoding for this line, at step 310 the encoding error for this line is determined as the sum of squares distance between the colours of the original pixels of this half-block and the set of encoded pixel colours according to this encoding. If this encoding error is the best (i.e. lowest) encoding error that has been thus far determined, then it is set as the current best error. Then the flow proceeds to step 315 where it is determined if there is another candidate luminance line in the sorted list. If there is, then the flow proceeds to step 320 where the next closest luminance line (in terms of the calculated total offset) is selected. Then at step 325 it is checked if the sum of squares distance to this line (i.e. the total offset for this line)—according to which the line was sorted in the candidate list—is greater than the best error determined so far (see step 310 ). If it is, then it is not possible for this line or any further lines to improve on that best error and the flow proceeds to the concluding step at step 330 wherein the half-block is encoded using the line which gave that best error, and in particular using the base colour on that line which gave that best error. If however at step 325 it is found that the total offset for this next line in the candidate list does not exceed the best error calculated so far then the flow returns to step 305 to determine the best encoding for this next line, and at step 310 to see if the encoding error for this next line improves on the best error so far. If at any iteration it is determined at step 315 that there is no further candidate line list then the flow proceeds to step 330 .
The procedure by which the best encoding for a given luminance line (step 305 in FIG. 7 ) is determined is now described with reference to the steps shown in FIG. 8 . First, at step 400 the first base point (candidate base colour) on this luminance line is selected. Then at step 405 the first table of luminance offset values is selected. Then, from this table of luminance offset values, at step 410 the best table entry (i.e. luminance offset value) for the first pixel of the half-block is determined. “Best” here means the entry which results in the lowest encoding error for this pixel. The encoding error for this pixel, i.e. the distance in colour space between the encoded pixel colour and the original pixel colour, is added to a cumulative encoding error for this half-block. At step 415 it is checked if this cumulative encoding error exceeds a target error for this half-block. Note that on the very first iteration of the process described in FIG. 8 for the first base point, first table and first pixel, there is naturally no pre-existing target error and hence on this very first iteration the result at step 415 will always be to follow the “no” path. Then at step 420 it is determined if there is another pixel within the half-block and if there is then at step 425 then best table entry (for the current table under consideration) is determined for this next pixel. The encoding error associated with this next pixel is also calculated and added to the cumulative error for this table. If the loop of steps 415 , 420 and 425 is completed for all pixels of the half-block (i.e. without failing the total error test at step 415 ) then at step 430 the total error calculated for the half-block for the current table is set as the new target error.
From either failing the total error test 415 or setting a new target error at step 430 , the flow proceeds to step 435 , at which it is determined if there is another table which can be considered for encoding this half-block. If there is then at step 440 that next table is selected and the flow returns to step 410 to try encoding the half-block of pixels using that table. If however another table is not available at step 435 then the flow proceeds to step 445 where it is determined if there is another base point (i.e. candidate base colour) on the luminance line currently under consideration. If there is, then the flow returns to step 405 , where the iterative determination process with respect to the available tables is carried out again using that new base colour. Once all base points on this line have been considered then the flow concludes at step 450 where the best encoding for this line is determined to be given by the base colour and luminance offsets which gave the target error.
It should be noted that the above described distances calculated in the predetermined colour space are in some embodiments calculated as perception-weighted distances, taking into account the sensitivity of the human eye to the difference colour components. Also the encoding error, in some embodiments may be calculated in terms of a peak signal to noise ratio. Such techniques are familiar to the skilled person and are not described in detail herein.
FIG. 9 schematically illustrates a general purpose computing device 500 of the type that may be used to implement the above described techniques. The general purpose computing device 500 includes a central processing unit 502 , a random access memory 504 and a read only memory 506 , connected together via bus 522 . It also further comprises a network interface card 508 , a hard disk drive 510 , a display driver 512 and monitor 514 and a user input/output circuit 516 with a keyboard 518 and mouse 520 all connected via the common bus 522 . In operation, when performing the necessary calculations to determine the encoding of each block of pixels, the central processing unit 502 will execute computer program instructions that may for example be stored in the random access memory 504 and/or the read only memory 506 . Program instructions could be additionally be retrieved from the hard disk drive 510 or dynamically downloaded via the network interface card 508 . The results of the processing performed may be displayed to a user via a connected display driver 512 and monitor 514 . User inputs for controlling the operation of the general purpose computing device 500 may be received via a connected user input output circuit 516 from the keyboard 518 or the mouse 520 . It will be appreciated that the computer program could be written in a variety of different computer languages. The computer program may be stored locally on a recording medium or dynamically downloaded to the general purpose computing device 500 . When operating under control of an appropriate computer program, the general purpose computing device 500 can perform the above described techniques and can be considered to form an apparatus for performing the above described technique. The architecture of the general purpose computing device 500 could vary considerably and FIG. 9 is only one example.
The techniques described herein enable the encoding of an image to be performed much faster than the techniques know in the prior art. For example, creating ETC compressed textures using existing tools is very slow (300 to 400 pixels per second, or 30 minutes to 1 hour for a typical texture, for the highest quality supported by the existing tools). The techniques described herein speed up the compression process by anything up to 125 times (in the example cases tested) giving compression speeds of up to 40,000 pixels per second. Furthermore, in many cases, this was done whilst also producing a higher quality result than the existing algorithm. This is of particular benefit in the context of developing and testing graphics applications, since applications may include dozens or hundreds of textures, and the techniques described herein allow developers to assess more quickly the quality of the compressed textures during development.
Although a particular embodiment has been described herein, it will be appreciated that the invention is not limited thereto and that many modifications and additions thereto may be made within the scope of the invention. For example, various combinations of the features of the following dependent claims could be made with the features of the independent claims without departing from the scope of the present invention. | An encoding method generates an encoded image according to a predetermined encoding format. The method includes the step of, for each block of pixels, determining an average color of colors of the block of pixels in the predetermined color space; selecting at least one luminance line in dependence on an offset in the color space of the average color from the at least one luminance line; identifying a set of candidate base colors lying on the at least one luminance line; and determining, using the set of candidate base colors and the luminance offset values, the set of encoded pixel colors. The base color and the set of luminance offsets are selected in dependence on an encoding error indicative of a sum distance in the color space between the set of encoded pixel colors and the colors of the block of pixels. | 7 |
This invention relates to a sonde for installation in a well, a well assembly comprising such a sonde, and methods for installing acoustic sensing equipment in a well and sensing acoustic vibration in a well.
BACKGROUND
Microseismic analysis of the geological strata around the bore of fluid injection and production wells is typically effected by the use of seismic sensor assemblies (sondes), mounted downhole in the area of the fluid flow. Usually a number of sondes are mounted in the well at different levels in the bore. Deployment techniques have been developed to allow the sensors to become almost completely mechanically decoupled from the flow induced noise from the tubing.
Systems for permanently installing a sonde against an inner wall of a pipe, such as the casing of a fluid extraction well, are known. Such systems are described in, for example, U.S. Pat. Nos. 5,092,423, 5,181,565, 5,200,581, 5,111,903, 6,289,985, 6,173,804 and 5,318,129.
Typically, a sonde comprises a clamp which permanently or semi-permanently engages with the inner casing of a well. For example, the clamp may be lowered into the well in a retracted state and then once in position activated to engage with the well casing using a pressure actuated system, which may use external pressure sources or well pressure. Such a clamp is described in patent application no. EP-A-1370891, the contents of which are incorporated herein by reference, which describes C-shaped ring clamps. It is also possible to activate the clamp near the top of the well, and simply drag it down the well, acting against friction between the clamp and well casing, into the desired position.
A disadvantage of these systems is that because the sondes (for example with C-shaped ring clamps) are released from the tubing and clamped to the inside of the casing, any large tubing movement, i.e. typically more than 15 cm, can cause the risk of coupling the sondes back to the tubing. Such movement is invariably axial or rotational. These systems only perform at their best when the tubing movement is small. Small movements can also be accommodated by the wires from the sensors mounted on the casing and running up the tubing, whereas large movements will result in breakage of these wires.
Well completions differ significantly from well to well and temperature changes cause thermal expansion to the installed tubing. Completions have to be designed to allow for the tubing axial or rotational movement, and this can be done by the installation of a seal bore packer for example.
For well completions of this type where tubing movement occurs, it would therefore be preferable to provide a means of allowing the sondes to move along the inside of the casing when the tubing moves while maintaining good mechanical decoupling.
With such an arrangement, the sondes must be able to move along the axis of the borehole when the tubing moves, this tubing movement being possible in either direction. Therefore, the sonde must be secured to the tubing by some mechanical means which must have the following properties:
a) it is strong enough to allow the sonde to be dragged along the casing; b) it does not change the frequency properties of the sonde by changing or adding unwanted resonance; and c) most importantly, it does not provide a path for flow noise from tubing to sonde.
It is an object of the present invention to provide a sonde having such securement means.
SUMMARY OF THE INVENTION
In accordance with a first object of the present invention there is provided a sonde for installation in a well comprising a clamp for engaging with the inner wall of a well casing and securing means for securing the clamp to inner tubing of the well, characterised by the securing means comprising attachment means for connection to the inner tubing and a rod connected between the clamp and the attachment means.
Advantageously, the dimensions and/or material of the rod are selected so as to minimise transfer of noise from the tubing to the sonde.
The securing means preferably comprises a plurality of such rods. With this arrangement, at least one such rod and attachment means may be provided on each side of the clamp along the axis of the well.
Advantageously, the attachment means is soft mounted to the tubing.
The attachment means may comprise electrical distribution means enabling electrical connection between the sonde and wellhead components, the electrical distribution means being fixed relative to the sonde.
The clamp may be substantially C-shaped.
Preferably, the clamp carries a sensor. The sensor may be electrically connected to the electrical distribution means.
In accordance with a second aspect of the present invention, there is provided a well assembly comprising a well, a well casing lining the wall of the well, tubing extending internally through the well and a sonde in accordance with the first aspect of the invention.
In accordance with a third aspect of the present invention, there is provided a method of installing acoustic sensing equipment in a well, comprising the steps of:
providing a sonde in accordance with any preceding claim, fitting the sonde to the inner tubing of a well while the clamp is in a retracted state, expanding the clamp so that it contacts the inner wall of the well casing, and pushing the sonde along the well to its desired position.
In accordance with a fourth aspect of the present invention, there is provided a method of sensing acoustic vibration in a well, comprising the steps of:
providing a sonde in accordance with any preceding claim, installing the sonde at a desired position in the well so that acoustic sensing equipment carried by the sonde is held against the inner wall of the well casing.
Thus the object of the invention is achieved by connecting at least one rigid “tether rod” between the sonde and the tubing. A plurality of such rods may be fitted above and below the sonde and attach on to this tubing at soft mounted interfaces above and below the sonde.
The cross sectional area of the rods must be small in comparison to the cross sectional area of the tubing, which provides a high ‘impedance’ mismatch between cable and tubing. In popular science terms: compare this to a thin rope connected to a heavy rope. If you swing the thin rope, a travelling wave will propagate through the rope, when it reaches the heavy rope this wave will be largely reflected, instead of travelling along the heavy rope. This works two ways, if you swing the heavy rope the wave will also be reflected at the thin rope instead of travelling further along the thin rope. Thus, although the sonde is mechanically coupled to the installed tubing, it is effectively isolated, acoustically, from the noise generated by the fluid flow in the tubing. The dimensions, especially the diameter, and the material of the tether rods can be calculated to provide such acoustic isolation over the band of frequencies required to be sensed by the sonde, taking into account the choice of material for the rods.
Embodiments in accordance with the invention have the following advantages over the prior art:
i) The acoustic sensors remain acoustically decoupled from the flow noise; ii) Potential damage to the sensor electrical wiring by tubing movement is prevented; iii) A strong connection to the tubing is provided. The rod size and number can be adjusted to suit requirements; iv) There is no low frequency resonance added in the seismic frequency band; v) The rods can be fitted to any shaped clamp equipment; and vi) Deployment from the surface is enabled without any remote actuation equipment. Therefore, the tool may be dragged down from the surface during installation. No actuation mechanism, e.g. downhole pressure supply is required, and the need for a threaded section of tubing required by prior art systems, typically 1500 mm long and carrying the pre-assembled clamp system, is eliminated.
DESCRIPTION OF DRAWINGS
The invention will now be described by way of example with reference to the accompanying drawings, in which:
FIG. 1 shows a first embodiment of the sonde in position in a well, the sonde comprising a C-shaped ring clamp; and
FIG. 2 shows a second embodiment in which the sonde comprises a different C-shaped clamp.
DETAILED DESCRIPTION
FIG. 1 shows a first embodiment of the invention wherein the sonde comprises a C-shaped spring clamp design as described in the patent application no. EP-A-1370891. Typically four acoustic sensors 1 are mounted in the C-shaped clamp 2 . The clamp 2 may be positioned within the well casing 3 by being fitted over production tubing 7 , compressed by a mechanical assembly and released hydraulically when the assembly has been lowered down the well casing 3 , to the required depth down the well. Alternatively the clamp may be compressed (e.g. manually) and fitted over tubing 7 near the top of the well and then allowed to engage the well casing and simply slide down the well in contact with the casing 3 until it is in position. As shown in this embodiment, the C-shaped sonde clamp 2 is attached to thin rigid tether rods 4 , typically six rods being used, i.e. three above and three below. The other ends of the rods are connected to attachment means 5 and 6 which are in turn affixed to the tubing 7 . The attachments 5 and 6 may be soft-mounted to tubing 7 , e.g. using a resiliently deformable material, such as a suitable polymer, between the attachment and the tubing, which acts to dampen acoustic vibration to prevent noise transfer between the tubing and the clamp, and hence to sensors 1 . The attachment 5 also supports a distribution unit 8 which provides an electrical interface between the wires 9 , from each of the acoustic sensors 1 , and the cable 10 to the wellhead and its acoustic signal processing system. Since the sonde is mechanically coupled to the distribution unit, i.e. the distribution unit is secured relative to the sonde, any movement of the well casing relative to the tubing does not result in damage to the electrical wiring, which is a potential risk in conventional systems.
In the second of the above positioning methods, installation of the sonde is effected by fixing the whole assembly, consisting of the sonde clamp 2 with sensors 1 coupled to the attachments 5 and 6 by the tether rods 4 , pre-wired to distribution unit 8 and cable 10 , to the tubing 7 , prior to lowering the tubing 7 down the well. With the assembly attached to the tubing 7 , the clamp 1 is compressed manually to allow it to slip into the casing, facilitated by the chamfered edges of the clamp. The tubing may then be lowered down the well with the clamp 2 sliding down the casing 3 , with the force to enable it to do so transmitted from the tubing 7 via the attachments 5 and 6 and the tether rods. This does not damage either the clamp or the well casing as the clamp is typically made of a very hard material, for example Inconel®, and also due to the lubricating effect of fluid in the well. Alternatively, the clamp may be retained in its compressed state until the correct position is reached down the well.
FIG. 2 shows a second embodiment of the invention applied to an alternative design of sonde C-shaped clamp which is also described in EP-A-1370891. In this case, sonde packs 11 each consisting of typically four sensors arranged in a tetrahedral configuration are attached to a spring clamp 12 . In the same manner as in the first embodiment, the clamp is attached to typically six thin rigid tether rods 4 , i.e. three above and three below, the other ends of the rods 4 connected to attachments 5 and 6 which are also affixed to the tubing 7 as in the first embodiment. The method of installation is somewhat different to the first embodiment though. The clamp shown in FIG. 2 is contracted and expanded by physical manipulation of the members 13 at the ends of the C-shape. In practice, a forked member (not shown) like in EP-A-1370891 is used to hold the members 13 together to contract the clamp until it is inserted into the well. The clamp may then either by positioned while the clamp is retracted and then expanded to hold it in position against the well casing, or expanded near the top of the well and pushed down to the desired position against the well casing. Expansion of the clamp is effected by removing the forked member from engagement with members 13 , so that the clamp moves into the expanded state. Sliding the expanded clamp down the casing does not damage either the clamp or the well casing as the clamp is typically made of a very hard material, for example Inconel®, and also due to the lubricating effect of fluid in the well.
It should be noted that both forms of clamp provide substantial force to press the sonde to the well casing to ensure good acoustic coupling. Experimental work with a prototype has demonstrated that the sliding friction force within the casing is sufficiently low for the tether rods to adequately overcome these forces during installation.
It should be noted that the invention is not limited to the embodiments shown, and various alternatives are possible within the scope of the claims. For example, although the invention has been described with reference to C-shaped clamps, any design of clamp may be used which can have the rods attached thereto. | A sonde for installation in a well including a clamp ( 2 ) for engaging with the inner wall of a well casing ( 3 ) and securing device for securing the clamp to inner tubing of the well, whereby the securing device includes an attachment device ( 5, 6 ) for connection to the inner tubing and a rod ( 4 ) connected between the clamp and the attachment device. | 4 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a Divisional of application Ser. No. 13/590,465, filed at Aug. 21 2012, the entirety of which is incorporated by reference herein.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to an electric curtain.
[0004] 2. Description of the Related Art
[0005] The visual system in humans allows individuals to assimilate information from the environment. The act of seeing starts when the lens of the eye focuses an image of its surroundings onto a light-sensitive membrane in the back of the eye, called the retina. The retina is actually part of the brain that is isolated to serve as a transducer for the conversion of patterns of light into neuronal signals. Then, the neuronal signals are processed by the brain and humans therefore see what they are seeing.
[0006] A refractive error, or refraction error, is an error in the focusing of light by the eye. The refractive error comprises different types, such as myopia, hyperopia or astigmatism. Myopia refers to a refractive defect of the optical properties of an eye that causes images to focus on a forward portion of the retina (i.e., a refractive error). Those optical defects are typically caused by, among other things, defects of the cornea, elongation of the eye structure, other conditions, or a combination of those conditions. Hyperopia, on the other hand, refers to a refractive error of the optical properties of an eye that causes images to focus on a portion behind the retina. Those optical defects are the result when the optics of the eye is not strong enough for the front to back length of the eye. Astigmatism refers to a refractive error that causes light entering the eye to focus on two points rather than one. It is caused by an uneven power of the cornea. Myopia, hyperopia, and astigmatism are the principle refractive errors that cause persons to seek treatment to correct their vision problems, but there is still no treatment that can deal with these problems at one time except for laser vision correction.
BRIEF SUMMARY OF THE INVENTION
[0007] An embodiment of the invention provides a focus adjustable apparatus adapted to be disposed on a transparent substrate to modulate a plurality of rays passing through the transparent substrate. The focus adjustable apparatus comprises a light modulation device, an eye tracking device, an eyesight status device and a controller. The light modulation device receives the rays from the transparent substrate and adjusts an emergent angle of each of the rays. The eye tracking device tracks a position of a user and estimates a distance between the user and the focus adjustable apparatus. The eyesight status device obtains an eyesight data of the user. The controller provides a control signal to drive the light modulation device by estimating the emergent angle of the each of the plurality of rays according to the distance between the user and the focus adjustable apparatus and the eyesight data of the user.
[0008] Another embodiment of the invention provides a display with an adjustable focus mechanism. The display comprises a display panel, a light modulation device and a controller. The display panel emits a plurality of rays to form an image. The light modulation device receives the rays from the display panel and adjusts an emergent angle of each ray. The controller provides a control signal to drive the light modulation device by estimating the emergent angle of the each of the plurality of rays according to an eyesight data of a user and a distance between the user and the display.
[0009] Another embodiment of the invention provides an electric curtain comprising sunlight detector and a light modulation device. The sunlight detector obtains a light data of sunlight. The light modulation device receives the sunlight and adjusts an emergent angle of the sunlight to refract the sunlight to a ceiling of a room.
[0010] A detailed description is given in the following embodiments with reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] The present invention can be more fully understood by reading the subsequent detailed description and examples with references made to the accompanying drawings, wherein:
[0012] FIG. 1 is a schematic diagram of an embodiment of a focus adjustable apparatus according to the invention.
[0013] FIG. 2 is a schematic diagram of an electro-wetting unit according to an embodiment of the invention.
[0014] FIG. 3 is a schematic diagram of an electro-wetting unit according to another embodiment of the invention.
[0015] FIG. 4 is a schematic diagram of an electro-wetting unit according to another embodiment of the invention.
[0016] FIG. 5 is a cross section diagram of a light modulation device according to an embodiment of the invention.
[0017] FIG. 6 is a schematic of an embodiment of a display device according to the invention.
[0018] FIG. 7 is a schematic diagram of another embodiment of a focus adjustable apparatus according to the invention.
[0019] FIG. 8 is a schematic diagram of an embodiment of an electric curtain according to the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0020] The following description is of the best-contemplated mode of carrying out the invention. This description is made for the purpose of illustrating the general principles of the invention and should not be taken in a limiting sense. The scope of the invention is best determined by reference to the appended claims.
[0021] FIG. 1 is a schematic diagram of an embodiment of a focus adjustable apparatus according to the invention. The focus adjustable apparatus is disposed on a transparent substrate 15 a of the display 15 . The focus adjustable apparatus comprises a light modulation device 11 , an eye tracking device 13 , an eyesight status device 14 and a controller 12 . The eye tracking device 13 tracks a position of a user 16 and estimates a distance d between the user 16 and the display 15 . The eye tracking device 13 further estimates an angle θ that varies according to a relative position of the user 16 with reference to the light modulation device 11 . The eyesight status device 14 obtains an eyesight data of the user. The eyesight data comprises an astigmatism degree, a degree of myopia or a degree of hyperopia of the user 16 . The eyesight status device 14 may acquire the eyesight data of the user 16 from an electronic patient record database and the user 16 needs to provide some security authorization data to the eyesight status device 14 , and then the eyesight status device 14 acquires the eyesight data according to the security authorization data. In another embodiment, the eyesight data is directly input to the eyesight status device 14 by the user. In another embodiment, the eyesight data is determined by an eye refractometer (not shown in FIG. 1 ). The eye refractometer is embedded in the eye tracking device. The eye refractometer projects a test pattern onto the retina of an eye to be examined, and determines the eyesight data according to the reflected test patter from the retina. Furthermore, the focus adjustable apparatus comprises a sensor for detecting an ambient light and the controller 12 controls the illumination of the rays refracted by the light modulation device 11 according to the illumination of the ambient light.
[0022] The light modulation device 11 receives a plurality of rays from the transparent substrate 15 a and adjusts an emergent angle of each of the rays. The emergent angle is determined by the controller 12 . The controller 12 estimate the emergent angle according to the eyesight data of the user 16 and the distance between the user 16 and the display 15 . In one embodiment, the focus adjustable apparatus further comprises a calculator (not shown in FIG. 1 ) to receive the distance between the user 16 and the display 15 and the eyesight data of the user 16 to generate a control parameter, and then the controller 12 receives the control parameter and estimates the emergent angle according to the control parameter from the calculator. The rays refracted by the light modulation device 11 form an in-focus image on a retina of the user 16 . In this embodiment, the light modulation device 11 comprises a plurality of electro-wetting units arranged in a matrix form. The electro-wetting units are driven by a dielectric force and the refraction index of each electro-wetting unit can be changed according to the magnitude of the dielectric force. In another embodiment, the light modulation device 11 is implemented by a plurality of Fresnel lens or Hologram elements arranged in a matrix or array form.
[0023] An electro-wetting unit is illustrated with FIG. 2 . FIG. 2 is a schematic diagram of an electro-wetting unit according to an embodiment of the invention. The electro-wetting unit 20 comprises a first electrode 21 , a second electrode 22 , a compartment 23 , and a first light modulating media (labeled as A) and a second light modulating media (labeled as B) filled in the compartment 23 (shown as the dotted line in FIG. 2 ), wherein the first light modulating media and second light modulating media are substantially immiscible and are of different refractive indices. The boundary between the first light and second light modulating media is adjusted by applying voltages to the first electrode 21 and the second electrode 22 according to a control signal from the controller, such as the controller 12 in FIG. 1 . The control signal is determined according to the emergent angle Φ by the controller.
[0024] FIG. 3 is a schematic diagram of an electro-wetting unit according to another embodiment of the invention. The electro-wetting unit 30 comprises a first electrode 31 , a second electrode 32 , a compartment 33 , a third electrode 34 and a first light modulating media (labeled as A) and a second light modulating media (labeled as B) filled in the compartment 33 (shown as the dotted line in FIG. 3 ), wherein the first light modulating media and second light modulating media are substantially immiscible and are of different refractive indices. In this embodiment, the first electrode 31 , the second electrode 32 and the third electrode 34 are optically transparent electrodes. The boundary between the first light and second light modulating media is adjusted by applying voltages to the first electrode 31 , the second electrode 32 and the third electrode 34 according to a control signal from the controller, such as the controller 12 in FIG. 1 . The control signal is determined according to the emergent angle 0 by the controller.
[0025] FIG. 4 is a schematic diagram of an electro-wetting unit according to another embodiment of the invention. The electro-wetting unit 40 comprises a first electrode 41 , a second electrode 42 , a bottom electrode 43 , a third electrode 44 , a fourth electrode 45 , a upper electrode 46 , a compartment 47 , and a first light modulating media (labeled as A), a second light modulating media (labeled as B) and a third light modulating media (labeled as C) filled in the compartment 47 (shown as the dotted line in FIG. 4 ), wherein the first light modulating media, the second light modulating media and the third light modulating media are substantially immiscible and are of different refractive indices. In this embodiment, the first electrode 41 , the second electrode 42 , the bottom electrode 43 , the third electrode 44 , the fourth electrode 45 and the upper electrode 46 are optically transparent electrodes. The first boundary 48 and the second boundary 49 can be adjusted by applying voltages to the first electrode 41 , the second electrode 42 , the bottom electrode 43 , the third electrode 44 , the fourth electrode 45 and the upper electrode 46 according to a control signal from the controller, such as the controller 12 in FIG. 1 . The control signal is determined according to the emergent angle Φ by the controller. In other embodiments, the electro-wetting unit is named as an electronically switchable light modulating cell which is disclosed in a pending U.S. patent application Ser. No. 13/016,384, filed Jan. 28, 2011 and entitled “LIGHT MODULATING CELL, DEVICE AND SYSTEM”, the entirety of which is incorporated by reference herein.
[0026] FIG. 5 is a cross section diagram of a light modulation device according to an embodiment of the invention. The light modulation device 50 comprises a glue layer 53 , a flexible substrate 52 and an electro-wetting array 51 . The light modulation device 50 can be adhered to a display device, a plane glass, a window, a lampshade, an eyeglass or other transparent substance via the glue layer 53 . The glue layer 53 may be implemented by a pressure sensitive adhesive material or a silica gel. The flexible substrate 52 may be a PET layer, a PI layer or a roll-able glass.
[0027] FIG. 6 is a schematic of an embodiment of a display device according to the invention. The display device 60 comprises a controller 61 , an eye tracking device 62 , an eyesight status device 63 , a light modulation device 64 and a panel 65 . The light modulation device 64 is adhered to the panel 65 . The eye tracking device 62 tracks a position of a user and estimates a distance d between the user and the display device 60 . The eye tracking device 62 further estimates an angle 0 that varies according to a relative position of the user with reference to the light modulation device 64 . The eyesight status device 63 obtains an eyesight data of the user. The eyesight data may comprise an astigmatism degree, a degree of myopia or a degree of hyperopia of the user. The eyesight status device 63 may acquire the eyesight data of the user from an electronic patient record database and the user needs to provide some security authorization data to the eyesight status device 63 , and then the eyesight status device 63 acquires the eyesight data according to the security authorization data. In another embodiment, the eyesight data is directly input to the eyesight status device 63 by the user. In another embodiment, the eyesight data is determined by an eye refractometer (not shown in FIG. 6 ) that is embedded in the eye tracking device 62 . The eye refractometer projects a test pattern onto the retina of an eye to be examined, and determines the eyesight data according to the reflected test patter from the retina. The sensor 66 detects an ambient light and the controller 61 controls the illumination of the rays refracted by the light modulation device 64 according to the illumination of the ambient light.
[0028] The light modulation device 64 receives a plurality of rays from the panel 65 and adjusts an emergent angle of each ray. By adjusting the emergent angle of each ray, the image therefore can be correctly focused on the retina of the eyes of the user. The emergent angle is determined by the controller 61 . The controller 61 estimates the emergent angle according to the eyesight data of the user and the distance between the user and the display 60 . In one embodiment, the controller 61 comprises a calculator (not shown in FIG. 6 ). The calculator receives the distance between the user and the display 60 and the eyesight data of the user to generate a control parameter, and then the controller 61 receives the control parameter and estimates the emergent angle according to the control parameter from the calculator. The rays refracted by the light modulation device 64 form an in-focus image on a retina of the user. In this embodiment, the light modulation device 64 comprises a plurality of electro-wetting units arranged in a matrix form. The electro-wetting units are driven by a dielectric force and the refraction index of each electro-wetting unit can be changed according to the magnitude of the dielectric force. In another embodiment, the light modulation device 64 is implemented by a plurality of Fresnel lens or Hologram elements arranged in a matrix or array form. For examples of the electro-wetting unit, reference can be made to FIGS. 2-4 .
[0029] In another embodiment, the user can directly control the light modulation device 64 via a remote control. The user can control emergent angles of rays refracted by the light modulation device 64 via the remote control. Once the emergent angles vary, the image seen by the user may be blurred or clear, thus, the user can instinctively control the light modulation device 64 only according to the displayed image. The control of the light modulation device 64 is similar to a zoom in/zoom out control or a focus control. Simply speaking, the light modulation device 64 plays a role similar to an eyeglass to ensure that the image can be correctly formed on the retina of the eyes of the user.
[0030] FIG. 7 is a schematic diagram of another embodiment of a focus adjustable apparatus according to the invention. The focus adjustable apparatus 70 comprises a light modulation device 71 , a controller 72 , an eye tracking device 73 , a motion detector 74 , a calculator 75 and an eye status device 76 . The light modulation device 71 is adhered to an inner or outer surface of a windshield of a vehicle. For the detailed structure of the light modulation device 71 , reference can be made to FIG. 5 , and thus, is not described here for briefly. The eye tracking device 73 tracks a position of a user and estimates a first distance d 1 between the user and the light modulation device 71 (or the windshield). The eye tracking device 73 further tracks the movement of the eyeball of a user and transmits an object information to the controller 72 . The object information indicates which object, such as the object 77 , the user is looking at. The object may be an obstacle, a moving vehicle or a moving/still object. The controller 72 then transmits a control signal to control the motion detector 74 to measure a second distance d 2 between the object 77 and the light modulation device 71 .
[0031] The eyesight status device 76 obtains eyesight data of the user. The eyesight data may comprise an astigmatism degree, a degree of myopia or a degree of hyperopia of the user. The eyesight status device 76 may acquire the eyesight data of the user from an electronic patient record database or a digital medical system and the user needs to provide some security authorization data to the eyesight status device 76 for acquiring the eyesight data. In another embodiment, the eyesight data is directly input to the eyesight status device 76 by the user. In another embodiment, the eyesight data is determined by an eye refractometer 77 . The eye refractometer 77 projects a test pattern onto the retina of an eye to be examined, and determines the eyesight data according to the reflected test pattern? from the retina. The sensor 78 detects an ambient light and the controller 72 controls the illumination of the rays refracted by the light modulation device 71 according to the illumination of the ambient light. In this embodiment, the eye refractometer 77 and the sensor 78 are optional for the focus adjustable apparatus 70 , but they still can be integrated into the focus adjustable apparatus 70 .
[0032] The light modulation device 71 receives a plurality of rays from the object 77 and adjusts an emergent angle of each ray. By adjusting the emergent angle of each ray, the image of the object 77 therefore can be correctly focused on the retina of the eyes of the user. The emergent angle is determined by the controller 72 . The controller 72 estimates the emergent angle according to the eyesight data of the user, the first distance d 1 and the second distance d 2 . The calculator 75 receives the first distance, the second distance and the eyesight data of the user to generate a control parameter. Then, the controller 61 receives the control parameter to estimate the emergent angle accordingly. The rays refracted by the light modulation device 71 form an in-focus image on a retina of the user. In this embodiment, the light modulation device 71 comprises a plurality of electro-wetting units arranged in a matrix form. The electro-wetting units are driven by a dielectric force and the refraction index of each electro-wetting unit can be changed according to the magnitude of the dielectric force. In another embodiment, the light modulation device 71 is implemented by a plurality of Fresnel lens or Hologram elements arranged in a matrix or array form. For the examples of the electro-wetting unit, reference can be made to FIGS. 2-4 , and thus, is not described here for briefly.
[0033] FIG. 8 is a schematic diagram of an embodiment of an electric curtain according to the invention. The electric curtain comprises a light modulation device 81 , a controller 82 , sunlight detector 83 and a tracking device 84 . The tracking device 84 tracks a position of the user and measures a distance d between the user and the light modulation device 81 and a height h of the user. The height can be input by the user via a remote control. The user can also control the angle θ 2 via the remote control. The sunlight detector 83 obtains light information of sunlight, such as an incident angle θ 1 and the illumination. The controller 82 then estimates the angle θ 2 according to the incident angle θ 1 , the distance d and the height h. The light modulation device 81 receives a control signal from the controller to refract the sunlight to a ceiling of a room. In this embodiment, the controller 82 transmits a control signal to adjust the angle θ 2 and the amount of the sunlight passing through the light modulation device 81 . The light modulation device 81 is a flexible film and adheres to a window. For the detailed structure of the light modulation device 81 , reference can be made to FIG. 5 , and thus, is not described here for briefly.
[0034] Since the light modulation device 81 can refract the sunlight to the ceiling of the room, the user may not directly feel the heat from the sunlight and the temperature of the room can be regulated at a higher temperature by an air conditioner. Furthermore, the light modulation device 81 prevents the eye of a user from receiving direct sunlight.
[0035] While the invention has been described by way of example and in terms of the preferred embodiments, it is to be understood that the invention is not limited to the disclosed embodiments. To the contrary, it is intended to cover various modifications and similar arrangements (as would be apparent to those skilled in the art). Therefore, the scope of the appended claims should be accorded the broadest interpretation so as to encompass all such modifications and similar arrangements. | An aspect of the invention provides an electric curtain. The electric curtain includes a sunlight detector for obtaining light information of sunlight and a light modulation device capable of receiving the sunlight and for adjusting an emergent angle of the sunlight to refract the sunlight to a ceiling of a room. | 4 |
BACKGROUND OF THE INVENTION
The invention relates to an arrangement for cleaning of waste water utilizing rotating biocontactors.
Actually known arrangements for cleaning of waste water based on the principle of rotating biodisks utilize alternative submerging of disks with adhering functional bioculture into waste water, and its subsequent emerging, securing thus its contact with air. A drawback of the known cleaning arrangements is the low amount of oxygen introduced into the waste water which is not supposed to be used for aeration, and the oxygenation of water has been solely accomplished by submerging a biocontactor into the waste water prior to exposing the biocontactor to air. A consequence thereof is a rather insufficient cleaning by the suspended culture, as the introduced amount of oxygen does not correspond to optimum cleaning conditions. Known water cleaning stations of this kind do not apply the recirculation of the mixture of water and sludge within the space of the biological tank, the consequence of which is unfavourable hydraulic conditions. It is also known that biodisk cleaning stations cannot secure cleaning of water by flocules torn-off from the disk surface, although that is the most active action of the grown film. An increase of the contact surface, that is, and increase in the diameter and of the number disks, leads to an increase in the size of the cleaning station and an increase in its actual and operational costs.
SUMMARY OF THE INVENTION
It is an object of this invention to eliminate to a substantial extend the above-mentioned drawbacks and to provide a water cleaning station which would operate more efficiently than the actually known stations of this kind. According to this invention, face plates are fixed near both ends of a rotatable shaft situated in a tank, which plates are connected near their circumference by longitudinal supporting bars, wherein the bars support individual biocontactors, represented by tubes wound on said supporting bars in such a manner that both open ends of tubes point in direction of rotation of the shaft.
BRIEF DESCRIPTION OF THE DRAWINGS
Examplary emobodiments of the arrangement for waste water cleaning according to this invention are shown diagrammatically in attached drawings where
FIG. 1 is an overall axonometric view of a cleaning apparatus in accordance with the invention,
FIG. 2 shows a side view of rotatable part of the arrangement indicating how staggered inlets and outlets of the biocontactors are arranged,
FIG. 3 is an axonometric view of a tubular biocontactor made of plastics and
FIG. 4 is another embodiment of a tubular biocontactor in accordance with the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
With reference to FIG. 1 the cleaning apparatus of the invention comprises a biological tank 1, in which a rotating shaft 2 is supported, provided, for instance, with an electric driving motor 3 with a gear system for rotating the shaft 2. Near both ends of the rotating shaft 2, face plates 4 are fixed thereon, which mutually interconnected by longitudinal supporting bars 5, around which individual tubular biocontactors 6 are wound. The tubular biocontactors 6 are wound in such a way, that their inlet openings 8 point in direction of rotation of the shaft 2. The tubes forming the biocontactor 9 are wound around the supporting bars 5 to form a turn a loop at the place near the inlet opening 8 of the biocontactor 6, which is at this place fixed to a bar 5 by a clamp 7. The whereafter the tube proceeds in the opposite direction on the supporting bars 5 to form at least a part of a turn and terminates at its opposite end 9, which again points in the direction of rotation of the shaft 2. The biocontactor 6 is fixed to a bar 5 by a clamp 7 near its opposite end 9. Both ends 8 and 9 of the tubular biocontactor 6 remain open.
The arrangement operates so that the rotating shaft 2 also rotates the face plates 4 and the longitudinal bars 5, around which a number of tubular biocontactors 6 are wound. By slow rotation of the biocontactors 6 in the biological tank 1, wherein, the biological tank 1 which is partly filled with waste water so that parts of biocontactors 6 are above the level of the waste water, the inlet opening 8 of each tubular biocontactor 6 becomes alternatively flooded, and in the course of continuating rotation, the internal space of the tubular biocontactor 6 is filled with waste water. At the moment the inlet opening 8 rises above the waste water level, the liquid proceeds to the lower part of the biocontactor 6 and its internal space starts to be filled by air (or by some gas in case the operation takes place in another medium) until the inlet opening 8 of the biocontactor 6 again comes in contact with the liquid level. In the course of the following rotation, air is enclosed in a part of the tubular biocontactor 6 between two liquid columns, and the originally entered liquid is forced to flow around the loop, around the inlet opening 8 and in direction of rotation of the rotating shaft 2, leaving the biocontactor 6 from the outlet opening 9. Air enclosed in the internal space of the biocontactor 6 is also forced into the liquid, causing an internsive aeration of the liquid in the tank 1. Individual biocontactors 6 are mutually shifted so that their inlet openings 8 and outlet openings 9 are staggered so that the electric motor is uniformly stressed, and particularly so that air is uniformly introduced into the liquid within the tank 1 and that an intensive and uniform aeration is accomplished. In the course of this operation, an increased pressure is generated within the tubular biocontactors 6 causing an increased transfer of oxygen into the biological film, thus increasing the efficiency of biological water cleaning. The arrangement enables recirculation of waste water and of the suspension from different places in the biological tank 1 to othe places thereof, the different places being determined by distances of inlet openings 8 from outlet openings 9 of biocontactors 6 wound on longitudinal bars 5. Hydrodynamic conditions in the tank 1 and the cleaning effect of the arrangement are thus substantially improved.
FIG. 2 shows a side view on the rotating part of the arrangement with a number of tubular biocontactors 6 wound around the longitudinal bars 5 connecting the face plates 4. The inlets 8 and outlets 9 of individual tubes of biocontactors 6 are uniformly distributed along the circumference of the face plates 4 in order to provide a uniform and effective aeration of the content of the tank 1 and a uniform stress on the driving motor.
FIG. 3 is an axonometric view of a tubular biocontactor 6 made of plastics of similar shape to that shown in FIG. 1.
FIG. 4 is an axonometric view of an alternative embodiment of a tubular biocontactor 6 where parts of the turns of the biocontactor 6 are connected by a tubular part which is substantially parallel to the axis of the shaft 2.
The arrangement according to this invention offers a number of advantages as compared to the known biocontactors in the shape of biodisks, the major advantage consisting in that no costly and inefficient biological disks need be used, whereby a substantially higher efficiency of cleaning is obtained. Another advantage is the high amount of oxygen introduced into the waste water with low energetic requirements. The high oxygenating capacity contributes to the improved efficiency of cleaning by means of torn-off biological film and flocules in suspension, and also by the simultaneous increased introduction of oxygen into the biological film in the internal space of the biocontactors due to the overpressure within the tubes. Due to rotation of the shaft, an improved mixing of the content of the biological tank is achieved. Another advantage is the possibility of recirculation of the mixture of water and sludge in any part of the biological tank. Due to removal of biodisks, the arrangement enables a substantial reduction of the size of the cleaning arrangement, a reduction of the weight of rotating parts and thus a reduction in weight of the whole cleaning arrangement, which results in a simultaneous reduction of energetic requirements. Due to a substantial increase of the efficiency of the cleaning arrangement, the actual costs and costs of operating of the cleaning are reduced.
The arrangement for cleaning of waste water according to this invention is suitable for application particuilarly for smaller or one family houses, recreation buildings, industrial and agricultural establishments with primarily sewage pollution. | Arrangement for cleaning of waste water by application of rotating biocontactors utilizing tubular biocontactors open at both ends wound on a rotating cylindrical frame adapted to be alternatively submerged below and raised above the level of the waste water, combining thereby the effect of cleaning by biocontact and of efficient aeration of the waste water. | 2 |
BACKGROUND OF THE INVENTION
This invention relates to a method of completing a well that penetrates a subterranean formation and, more particularly, relates to a well completion technique for controlling the production of sand from the formation.
In the completion of wells drilled into the earth, a string of casing is normally run into the well and a cement slurry is flowed into the annulus between the casing string and the wall of the well. The cement slurry is allowed to set and form a cement sheath which bonds the string of casing to the wall of the well. Perforations are provided through the casing and cement sheath adjacent the subsurface formation.
Fluids, such as oil or gas, are produced through these perforations into the well. These produced fluids may carry entrained therein sand, particularly when the subsurface formation is an unconsolidated formation. Produced sand is undesirable for many reasons. It is abrasive to components found within the well, such as tubing, pumps, and valves, and must be removed from the produced fluids at the surface. Further, the produced sand may partially or completely clog the well, substantially inhibiting production, thereby making necessary an expensive workover. In addition, the sand flowing from the subsurface formation may leave therein a cavity which may result in caving of the formation and collapse of the casing.
In order to limit sand production, various techniques have been employed for preventing formation sands from entering the production stream. One such technique, commonly termed "gravel packing", involves the forming of a gravel pack in the well adjacent the entire portion of the formation exposed to the well to form a gravel filter. In a cased perforated well, the gravel may be placed inside the casing adjacent the perforations to form an inside-the-casing gravel pack or may be placed outside the casing and adjacent the formation or may be placed both inside and outside the casing. Various such conventional gravel packing techniques are described in U.S. Pat. Nos. 3,434,540; 3,708,013; 3,756,318; and 3,983,941. Such conventional gravel packing techniques have generally been successful in controlling the flow of sand from the formation into the well.
In U.S. Pat. No. 4,378,845, there is disclosed a special hydraulic fracturing technique which incorporates the gravel packing sand into the fracturing fluid. Normal hydraulic fracturing techniques include injecting a fracturing fluid ("frac fluid") under pressure into the surrounding formation, permitting the well to remain shut in long enough to allow decomposition or "break-back" of the cross-linked gel of the fracturing fluid, and removing the fracturing fluid to thereby stimulate production from the well. Such a fracturing method is effective at placing well sorted sand in vertically oriented fractures. The preferred sand for use in the fracturing fluid is the same sand which would have been selected, as described above, for constructing a gravel pack in the subject pay zone in accordance with prior art techniques. Normally, 20-40 mesh sand will be used; however, depending upon the nature of the particular formation to be subjected to the present treatment, 40-60 or 10-20 mesh sand may be used in the fracturing fluid. The fracturing sand will be deposited around the outer surface of the borehole casing so that it covers and overlaps each borehole casing perforation. More particularly, at the fracture-borehole casing interface, the sand fill will cover and exceed the width of the casing perforations, and cover and exceed the vertical height of each perforation set. Care is also exercised to ensure that the fracturing sand deposited as the sand fill within the vertical fracture does not wash out during the flow-back and production steps. After completion of the fracturing treatment, fracture closure due to compressive earth stresses holds the fracturing sand in place.
In most reservoirs, a fracturing treatment employing 40-60 mesh gravel pack sand, as in U.S. Pat. No. 4,378,845, will prevent the migration of formation sands into the wellbore. However, in unconsolidated or loosely consolidated formations, such as a low resistivity oil or gas reservoir, clay particles or fines are also present and are attached to the formation sand grains. These clay particles or fines, sometimes called reservoir sands as distinguished from the larger diameter or coarser formation sands, are generally less than 0.1 millimeter in diameter and can comprise as much as 50% or more of the total reservoir components. Such a significant amount of clay particles or fines, being significantly smaller than the gravel packing sand, can migrate into and plug up the gravel packing sand, thereby inhibiting oil or gas production from the reservoir.
It is, therefore, an object of the present invention to provide a novel sand control method for use in producing an unconsolidated or loosely consolidated oil or gas reservoir which comprises a hydraulic fracturing method that stabilizes the clay particles or fines along the fracture face and which also creates a very fine grain gravel pack along the length of such fracture face.
SUMMARY OF THE INVENTION
A sand control method is provided for use in a borehole having an unconsolidated or loosely consolidated oil or gas reservoir which is otherwise likely to introduce substantial amounts of sand into the borehole. The borehole casing is perforated through the reservoir at preselected intervals. The reservoir is hydraulically fractured by injecting a fracturing fluid through the casing perforations containing a clay stabilizing agent for stabilizing the clay particles or fines along the resulting formation fracture for the entire length of the fracture face so that they adhere to the formation sand grains and don't migrate into the fracture during oil or gas production from the reservoir. A proppant containing a gravel packing sand is injected into the formed fracture. Oil or gas is then produced from the reservoir through the fracture.
The fracturing fluid is injected at a volume and rate to allow the stabilizing agent to penetrate the fracture face to a depth sufficient to overcome the effects of fluid velocity increases in oil or gas production flow or the movement of clay particles or fines located near the fracture face into the fracture as such production flow linearly approaches the fracture face.
A fine grain sand may also be included in the fracturing fluid which is significantly smaller than the gravel packing sand. The hydraulic fracturing pushes the fine grain sand up against the face of the fracture to produce a fine grain gravel filter for preventing the migration of clay particles or fines from the reservoir into the fracture, which can plug the gravel packing sand, which is thereafter injected into the fracture. Preferably, the fine grain sand is about 100 mesh and the gravel packing sand is about 40-60 mesh.
In a yet further aspect, a gravel pack may be added inside the casing prior to production to assure the extension of gravel packing material into the fracture since the fracture step has brought the fracture right up to the casing perforations.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagrammatic view of a foreshortened, perforated well casing at a location within an unconsolidated or loosely consolidated formation, illustrating vertical perforations, vertical fractures, and fracturing sands which have been injected into the formation to create the vertical fractures in accordance with the method of the present invention.
FIG. 2 is a cross-sectional end view of the reservoir fracture of FIG. 1.
DESCRIPTION OF THE PREFERRED EMBODIMENT
In FIG. 1, a foreshortened borehole casing, designated generally as 10, is illustrated which is disposed within a loosely consolidated or unconsolidated formation 15. The borehole casing 10 may be a conventional perforatable borehole casing, such as, for example, a cement sheathed, metal-lined borehole casing.
The next step in the performance of the preferred embodiment method is the perforating of casing 10 to provide a plurality of perforations at preselected intervals therealong. Such perforations should, at each level, comprise two sets of perforations which are simultaneously formed on opposite sides of the borehole casing. These perforations should have diameters between 1/4 and 3/4 of an inch, be placed in line, and be substantially parallel to the longitudinal axis of the borehole casing.
In order to produce the desired in-line perforation, a conventional perforation gun should be properly loaded and fired simultaneously to produce all of the perforations within the formation zone to be fractured. Proper alignment of the perforations should be achieved by equally spacing an appropriate number of charges on opposite sides of a single gun. The length of the gun should be equal to the thickness of the interval to be perforated. Azimuthal orientation of the charges at firing is not critical, since the initial fracture produced through the present method will leave the wellbore in the plane of the perforations. If this orientation is different from the preferred one, the fracture can be expected to bend smoothly into the preferred orientation within a few feet from the wellbore. This bending around of the fracture should not interfere with the characteristics of the completed well.
Following casing perforation, the formation is fractured in accordance with the method of the present invention to control sand production during oil or gas production. When fracturing with the method taught in U.S. Pat. No. 4,378,845, oil or gas production inflow will be linear into the fracture as opposed to radial into the well casing. From a fluid flow standpoint, there is a certain production fluid velocity required to carry fines toward the fracture face. Those fines located a few feet away from the fracture face will be left undisturbed during production since the fluid velocity at the distance from the fracture face is not sufficient to move the fines. However, fluid velocity increases as it linearly approaches the fracture and eventually is sufficient to move fines located near the fracture face into the fracture. It is, therefore, a specific feature of the present invention to stabilize such fines near the fracture faces to make sure they adhere to the formation sand grains and don't move into the fracture as fluid velocity increases. Prior stabilization procedures have only been concerned with radial production flow into the well casing which would plug the perforations in the casing. Consequently, stabilization was only needed within a few feet around the well casing. In an unconsolidated sand formation, such fines can be 30%-50% or more of the total formation constituency, which can pose quite a sand control problem. Stabilization is, therefore, needed a sufficient distance from the fracture face along the entire fracture line so that as the fluid velocity increases toward the fracture there won't be a sand control problem.
A brief description of the fracturing treatment of the invention will now be set forth, following which a more detailed description of an actual field fracturing operation carrying out such a fracturing treatment will also be set forth. Intially, a fracture fluid containing an organic clay stabilizing agent is injected through the well casing perforations 10 into the formation 11, as shown in FIG. 1. Such a stabilizing agent adheres the clay particles or fines to the coarser sand grains. In the same fracturing fluid injection, or in a second injection step, a very small mesh sand, such as 100 mesh, is injected. As fracturing continues, the small mesh sand will be pushed up against the fractured formation's face 16 to form a layer 12. Thereafter, a proppant injection step fills the fracture with a larger mesh sand, preferably 40-60 mesh to form a layer 13. A cross-sectional end view of the reservoir fracture is shown in FIG. 2. It has been conventional practice to use such a 40-60 mesh sand for gravel packing. However, for low resistivity unconsolidated or loosely consolidated sands, a conventional 40-60 mesh gravel pack will not hold out the fines. The combination of a 100 mesh sand layer up against the fracture face and the 40-60 proppant sand layer makes a very fine grain gravel filter that will hold out such fines. As oil or gas production is carried out from the reservoir, the 100 mesh layer sand will be held against the formation face by the 40-60 mesh proppant layer and won't be displaced, thereby providing for such a very fine grain gravel filter at the formation face. Fluid injection with the 40-60 mesh proppant fills the fracture and a point of screen out is reached at which the proppant comes all the way up to and fills the perforations in the well casing. The fracturing treatment of the invention is now completed and oil or gas production may now be carried out with improved sand control. Prior to production, however, it might be further advantageous for sand control purposes to carry out a conventional inside the casing gravel pack step. Such a conventional gravel pack step is assured of extending the packing material right into the fracture because the fracturing step has brought the fracture right up to the well casing perforations.
Having briefly described the hydraulic fracturing method of the invention for increasing sand control, a more detailed description of an actual field operation employed for carrying out such method will now be set forth. Reference to Tables I and II will aid in the understanding of the actual field operation. Initially, as shown in step 1 in Table I, 7,500 gallons of a 2% KCl solution containing 1% by volume of a clay stabilizer, such as Western's Clay Master 3 or B. J. Hughes' Claytrol, is injected into the reservoir. For a 40-foot fracture height, about 187.5 gallons of clay stabilizing material was used per foot of formation radially from the well casing pumped at a rate of 20 barrels per minute so as to provide as wide a fracture as possible. This contrasts with conventional gravel packing techniques of using clay stabilizing agents to treat the formation outward of one to two feet from the wellbore with about 25-50 gallons per foot at a much lower pumping rate.
In step 2, 5,000 gallons of fracturing fluid was injected having a 50 lb./1,000 gal. cross-linked HPG in water containing 2% KCl, 20 lb./1,000 gal. fine particle oil soluble resin and 1 lb./gal. 100 mesh sand.
In steps 3-7, 43,500 lbs. of 40-60 mesh sand proppant is incrementally added with 11,500 gallons of fracturing fluid. During the final 500 gallons of fluid injection, the cross-linker was eliminated and the pumping rate reduced to 5 barrels per minute.
In step 8, no further proppant was added and the fracture was flushed with 1,600 gallons of 2% KCl water. In each of steps 2-8, the injection fluid contained a 1% by volume of the organic clay stabilizing agent.
The final stage of the fracturing treatment was designed to the point of screen out, leaving the perforations covered with the fracturing sand inside the well casing. At this point, injection was continued until 7,500 gallons of fluid containing 2% KCl water and organic clay stabilizing agent had been displaced into the fracture. Finally, the KCl water was displaced with a ZnBr 2 weighted fluid.
Following the fracturing treatment, a conventional gravel pack was placed in and immediately surrounding the well casing to hold the 40-60 mesh sand in place and the well was opened to oil or gas flow from the reservoir.
TABLE I______________________________________Fracturing Treatment Fluid Vol. (Gals.) Proppant (Lbs.)Step No. Incremental Incremental______________________________________1 7500 02 5000 03 2500 25004 2500 50005 3000 120006 2000 120007 1500 120008 1600 0______________________________________ Note: Pump rate = 20 BPM and Proppant = 40/60 mesh sand.
TABLE II______________________________________Treatment Volumes & Materials______________________________________Step 1: 7500 gals. Maxi-Pad containing per 1000 gals.: 170 lbs. KCl (2%) 3 gals. Clay Master 3 (clay stabilizer) 2 gals. Flo-Back 10Step 2: 5000 gals. Apollo-50 containing per 1000 gals.: 170 lbs. KCl 3 gals. Clay Master 3 2 gals. Flo-Back 10 0.25 gals. Frac-Cide 2 (bacteria) 20 lbs. Frac SealSteps 3-7: 11,500 gals Apollo-50 containing per 1000 gals.: 170 lbs. KCl 3 gals. Clay Master 3 2 gals. Flow-Back 10 0.25 gals. Frac-Cide 2 20 lbs. Frac-Seal 0.5 lbs. B-5 (breaker)Step 8: 1600 gals. of same fluid as steps 3-7Flush step: 7500 gals. fresh water containing per 1000 gals.: 170 lbs. KCl 3 gals. Clay Master 3 2 gals. Flo-Back 10 10 lbs. J-12 (gelling agent)______________________________________ | A subsurface oil or gas reservoir is hydraulically fractured by injecting a fracturing fluid through perforations in the casing of a well penetrating into such subsurface reservoir. The fracturing fluid contains a clay stabilizing agent for stabilizing clay particles or fines along the face of the resulting formation fracture. A proppant comprising a gravel packing sand is injected into the fracture. Oil or gas is then produced from the reservoir through the fracture into the well. | 4 |
[0001] This application claims the benefit of provisional application No. 60/508,203, filed Oct. 2, 2003, which is incorporated herein by this reference.
BACKGROUND
[0002] The present application relates to the execution of script based application programs.
[0003] There is a continually increasing number of terminal devices in use today, such as mobile telephones, PDAs with wireless communication capabilities, personal computers, self service kiosks and two-way pagers. Software applications which run on these devices increase their utility. For example, a mobile phone may include an application which retrieves the weather for a range of cities, or a PDA may include an application that allows a user to shop for groceries. These software applications take advantage of connectivity to a network in order to provide timely and useful services to users. However, due to the restricted resources of some devices, developing software applications for a variety of devices remains a difficult and time-consuming task.
[0004] Scripting Language based applications can be limited in their ability to supply and execute sophisticated logic and complex processing. More traditional programming languages contain explicit function and/or procedure calls to implement more complex functionality, however, these languages use more complicated syntax and traditionally require more sophisticated programming knowledge to use.
[0005] A further disadvantage of traditional programming languages in that they are not completely neutral to the platform used for executing the applications. Another disadvantage of current scripting languages, such as JavaScript, and traditionally programming languages, such as C++, is that the programming capabilities of the languages are not extensible.
[0006] Extendable script based systems and methods are disclosed to obviate or mitigate at least some of the above-presented disadvantages.
SUMMARY
[0007] Scripting Language based applications can be limited in their ability to supply and execute sophisticated logic and complex processing. More traditional programming languages contain explicit function and/or procedure calls to implement more complex functionality, however, these languages use more complicated syntax and traditionally require more sophisticated programming knowledge to use. A further disadvantage of traditional programming languages in that they are not completely neutral to the platform used for executing the applications. Contrary to current systems and methods for implementing script based workflows, there is provided systems and methods for extending the capabilities of an application program for execution by a terminal. The application includes a script based workflow and non-executable content. One such method comprises loading the workflow for interpretation by a script interpreter, such that the workflow is configured for having a plurality of executable elements. This method also provides a global symbol structure for reference by the executable elements, the global symbol structure including addressing for coupling selected ones of the executable elements to corresponding external components. The external components are provided by a native runtime environment of the terminal for performing the action specified by the selected executable elements. This method can also execute the executable elements in sequence such that execution of the selected ones of the execution elements are redirected to the respective external components through the corresponding global symbols of the global symbol structure. Predefined knowledge of the contents of the global symbol structure is shared by the runtime environment and the workflow of the application.
[0008] A method is disclosed for extending the capabilities of an application program for execution by a terminal, the application including a script based workflow and non-executable content, the method comprising the steps of: loading the workflow for interpretation by a script interpreter, the workflow configured for having a plurality of executable elements; providing a global symbol structure for reference by the executable elements, the global symbol structure including addressing for coupling selected ones of the executable elements to corresponding external components, the external components provided by a native runtime environment of the terminal for performing the action specified by the selected executable elements; and executing the executable elements in sequence such that execution of the selected ones of the execution elements are redirected to the respective external components through the corresponding global symbols of the global symbol structure; wherein predefined knowledge of the contents of the global symbol structure is shared by the runtime environment and the workflow of the application.
[0009] A terminal configured for extending the capabilities of an application program for execution by a native runtime environment is also disclosed, the application including a script based workflow and non-executable content, the terminal comprising: a script interpreter for interpreting the workflow, the workflow configured for having a plurality of executable elements; a global symbol structure configured for reference by the executable elements, the global symbol structure including addressing for coupling selected ones of the executable elements to corresponding external components, the external components provided by the native runtime environment of the terminal for performing the action specified by the selected executable elements; a proxy redirector module for redirecting the selected ones of the execution elements during execution of the workflow, the selected ones of the execution elements being redirected to the respective external components through the corresponding global symbols of the global symbol structure; wherein predefined knowledge of the contents of the global symbol structure is shared by the runtime environment and the workflow of the application.
[0010] A computer program product is also provided for extending the capabilities of an application program for execution by a native runtime environment of a terminal, the application including a script based workflow and non-executable content, the computer program product comprising: a computer readable medium; a script interpreter module stored on the computer readable medium for interpreting the workflow, the workflow configured for having a plurality of executable elements; a global symbol structure stored on the computer readable medium configured for reference by the executable elements, the global symbol structure including addressing for coupling selected ones of the executable elements to corresponding external components, the external components provided by the native runtime environment of the terminal for performing the action specified by the selected executable elements; a proxy redirector module coupled to the global symbol structure for redirecting the selected ones of the execution elements during execution of the workflow, the selected ones of the execution elements being redirected to the respective external components through the corresponding global symbols of the global symbol structure; wherein predefined knowledge of the contents of the global symbol structure is shared by the runtime environment and the workflow of the application.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] These and other features will become more apparent in the following detailed description in which reference is made to the appended example drawings, wherein:
[0012] FIG. 1 is a block diagram of a network system;
[0013] FIG. 2 is a block diagram of a generic terminal of FIG. 1 ;
[0014] FIG. 3 shows a processing framework of the terminal of FIG. 2 ;
[0015] FIG. 4 shows representation of application spaces of the application of FIG. 3 ; and
[0016] FIG. 5 is as sample workflow “getcompanyInfo” for the script of FIG. 4 .
DETAILED DESCRIPTION
[heading-0017] Network System
[0018] Referring to FIG. 1 , a network system 10 comprises a plurality of terminals 100 for interacting with one or more application servers 110 accessed by a server 106 , which can be a management server, via a coupled Wide Area Network (WAN) 104 such as but not limited to the Internet. The terminals receive application programs 107 from the application server 110 via the server 106 over the network 104 . The generic terminals 100 can be any suitable computing platform such as but not limited to wired devices such as desktop terminals 116 or other wired devices (e.g., notebook computer), wireless devices 101 , PDAs, self-service kiosks and the like. Further, the system 10 can also have a gateway server 112 for connecting the desktop terminals 116 (or other wired devices) via a Local Area Network (LAN) 114 to the server 106 .
[0019] Further, the system 10 can have a wireless network 102 for connecting the wireless devices 101 to the WAN 104 . It is recognized that other terminals and computers (not shown) could be connected to the server 106 via the WAN 104 and associated networks other than as shown in FIG. 1 . The generic terminals 100 , wireless devices 101 and personal computers 116 are hereafter referred to as the terminal 100 for the sake of simplicity. Further, the networks 102 , 104 , 114 of the system 10 will hereafter be referred to as the network 104 , for the sake of simplicity. It is recognized that there could be multiple servers 106 , 110 , and/or that the functionality of the servers 106 and 110 could be combined, if desired. It is further recognized that the servers 106 , 110 could be implemented by a service provider 118 providing a schema-defined service, such as a web service by example. Further, the terminals 100 could also operate as stand-alone devices when obtaining and executing the application 107 . For example, the application can be loaded onto terminals via a computer readable medium 212 , (see FIG. 2 ), as further defined below; in addition, or instead, the application can be loaded onto the terminal via a direct wired connection (e.g., USB port, serial interface, etc.) to an external media device or computing platform.
[0020] This system 10 applies to applications 107 that are partitioned into an associated script based workflow 307 (see FIG. 3 ), and non-executable content. Non-executable content may be discrete elements or templates that describe application entities in some predefined language (such as but not limited to structured definition languages such as XML). Content is evaluated within a Container Framework 206 (see FIG. 3 ) of the terminal 100 and is available to the workflow script 307 as a library of Global Symbols 324 (see FIG. 3 ). This library helps to proxy access to the appropriate service 304 or obtains the requested data. The process of addressing external non-executable entities of the application 107 by the workflow is referred to as Proxied Redirection, as further described below. The application 107 provisioned on the terminal 100 can also have access to local entities through a local symbol table 322 (see FIG. 3 ).
[heading-0021] Generic Terminal
[0022] Referring to FIG. 2 , the terminals 100 can include, without limitation, mobile telephones (or other wireless devices), PDAs, notebook and/or desktop computers, two-way pagers or dual-mode communication terminals. The terminals 100 include a network connection interface 200 , such as a wireless transceiver or a wired network interface card or a modem, coupled via connection 218 to a terminal infrastructure 204 . The connection interface 200 is connectable during operation of the terminals 100 to the network 104 , such as to the wireless network 102 by wireless links (e.g., RF, IR, etc.) (see FIG. 1 ), which enables the terminals 100 to communicate with each other and with external systems (such as the server 106 —see FIG. 1 ) via the network 104 and to coordinate the requests/response messages 105 between the terminals 100 and the servers 106 , 110 . The network 104 supports the transmission of the application programs 107 in the requests/response messages 105 between terminals 100 and external systems, which are connected to the network 104 . The network 104 may also support voice communication for telephone calls between the terminals 100 and terminals which are external to the network 104 . A wireless data transmission protocol can be used by the wireless network 102 , such as but not limited to DataTAC, GPRS or CDMA.
[0023] Referring again to FIG. 2 , the terminals 100 also have a user interface 202 , coupled to the terminal infrastructure 204 by connection 222 , to facilitate interaction with a user (not shown). The user interface 202 can includes one or more user input devices such as but not limited to a QWERTY keyboard, a keypad, a trackwheel, a stylus, a mouse, a microphone and one or more user output devices such as an LCD screen display and/or a speaker. If the screen is touch sensitive, then the display can also be used as the user input device as controlled by the terminal infrastructure 204 .
[0024] Referring again to FIG. 2 , operation of the terminal 100 is enabled by the terminal infrastructure 204 . The terminal infrastructure 204 includes the computer processor 208 and the associated memory module 210 . The computer processor 208 manipulates the operation of the network interface 200 , the user interface 202 and the framework 206 of the communication terminal 100 by executing related instructions, which are provided by an operating system and client application programs 107 located in the memory module 210 ; the computer processor 208 can include one or more processing elements that may include one or more general purpose processors and/or special purpose processors (e.g., ASICs, FPGAs, DSPs, etc.). Further, it is recognized that the terminal infrastructure 204 can include a computer readable storage medium 212 coupled to the processor 208 for providing instructions to the processor for loading and executing client application programs 107 . The computer readable medium 212 can include hardware and/or software such as, by way of example only, magnetic disks, magnetic tape, optically readable medium such as CD/DVD ROMS, and memory cards. In each case, the computer readable medium 212 may take the form of a small disk, floppy diskette, cassette, hard disk drive, solid state memory card, or RAM provided in the memory module 210 . It should be noted that the above listed example computer readable mediums 212 can be used either alone or in combination.
[heading-0025] Processing Framework
[0026] Referring to FIG. 2 , a client runtime environment is provided by the processing framework 206 . Multiple such runtime environments could potentially be available for use by the processing framework 206 of a given terminal 100 . The framework 206 of the terminal 100 is coupled to the infrastructure 204 by the connection 220 and is an interface to the terminal 100 functionality of the processor 208 and associated operating system of the infrastructure 204 . The client runtime environment of the terminals 100 is preferably capable of generating, hosting and executing the client application programs 107 on the terminal 100 ; if multiple runtime environments are available, a particular one can be selected for use with a given application program 107 . Once loaded onto the terminal 100 , the applications 107 can be executed by the component framework 206 on the device 100 , which can convert the component applications 107 into native code, which is executed by the processor 208 in the device infrastructure 204 . Alternatively, the applications 107 may be executed as native code or interpreted by another software module or operating system on the terminal 100 . In any event, the applications 107 are run in a terminal runtime environment provided by the terminal 100 ; the client runtime is potentially one selected from a set of available client runtime environments. Referring again to FIG. 1 , one or more of the client runtime environments provided by the terminal 100 can be configured to make the terminals 100 operate as web clients of the web services (of a web service 118 ). It is recognized that the client runtime environment can also make the terminals 100 clients of any other generic schema-defined services supplied by the service 118 . The framework 206 hosts and evaluates the application 107 , as well as provides services 304 to interpret workflow components, evaluate non-executable application entities, and resolve application references to non-executable content or built in functionality.
[0027] One or more of the terminal runtime environment of the framework 206 preferably support the following basic functions for the resident executable versions of the client application programs 107 (see FIG. 2 ), such as but not limited to:
have predefined knowledge of the local symbol table 322 (see FIG. 3 ) and the global symbol table 324 (see FIG. 3 ). The knowledge of the contents of the global symbol table 324 is shared between the application 107 and the framework 206 ; provide a communications capability to send messages 105 to the server 106 via the network 104 ; provide data input capabilities by the user on an input device of the terminals 100 to supply data parts for outgoing messages 105 to the server 106 ; provide data presentation or output capabilities for response messages 105 (incoming messages) or uncorrelated notifications of the server 106 ; provide data storage services to maintain local client data in the memory module 210 (see FIG. 2 ) of the terminal 100 ; and provide an execution environment for a scripting language for coordinating operation of the application 107 .
[0034] Further, specific functions of the client runtime environment can include, without limitation, service support for language, coordinating memory allocation, networking, management of data during I/O operations, coordinating graphics on an output device of the terminals 100 and providing access to core object oriented classes and supporting files/libraries. Examples of the runtime environments implemented by the terminals 100 can include such as but not limited to Common Language Runtime (CLR) by Microsoft and Java Runtime Environment (JRE) by Sun Microsystems.
[0035] Referring again to FIG. 3 , the processing framework 206 implements the ability to extend script based commands of the application 107 through the global symbol table 324 , further described below. The Processing Framework 206 can provide generic service module 304 functionality separate from the application program 107 . Further, the framework 206 can also have other modules such as but not limited to; an Application Manager 306 , an Interpreter Module 308 , a Script Interpreter 310 , a provisioning manager 311 and a Proxy Redirector 312 . It is recognised that separate service functionality is shared by a plurality of applications 107 . The service modules 304 include such as but not limited to a Persistence Module 314 , a Communications Module 316 , a Screen (presentation) Module 318 and a Device Access Module 320 .
[0036] Referring again to FIG. 3 , the generic service modules 304 interact with the application 107 through the global symbol table 324 . The functionality of commands of the script 307 of the application 107 are enhanced or otherwise extended through interaction with functional and/or non-executable components 326 , 328 , 330 , 332 operated by the modules 304 , as further described below. The communication service 316 manages connectivity between the component application programs 107 and the external system 10 via the network 104 , including the ability to communicate with the server 106 as required during execution of the application 107 . The persistence manager 314 allows updated data content of the application programs 107 to be stored in the memory module 210 . The screen manager 318 interacts with the user interface 202 (see FIG. 2 ) to obtain input from the user and display or otherwise present output to the user of the terminal 100 . The screen manager 318 is responsible for communicating data to and from the interface 202 , which is expressed in a native format of the terminal 100 . The device access module 320 monitors interaction between the various application programs 107 and other functional entities (such as the modules 304 ) resident on the terminal 100 . It is recognised that other configurations and partitioning of functionality of the modules 304 with respective services 314 , 316 , 318 , 320 for extending the functionality of the application script 307 can be other than shown, as desired.
[0037] Referring again to FIG. 3 , the framework 206 has the provisioning manager 311 that manages the provisioning of the software applications 107 on the terminal 100 . Application provisioning can include storing, retrieving, downloading and removing applications 107 , and configuring the application programs 107 for access to services 304 which are accessible the global symbol table 324 . The Application Manager 306 can be used to interact with the user interface 202 (see FIG. 2 ), manages application lifetime etc. The Interpreter Module 308 manages references to workflow native local symbols 322 and external Global Symbols 324 . The Script Interpreter 310 executes the script 307 in the language of the workflow of the application 107 . The Script Interpreter 310 is depicted as a component of the Interpreter Module 308 ; however, the Script Interpreter 310 can be a stand-alone component in other implementations. The Proxy Redirector 312 handles requests to any of the set of Global Symbols 324 and directs the request to the appropriate service module 304 for subsequent extension of the script function. Global Symbols of the table 324 are references from within the executable workflow of the script 307 to components 326 , 328 , 330 , 332 that are provided by the Container Framework 206 . These global symbols 324 contain implicitly the details of functionality as required by the applications 107 . Local Symbols of the table 322 are references from within the executable workflow of the script 307 for entities that are defined elsewhere in the application 107 (such as but not limited to non-executable entities). The local symbols of the table 322 represent local functionality provided by the application program 107 , as compared to the global symbols of the table 324 that provide extended capabilities through the service modules 304 .
[0038] It is recognized that other configurations of the processing framework 206 with respective services 306 , 308 , 310 , 312 for implementing the symbol tables 322 , 324 can be other than shown, as desired. Such alternate configurations can include, without limitation, alternative distribution among functionality among services and/or combination of functionality within other services.
[heading-0039] Proxied Processing
[0040] Referring to FIG. 4 , in the case of a mixed content application 107 it is typically not possible to execute the entire application 107 monolithically within one scope. Rather it is convenient to model some aspects of the application 107 in a separate space 400 , and allow discrete executable units of the script 307 to address and manipulate that space 400 through the table 324 or other data structure. The table 324 is coupled to the set of Global Symbols that are provided to the Proxy Redirector 312 (see FIG. 3 ) and are available to the Script Interpreter 310 (see FIG. 3 ) in the semantics of the scripting language of the script 307 . This approach allows discrete and non-continuous executable segments of the script 307 to address and manipulate the framework 206 based components 326 , 328 , 330 , 332 uniformly, affecting the behavior of the application 107 as a whole. For example, FIG. 4 shows a visual representation of the application spaces 400 as they are distributed at runtime. As depicted, the application workflow 307 makes reference 404 to symbols 324 that are defined in the nebulous space 400 of non-executable application entities (shown as cloud 400 ). Through services 304 (see FIG. 3 ) supplied by the container framework 206 , these accesses are proxied 406 to the actual native execution space 402 of the terminal 100 required to satisfy the reference. The native execution space 402 includes access to the external (in regard to the application 107 ) components 326 , 328 , 330 , 332 of the service modules 304 that can be resident on the framework 206 of the terminal 100 .
[heading-0041] External Components
[0042] Referring again to FIG. 3 , the external components 326 , 328 , 330 , 332 are accessed via the global symbols 324 through the corresponding service modules 314 , 316 , 318 , 320 . The component 326 can represent a data component, which can be used to define data entities, which are referenced by the script 307 . Examples of data components 326 may include orders, users, and financial transactions. Data components 326 can define what information is required to describe the data entities, and in what format the information is expressed. For example, the data component 326 may, in a particular instance, define an order which is comprised of a unique identifier for the order which is formatted as a number, a list of items which are formatted as strings, the time the order was created which has a date-time format, the status of the order which is formatted as a string, and a user who placed the order which is formatted according to the definition of another one of the data components 326 . Further, referring to FIG. 1 , since data parts (elements) are usually transferred from message 105 to message 105 according to Web Service 118 choreography rules, preferably there is persistence of data components 326 . It is recognised that data components 326 may be dynamically generated according to Web Service(s) 118 choreography definitions (if available) or defined by the application designer based on complex type definitions and/or message correlation information.
[0043] Referring again to FIG. 3 , the external component 328 can represent a message component 404 , which can define the format of messages used by the component application program 107 to communicate with other resident applications 107 on the terminal 100 and/or external systems such as the web service 118 (see FIG. 1 ). For example, one of the message components 328 may describe, in a particular instance, a message for placing an order, which includes the unique identifier for the order, the status of the order, and notes associated with the order. Message component 328 definitions can, in some instances, be written in a structured definition language and, in some such instances, can uniquely represent (and map to) WSDL messages, and can be generated dynamically at runtime. Accordingly, the dynamic generation can be done for the component definitions for client application messages 105 (see FIG. 1 ), and associated data content, from standard Web Service 118 metadata in a definition language used to express the web service interface, such as, but not limited to, WSDL and BPEL.
[0044] Referring again to FIG. 3 , the external component 330 can represent a presentation component. The presentation component 330 can define the appearance and behavior of the component application program 107 as it displayed by the user interface 202 (see FIG. 2 ). The presentation components 330 can specify GUI screens and controls, and actions to be executed when the user interacts with the component application 107 using the user interface 202 . For example, the presentation components 330 may define screens, labels, edit boxes, buttons and menus, and actions to be taken when the user types in an edit box or pushes a button. The majority of Web Service 118 (see FIG. 1 ) consumers use a visual presentation of Web Service operation results, and therefore provide the runtime environment on their terminals 100 capable of displaying user interface screens.
[heading-0045] Proxied Referencing
[0046] Referring to FIGS. 3 and 4 , Proxied Referencing is the process by which the Script Interpreter 310 may satisfy requests 404 for framework 206 based components 326 , 328 , 330 , 332 that are typically not available in the language of the workflow 307 . The Proxied Redirector 312 relies on the set of symbols that are supplied by the Application Manager 306 when the application 107 starts. These symbols 324 may correspond to components that are defined by the application 107 itself (i.e. local symbols 322 ), or may correspond to functionality that is provided by the framework 206 (i.e. global symbols 324 ). In either case, the set of symbols is completely arbitrary to the Interpreter Module 308 . It is recognized that the potential contents of the global symbol library 324 is fixed knowledge shared between the developer of the script 307 and the developer of the functional modules 304 providing the externally referenced functionality linked via the global symbols 324 .
[heading-0047] Proxied Referencing Scheme by Example
[0048] Referring to FIGS. 3 and 4 , to illustrate how a proxied scheme 500 (see FIG. 5 ) may apply to the type of applications 107 described, take the case of a sample set of applications 107 that use a scripting language (such as ECMAScript) to define workflow elements of the script 307 and allows expression of Screens 330 , Messages 328 and Data 326 components in some structured language (such as XML). It is recognized that the corresponding functional modules 318 , 316 , 314 for providing access to the components 330 , 328 , 326 can be based on the native runtime language, or optionally one or more languages.
[heading-0049] Screens 330
[0050] Screens 330 describe visual components that are presented and displayed to the user. Screens 330 specify how interaction with a user is handled. As part of its definition, the Screen 330 specifies all of the data collection fields that comprise it and how information is presented. The screen 330 is referenced by its name, for example scrName, (a global symbol 324 ) and supports access to any of its various data fields and can also provides built in functions such as but not limited to:
check( ); and display( ).
Messages 328
[0054] Messages 328 are composed of various fields that are carried to and from the application 107 . The message 328 is referenced by name, for example msgName, (a global symbol 324 ) and supports such as but not limited to the functional ability to send( ). All fields of the message 328 may be addressed by name.
[heading-0055] Data 326
[0056] Data 326 are composed of addressable fields and are referenced by name, for example dataName, (a global symbol 324 ). The data 326 may be such as but not limited to load( )'ed and save( )'ed. The load( ) operation specifies a parameter that uniquely identifies the Data 326 .
[heading-0057] Workflow
[0058] Workflow elements of the script 307 can be are written in a suitable scripting and/or coding language such as ECMAScript and are addressable by name, workflowName, (a global symbol 324 ).
[0059] A sample workflow is given below. This workflow shows a typical scripting language that has embedded references to external symbols 324 that are associated with the Framework 206 . These symbols are:
scrOrderEntry and scrCompanyInfo, both variables representative of typical Screen 330 global objects 324 ; dataCompany, a variable representative of Data 326 global object 324 ; and msgGetSubsidiaries, a variable representative of Message 328 global object 324 .
[0063] In addition, each of these references 404 is further refined by accessing either fields of the non-executable content (plain text) or functions (italics).
Workflow: getCompanyInfo { scrOrderEntry. check (“itemId”); companyName = scrOrderEntry.partVendor; company = dataCompany. load (companyName); if(company.hasSubsidiaries) { msgGetsubsidiaries. send ( ); } scrCompanyInfo. display ( ); }
[0064] Referring to FIG. 5 the scheme 500 illustrates how the various modules of FIG. 3 inter-operate to achieve the goal of vectoring requests for these global symbols 324 to the framework 206 .
[heading-0065] The series of steps for executing this workflow 307 are as follows:
[none]
1. At some point during the application 107 evaluation by the Application Manager 306 a request for execution of workflow script 307 getCompanyInfo is made;
2. The Application Manager 306 instructs 501 the Script Interpreter 310 of the Interpreter Module 308 to load the workflow 307 ;
3. The Application Manager 306 supplies 502 the symbol library 322 , 324 to the Proxy Redirection Module 312 that satisfies all external references to messages 328 , screens 330 and data 326 components.
4. The Application Manager 306 then instructs the Script Interpreter to begin executing 503 the script 307 . The script 307 is interpreted as a series of symbols 322 , 324 that are recognized as either being language defined (i.e. reserved), declared (i.e. by the script 307 ) as local symbols 322 , or unknown, that is external symbols 324 ;
5. References 404 to unknown symbols 324 such as the screen scrCompanyInfo or msgGetSubsidiaries, are passed 504 to the Proxy Redirection Module 312 ;
6. The Proxy Redirection Module 312 recognizes the symbol from its Global Symbol library 324 as provided by the Application Manager 306 ; and
7. The Proxy Redirection Module 312 processes the reference, supplying requested fields or executing requests such as message send( ) by addressing 506 , 508 , 510 them to the appropriate framework service 316 , 314 , 318 respectively.
[0073] The above description relates to one or more exemplary systems and methods. Many variations will be apparent to those knowledgeable in the field, and such variations are within the scope of the application.
[0074] For example, although XML and a subset of ECMAScript are used in the examples provided, other languages and language variants may be used to define the components 326 , 328 , 330 and the script 307 , as desired. Further, using this approach the system 10 as a whole may expand application 107 execution beyond the capabilities of the scripting language of the script 307 . Complex processing or more sophisticated logic can be moved to the framework 206 where it may be handled more efficiently (i.e. natively) and shared by a plurality of the applications 107 .
[0075] The application 107 may be completely neutral to the type of Framework 206 that the application 107 is addressing. Moreover this approach can facilitate greater extensibility of the system 10 as the Framework 206 exports an arbitrary set of the Global Symbols 324 that may be enhanced at a later time. In this way the scripting grammar of the script 307 can remain unchanged while programming capabilities at the developers disposal can be extended through modification of the reference 406 (see FIG. 4 ) linking the individual script elements of the script 307 to the shared service modules 304 , as well as through modification of the contents of the components 326 , 328 , 330 , 332 . | Scripting Language based applications can be limited in their ability to supply and execute sophisticated logic and complex processing. More traditional programming languages contain explicit function and/or procedure calls to implement more complex functionality, however, these languages use more complicated syntax and traditionally require mosophisticated programming knowledge to use. There are provided systems and methods for extending the capabilities of an application program for execution by a terminal. The application includes a script based workflow and non-executable content. One such method comprises loading the workflow for interpretation by a script interpreter, such that the workflow is configured for having a plurality of executable elements. This method also provides a global symbol structure for reference by the executable elements, the global symbol structure including addressing for coupling selected ones of the executable elements to corresponding external components. The external components are provided by a native runtime environment of the terminal for performing the action specified by the selected executable elements. This method also executes the executable elements in sequence such that execution of the selected ones of the execution elements are redirected to the respective external components through the corresponding global symbols of the global symbol structure. Predefined knowledge of the contents of the global symbol structure is shared by the runtime environment and the workflow of the application. | 7 |
TECHNICAL FIELD
[0001] The present invention relates to a liquid material obtained from a gas composed of oxygen and hydrogen obtained by electrolysis under vibratory agitation, a regasified gas composed of oxygen and hydrogen obtained from the liquid material, a manufacturing method and device thereof, and a fuel which is composed of the liquid material and/or regasified gas and does not generate a carbonic acid gas when burning.
BACKGROUND ART
[0002] When water is electrolyzed, a hydrogen gas and an oxygen gas are respectively generated from a cathode and an anode. Nowadays, this is in the spotlight owing to arrival of hydrogen energy generation. However, a main trend in conventional methods is that a hydrogen gas is extracted and separated from an oxygen gas, and only the hydrogen gas is used while the oxygen gas is disposed of. This is because a mixture of hydrogen and oxygen gases explodes under a low atmospheric pressure of 2 to 3 atm. Usually, this mixture gas is called a detonating gas. Therefore, pressing of a mixture gas of hydrogen and oxygen is prohibited under the Security Regulation for General High-Pressure Gas, Section 9 in Japan.
[0003] Conventionally, a mixture gas of hydrogen and oxygen is called a Brown's gas. This technology relates to developments achieved by Dr. Yull Brown in Brown Energy System Technology PTY. LTD. in Australia. See PTL 1.
[0004] The Brown's gas is known to have a property of standing compression up to 5 kgf/cm 2 and changes back to water when the gas is pressed much, as described in PTL 2, page 6, column 9, lines 5 to 8.
[0005] Meanwhile, the present inventor has proposed, in PTLs 3 to 5, techniques for manufacturing hydrogen and oxygen gases by using a vibratory agitation means. Regardless of containing only hydrogen and oxygen as components, a gas composed of hydrogen and oxygen obtained according to any of these methods is incredibly far more stable compared with a gas composed of hydrogen and oxygen which is obtained according to known conventional methods.
{Citation List}
{Patent Literature}
{PTL 1} JP-U-3037633
{PTL 2} JP-A-2002-348694
{PTL 3} WO 02/090621 A1
{PTL 4} WO 03/048424 A1
{PTL 5} JP-A-2005-232512
SUMMARY OF INVENTION
Technical Problem
[0006] However, a range of use is greatly limited with only an embodiment of directly using a gas generated by using techniques disclosed in PTLs 3 to 5.
[0007] If a gas composed of hydrogen and oxygen obtained by electrolyzing water under vibratory agitation is liquidized, stored, and further regasified again, use applications are enhanced limitlessly insofar as the regasified gas has the same physical properties and maintains a property of no explosion risk.
[0008] The present invention has a first object of providing a method and a device for manufacturing a liquid material, and of providing the liquid material itself, wherein the liquid material is composed of hydrogen and oxygen and obtained from a gas composed of hydrogen and oxygen obtained by electrolyzing water under vibratory agitation, without losing peculiar properties to the gas, apart from conventional techniques of liquidizing hydrogen and oxygen separately.
[0009] The present invention has a second object of providing a method and a device for manufacturing a liquid material composed of hydrogen and oxygen without losing peculiar properties to a gas composed of hydrogen and oxygen obtained by electrolyzing water under vibratory agitation, for storing the liquid material for a required time period in the state of liquid, and for regasifying the liquid material at a required time point, and of providing a regasified gas composed of hydrogen and oxygen obtained by the method and device.
[0010] The present invention has a third object of providing a fuel which does not generate a carbonic acid gas at all when burning.
Solution to Problem
[0011] According to the present invention to achieve the aforementioned first object, there is provided a manufacturing method for manufacturing a liquid material composed of hydrogen and oxygen, wherein an electrolytic solution containing an electrolyte of 5 to 30 weight % is electrolyzed in an electrolytic bath by use of an electrode group provided at an interval of 3 to 10 mm in the electrolytic bath under conditions of an electric current density of 5 to 20 A/dm 2 , a bath temperature of 20 to 70° C., and strong alkali, while subjecting the electrolytic solution to vibratory agitation, and a gas composed of hydrogen and oxygen which is thereby generated is liquidized by cooling.
[0012] According to an aspect of the invention, when liquidizing the gas composed of hydrogen and oxygen, cooling is performed with the pressure of the gas set at 0.1 to 0.5 MPa. According to another aspect of the invention, when liquidizing the gas composed of hydrogen and oxygen, cooling to −190 to −250° C. is performed. According to still another aspect of the invention, the condition of strong alkali described above corresponds to pH 14 or more.
[0013] Further, according to the present invention to achieve the aforementioned first object, there is provided a manufacturing device for manufacturing a liquid material composed of hydrogen and oxygen, the device being used for practicing or executing the above-mentioned method for manufacturing the liquid material, the device comprising:
[0000] (A) an electrolytic bath;
(B) an electrode group provided at an interval of 3 to 10 mm in the electrolytic bath;
(C) a vibratory agitation unit for subjecting an electrolytic solution in the electrolytic bath to vibratory agitation;
(D) a collection unit for collecting a generated gas composed of hydrogen and oxygen; and
(E) a liquidizing unit for liquidizing the collected gas composed of hydrogen and oxygen by cooling.
[0014] According to an aspect of the liquid material composed of hydrogen and oxygen according to the present invention, which is manufactured by the above-mentioned manufacturing method for manufacturing the liquid material composed of hydrogen and oxygen, the hydrogen and oxygen exist as liquid materials under conditions of −190 to −250° C. and 3 to 300 kgf/cm 2 . In the present specification, MPa and kgf/cm 2 are used as units expressing pressures. However, these pressures are described supposing that 0.1 MPa is substantially equivalent to 1 kgf/cm 2 .
[0015] Also, according to the present invention to achieve the aforementioned second object, there is provided a manufacturing method for manufacturing a regasified gas composed of hydrogen and oxygen, wherein the liquid material composed of hydrogen and oxygen, which is manufactured by the above-mentioned manufacturing method for manufacturing the liquid material composed of hydrogen and oxygen, is stored and thereafter gasified.
[0016] According to an aspect of the invention, heating is performed when gasifying the liquid material composed of hydrogen and oxygen. According to another aspect of the invention, the temperature of the liquid material is returned to a normal temperature by the heating.
[0017] Further, according to the present invention to achieve the aforementioned second object, there is provided a manufacturing device for manufacturing a regasified gas composed of hydrogen and oxygen, the device being used for practicing or executing the above-mentioned manufacturing method for manufacturing a regasified gas composed of hydrogen and oxygen, the device comprising:
[0000] (A) an electrolytic bath;
(B) an electrode group provided at an interval of 3 to 10 mm in the electrolytic bath;
(C) a vibratory agitation unit for subjecting an electrolytic solution in the electrolytic bath to vibratory agitation;
(D) a collection unit for collecting a generated gas composed of hydrogen and oxygen;
(E) a liquidizing unit for liquidizing the collected gas composed of hydrogen and oxygen by cooling;
(F) a storage unit for storing a liquid material obtained by the liquidizing unit, and
(G) a regasifying unit for regasifying the liquid material.
[0018] According to an aspect of the regasified gas composed of hydrogen and oxygen according to the present invention, which is manufactured by the above-mentioned manufacturing method for manufacturing the regasified gas composed of hydrogen and oxygen, hydrogen and oxygen do not substantially react with each other under a pressure of 3 to 300 kgf/cm 2 but exist stably in gas states in a metal container.
[0019] Also according to the present invention to achieve the aforementioned third object, there is provided a fuel which is composed of the above-mentioned liquid material composed of hydrogen and oxygen and/or the above-mentioned regasified gas composed of hydrogen and oxygen, and generates no carbonic acid gas at all while burning.
ADVANTAGEOUS EFFECTS OF INVENTION
[0020] According to the present invention, there are provided a method and a device for manufacturing a liquid material, and the liquid material itself, wherein the liquid material is composed of hydrogen and oxygen and obtained from a gas (initial gas) composed of hydrogen and oxygen obtained by electrolyzing water under vibratory agitation, without losing peculiar properties to the initial gas.
[0021] Also according to the present invention, there are provided a method and a device for storing the above-mentioned liquid material for a required time period in the state of liquid and regasifying the liquid material at a required time point, and there is also provided a regasified gas composed of hydrogen and oxygen obtained by such method and device.
[0022] Further according to the present invention, there is provided a fuel which which is composed of the above-mentioned liquid material composed of hydrogen and oxygen and/or the above-mentioned regasified gas composed of hydrogen and oxygen, and generates no carbonic acid gas at all while burning.
[0023] The initial gas composed of hydrogen and oxygen, which is obtained by electrolysis of water under vibratory agitation, is liquidized to obtain a liquid material composed of hydrogen and oxygen. The liquid material is stored and is regasified to obtain a regasified gas composed of hydrogen and oxygen. The regasified gas has the same physical properties as the initial gas, and has an extremely low explosion risk. Accordingly, the liquid material composed of hydrogen and oxygen and the regasified gas composed of hydrogen and oxygen according to the present invention are applicable to an extremely wide range of use.
BRIEF DESCRIPTION OF DRAWINGS
[0024] FIG. A schematic cross-sectional view of an electrolytic device including a vibratory agitation unit used in an example.
[0025] FIG. 2 A top view of the electrolytic device shown in FIG. 1 .
[0026] FIG. 3 A cross-sectional view of a gas cylinder made of SUS304.
[0027] FIG. 4 A top view of the gas cylinder made of SUS304 shown in FIG. 3 .
[0028] FIG. 5 A side view of the gas cylinder made of SUS304 shown in FIG. 3 .
[0029] FIG. 6 A configuration diagram of a gas compression device.
[0030] FIG. 7 A configuration diagram of a combustion device used in the example.
[0031] FIG. 8 A view representing a state of a flame obtained by burning a gas composed of hydrogen and oxygen, which is obtained by electrolysis under vibratory agitation.
[0032] FIG. 9 A view representing a melting state and a gasifying state of a titanium plate caused by a flame obtained by burning a gas composed of hydrogen and oxygen, which is obtained by electrolysis under vibratory agitation.
[0033] FIG. 10 A view representing a melting state and a gasifying state of a tantalum plate caused by a flame obtained by burning a gas composed of hydrogen and oxygen, which is obtained by electrolysis under vibratory agitation.
[0034] FIG. 11 A view representing a melting state and a gasifying state of a tungsten rod caused by a flame obtained by burning a gas composed of hydrogen and oxygen, which is obtained by electrolysis under vibratory agitation.
DESCRIPTION OF EMBODIMENTS
[0035] In the present invention, an electrolytic solution is electrolyzed in an electrolytic bath under vibratory agitation, thereby to generate an initial gas composed of hydrogen and oxygen. Techniques which can be used to generate such an initial gas are described in PTLs, e.g., Japanese Patent Nos 1941498, 2707530, 2762388, 2767771, 2852878, 2911350, 2911393, 3035114, 3142417, 3196890, 332084 and 3854006, JP-A-10-309453, JP-A-11-253782, JP-A-2000-317295, JP-A-2001-288591, JP-A-2002-53999, JP-A-2002-121699, JP-A-2002-146597, JP-A-2005-232512, WO 02/090621 A1, WO 03/048424 A1, and WO 2004/092059 A1, which relates to inventions of the present invention.
[0036] Practicable vibratory agitation conditions are conditions described in the foregoing PTLs.
[0037] The electrolysis is practicable under conditions described in the foregoing PTLs. Particularly in the present invention, an electrolytic solution containing an electrolyte of 5 to 30 weight % is employed, and a group of electrodes is located in the electrolytic bath at intervals of 3 to 10 mm. Applied conditions are a current density of 5 to 20 A/dm 2 , a bath temperature of 20 to 70° C., and strong alkali.
[0038] The electrolyte employed in the present invention is not particularly limited, and NaOH or KOH is usually employed. Water to dissolve such an electrolyte and prepare an electrolytic solution may be of any type, and ion-exchanged water or distilled water is usually employed. The concentration of the electrolyte in the electrolytic solution is not particularly limited but is generally 30 weight % or lower, preferably 25 weight % or lower, or most preferably 15 to 25 weight %. In the present invention, if the concentration of the electrolyte is less than 5 weight %, electric current flow decreases thereby increasing resistance, and electric current efficiency decreases thereby further causing increase in temperature. Consequently, decrease in generation amount of the initial gas further results. If the concentration of the electrolyte is far more than 30 weight %, the electrolyte is deposited on the electrode plate, and electrolysis efficiency decreases as a result.
[0039] In the present invention, if the current density is increased, electrolysis efficiency preferably increases in one aspect while the bath temperature simultaneously increases thereby adversely decreasing the generation amount of the initial gas. In the present invention, a range of 5 to 20 A/dm 2 has been found to be totally suitable from a large number of experimental results.
[0040] In the present invention, a range of 20 to 70° C. has been found to be suitable for the bath temperature in consideration of long time operation, a generation amount of the initial gas, electrolysis efficiency, etc., from a large number of experimental results.
[0041] The value of pH depends on the electrolyte used. A suitable pH value is correlative to electrolyte, electric current density, and bath temperature. Also in the present invention, the best efficiency has resulted under a condition of strong alkali of preferably pH 14 or higher, as a result of repeatedly carried out experiments in various conditions concerning electrolyte, electric current density, bath temperature, etc.
[0042] Also in the present invention, electrodes constituting the electrode group are preferably maintained at a constant interval. This interval is 3 to 10 mm, preferably 3 to 5 mm. The number of electrodes constituting the electrode group is preferably between 4 and 1000.
[0043] The initial gas composed of hydrogen and oxygen which is generated as described above can be compressed to 3 to 300 kgf/cm 2 . A storage device (tank or gas cylinder) can be downsized by highly compressing a pressure of the initial gas to 3 to 300 kgf/cm 2 , and accordingly can be easily transported and mounted. The compression range of 3 to 300 kgf/cm 2 is suitable for practicing the initial gas. In the present invention, when liquidizing the initial gas, the pressure of the initial gas is set to 0.1 to 0.5 MPa (preferably 0.1 to 0.3 MPa), and the initial gas is cooled to −190 to −250° C. That is, if an initial gas is stored under a higher pressure than this range, the pressure of the initial gas is decreased to 0.1 to 0.5 MPa, and cooling is then performed.
[0044] There may be used the same devices as described in the foregoing PTLs for (A) the electrolytic bath, (B) the electrode group provided at an interval of 3 to 10 mm in the electrolytic bath, (C) the vibratory agitation unit for subjecting an electrolytic solution in the electrolytic bath to vibratory agitation, and (D) the unit for collecting a generated gas composed of hydrogen and oxygen.
[0045] As (E) the unit for liquidizing the collected gas composed of hydrogen and oxygen by cooling, a combination of a compression device which will be described later and a cooling device wherein liquid helium is used as a coolant may be employed.
[0046] The initial gas composed of hydrogen and oxygen, which was obtained by electrolysis under vibratory agitation, was stored in a container made of stainless steel under pressure of 0.54 MPa, and was cooled to −222° C. by liquid helium. Then, there occurred a greater pressure drop to −0.03 MPa than a pressure drop caused by cooling. As can be understood from this simple test, a fact that a pressure drop occurred exceeding a volume reduction caused by cooling proves that the gas was safely liquidized. Therefore, the initial gas seems not to be a mixture of hydrogen and oxygen in molecular states like the Brown's gas but can be considered to have caused any covalent bond of hydrogen and oxygen.
[0047] This fact complies with a phenomenon that the initial gas can be highly compressed to 20 to 30 MPa and no pressure drop occurred from compressed storage for six months using a gas cylinder made of stainless steel.
[0048] In the present invention, the liquid material composed of hydrogen and oxygen is stored for a desired period of time and then gasified (regasified) upon necessity, to obtain a regasified gas. When gasifying the liquid material, heating (including a natural temperature rise based on removal of a coolant) is performed, and preferably the temperature of the liquid material is returned to a normal temperature by heating.
[0049] There may be used the same devices as described above for the foregoing items (A) to (E) in the device used for practicing the method for manufacturing a regasified gas composed of hydrogen and oxygen.
[0050] As (F) the storage unit for storing the liquid material obtained by the liquidizing unit, a metal container (a gas cylinder or a tank) made of stainless steel can be used. As (G) the regasifying unit for regasifying the liquid material, a discharge device such as a nozzle or a burner which discharges the liquid material into air can be used.
[0051] The present inventor asked Hokkaido University and Nagoya University to carry out ingredient analysis of the initial gas composed of hydrogen and oxygen. Hence, atomic hydrogen (H), oxygen (O), a hydroxyl group (OH), and deuterium (D) were confirmed to be mixed in the initial gas, in addition to a hydrogen gas (H 2 ) and an oxygen gas (O 2 ). Thus, “composed of hydrogen and oxygen” which qualifies the regasified gas or liquid material and the initial gas in the present specification and claims is intended to mean being composed of a material containing, as components, hydrogen atoms (including deuterium atoms, tritium atoms, etc.) and oxygen atoms.
[0052] The regasified gas according to an aspect of the present invention has the same composition as a hydrogen-oxygen mixture gas described in JP-A-2005-232512.
[0053] Why accessory ingredients other than hydrogen and oxygen gases are mixed in by only physical operation of vibratory agitation will now be considered below. A key to answer this question is to change, into nanobubbles, a gas generated by electrolysis under vibratory agitation at a normal temperature under a normal pressure. The change into nanobubbles is exactly what produces new chemical reactions beyond conventional science, which lead to generation of a nonexplosive covalent bond gas.
[0054] The gas is nonexplosive regardless of being composed of hydrogen and oxygen because gasses of the accessory ingredients are generated, well balanced as a natural process which accompanies no artificial compulsion. The gasses of the accessory ingredients function as a buffer which prevents explosion caused by reaction between hydrogen and oxygen.
[0055] Sizes of generated bubbles extremely differ between electrolysis under vibratory agitation according to the present invention and conventional electrolysis. In electrolysis according to a conventional method, bubbles formed by oxygen and hydrogen gases have sizes of 1 to 5 mmφ which are visible for naked eyes. In contrast, in electrolysis according to the present invention under vibratory agitation, bubbles have sizes of 5 to 700 nm which are invisible for naked eyes, e.g., 20 to 700 nm or 5 to 200 nm, and water becomes to a state in which the entire water seems to be “milky”.
[0056] For example, if a spark is created above an electrolytic solution being electrolyzed with use of an electrolytic bath having an opening of 1000 mm×2000 mm, hydrogen and oxygen gases explode when creating a spark in case of the conventional electrolysis. However, a gas composed of hydrogen and oxygen, which is obtained by electrolysis under vibratory agitation according to the present invention, does not explode at all even if a spark is created.
[0057] When hydrogen obtained by the conventional electrolysis is stored in a metal gas cylinder (in place of a gas cylinder made of stainless steel used in examples, a metal gas cylinder made of steel, cast iron, or aluminum alloy may be used), the gas cylinder is embrittled by hydrogen or hydrogen escapes permeating through the metal gas cylinder. Therefore, long-term storage is impossible. However, a gas composed of hydrogen and oxygen, which is obtained by electrolysis under vibratory agitation, can be compressed under a high pressure (e.g., the gas could be compressed to 200 kgf/cm 2 :20 MPa without causing explosion). Besides, there is an actual result that a gas composed of hydrogen and oxygen, which was compressed and stored in a gas cylinder made of stainless steel under 10 MPa, did not cause hydrogen leakage at all even through long-term storage for six months but maintained initial pressure of 10 MPa.
[0058] According to conventional common sense, it is considered that, if a mixture gas composed of hydrogen and oxygen, which is obtained by electrolysis under vibratory agitation, is liquidized, features of this gas are lost and the gas changes to mere water as the Brown's gas does.
[0059] However, the gas composed of hydrogen and oxygen, which is obtained by electrolysis under vibratory agitation, has been found to have a surprising property that, if the gas is liquidized by compression to 5 kgf/cm 2 and cooling to −220° C. by using liquid helium, the gas does not return to mere water but a gas obtained by regasifying the liquid material returns to a gas (a regasified gas) having equivalent physical properties to the initial gas and exhibits the peculiar property again.
[0060] The Brown's gas is known to explode due to molecular friction between hydrogen and oxygen gases when compressed to 0.2 MPa or more. However, as described above, the gas composed of hydrogen and oxygen, which is obtained by electrolysis under vibratory agitation, has a peculiar property that the gas can be stored stably for a long period of time in a highly compressed state of 20 to 30 MPa and causes no explosion. These wonderful properties are not lost even after the gas is liquidized and thereafter regasified. That is, in case of the regasified gas according to the present invention, hydrogen and oxygen gases do not substantially react under a pressure of 3 to 300 kgf/cm 2 but these gases can exist stably in gas states in a container. Further, the liquid material according to the present invention can exist as a liquid under conditions of −190 to −250° C. and 3 to 300 kgf/cm 2 .
[0061] In conventional rocket fuels, hydrogen and oxygen are compressed, liquidized, and stored in separate tanks, respectively, because of danger. Hydrogen and oxygen are jetted and mixed immediately before use. Nevertheless, explosions often occurred in fact. In the gas composed of hydrogen and oxygen according to the present invention, hydrogen and oxygen are not mixed in molecular states but exist stably in a certain connection state. Therefore, the gas can be repeatedly gasified and liquidized, can be handled far more safely than in the conventional combustion systems of jetting and mixing liquid hydrogen and liquid oxygen, and further can be stored for a long period of time. Accordingly, application of the gas to a rocket fuel is available. In this manner, the gas can be expected to dramatically contribute to space engineering.
[0062] In addition, if the liquid material or regasified gas composed of hydrogen and oxygen according to the present invention is burnt, no carbonic acid gas is generated at all. Therefore, the liquid material or regasified gas is ideal clean energy. Further, what is generated as a result of combustion is water, i.e., an indispensable material for human being is supplied by burning the liquid material or regasified gas composed of hydrogen and oxygen according to the present invention.
[0063] A fuel formed of the liquid material or regasified gas composed of hydrogen and oxygen according to the present invention is capable of burning an emulsion (a water content of 70%) with an oil including a great amount of water.
[0064] If the liquid material or regasified gas composed of hydrogen and oxygen according to the present invention is used, tungsten can be gasified by heating for only one second or so. This suggests that the liquid material or regasified gas composed of hydrogen and oxygen according to the present invention has extremely high energy.
[0065] Since the liquid material or regasified gas composed of hydrogen and oxygen according to the present invention thus has extremely high energy, there is hidden potentiality that elemental transmutation can be caused by using the gas.
[0066] The device for manufacturing the liquid material or regasified gas composed of hydrogen and oxygen according to the present invention need not be provided with a diaphragm between electrodes because the liquid material or regasified gas obtained has an extremely low explosion risk.
[0067] The liquid material or regasified gas composed of hydrogen and oxygen according to the present invention is useful as a fuel for a fuel cell, and has resulted in electromotive force which is greater by 5 to 7% than in case of using pure hydrogen as a fuel.
[0068] In particular, the liquid material or regasified gas composed of hydrogen and oxygen according to the present invention is useful as an energy source for gas electric power generator. For example, electric power was generated by supplying a portable gas electric power generator with a liquid material or regasified gas composed of hydrogen and oxygen according to the present invention with the pressure of the material or gas adjusted to 0.2 MPa. An engine worked comfortably and could lighten an electric bulb of 100 W. Therefore, use as an energy source for a gas electric power generator is expected.
[0069] The liquid material or regasified gas composed of hydrogen and oxygen according to the present invention in a highly compressed state can be directly used as a fuel for engines of vehicles and other machineries. As a result, reduction of CO 2 can be realized in a short period, and accordingly, prevention of global warming can be achieved instantaneously.
[0070] Further, the liquid material or regasified gas composed of hydrogen and oxygen according to the present invention can be used as a new clean fuel for home use, which will take the place of city gas or propane gas. Realization thereof is expected to come in the near future.
Examples
[0071] Hereinafter, the present invention will be described below with reference to examples. However, the examples do not limit the present invention at all.
[0072] An electrolytic device (gas generation device) comprising a vibratory agitation unit represented in FIGS. 1 to 2 was used. This device is equivalent to commercial “Hydrogen/Oxygen Gas (OHMASA-GAS) Generation Device” (manufactured by JAPAN TECHNO CO., LTD.) which is a product name. In an electrolytic bath of this device, KOH aqueous solution containing KOH of 15 weight % at a normal temperature was prepared. In accordance with device specifications, electrolysis was performed while the vibratory agitation unit was driven to supply vibration of 35 to 50 Hz to vibration blades. As a result of vibratory agitation caused by the vibration blades, gases electrolytically generated on the electrode group (cell) constituted by plural electrodes opposed to each other were changed into as small bubbles as cannot be observed with eyes, i.e., bubbles of nano sizes. The bubbles were dispersed into the solution and then discharged to the upper space of the electrolytic bath. In order to allow a burning flame of a gas composed of hydrogen and oxygen to be observable with eyes, a system was employed which burns the generated gas composed of hydrogen and oxygen after dipping the gas through an alcohol bath.
[0073] Reasons why the gas was dipped through the alcohol bath are to adjust a burning temperature and to put a gas composed of hydrogen and oxygen in a state observable with eyes by dipping the gas through an alcohol bath because this gas is colorless and transparent and its flame which is not observable with eyes is dangerous if the gas is burnt. Therefore, no alcohol bath is required insofar as no problem occurs if a combustion gas need not be observable with eyes.
[0074] The gas manufactured by a method as described above was subjected to a compression test, a leakage test, and a drop test as follows by an independent administrative agency BUILDING RESEARCH INSTITUTE.
<Compression Test>
[0075] A low pressure compression test was carried out in which a gas composed of hydrogen and oxygen obtained by electrolysis of water under vibratory agitation was injected into a gas cylinder made of stainless steel (SUS304) represented in FIGS. 3 to 5 under a pressure of 3 to 20 kgf/cm 2 applied. No explosion occurred.
[0076] More specifically, the low pressure compression test was carried out in a manner as follows by using a device represented in FIG. 6 . FIG. 6 represents a state before staring the low pressure compression test wherein states of valves were as follows:
Valve A: Close Valve B: Close Valve C: Open Valve D: Open Valve E: Close Valve F: Open Valve G: Open Valve H: Close Valve I: Open Other valves: Close
[0087] After checking that the valves were put in the aforementioned states respectively, the low pressure compression test was carried out in an operation procedure as follows.
<Operation Procedure 1 >
[0088] Open the valves B and E, close the valve F, open the valve H, and close the valve I. Next, connect a water tank pipe (denoted by a broken line) to a joint port to a generation device of a gas composed of hydrogen and oxygen. Feed water to low and high pressure tanks by a low pressure booster pump, thereby to discharge air from both tanks. Close the valve B upon completion of the discharge.
<Operation Procedure 2 >
[0089] Disconnect the water tank pipe (denoted by a broken line) connected, in accordance with the operation procedure 1 , to the joint port to the generation device of the gas composed of hydrogen and oxygen. Connect thereto a gas pipe from the generation device of the gas composed of hydrogen and oxygen.
[0090] Close the valve C and open the valve A. Next, open the valve B to feed the gas composed of hydrogen and oxygen, and discharge water from the high and low pressure tanks. Close the valve A upon completion of the discharge of water, and inject the gas composed of hydrogen and oxygen into the tanks until the pressure of each tank reaches 0.2 MPa. Close the valve B upon completion of the injection.
[0091] A procedure for compression to a high pressure is as follows.
<Operation Procedure 3 >
[0092] Open the valve C, and feed water to the low pressure tank by the low pressure booster pump to compress the gas in the tank to 1.8 MPa. Close the valves D and E upon completion of the compression.
<Operation Procedure 4 >
[0093] Open the valve F, and feed water to a high pressure tank having a larger capacity by a high pressure booster pump, to compress the gas. Compress the inside of a high pressure tank having a smaller capacity to 10 MPa. Further, open the valves D and E to discharge water in the high pressure tank having a greater capacity to the low pressure tank, in order to attain compression to a high pressure of 2 to 20 MPa. Then, close the valves D and E upon completion of the discharge. Operation of this operation procedure 4 is repeated until a predetermined pressure is attained. In accordance with this procedure, a high pressure compression test at 20 to 200 kgf/cm 2 was carried out actually, and no explosion occurred.
[0094] From this experiment proved that a conventional mixture gas of hydrogen and oxygen explodes when the pressure reaches 3 kgf/cm 2 while a gas composed of hydrogen and oxygen obtained by electrolysis of water under vibratory agitation does not explode.
<Leakage Test>
[0095] On Oct. 8, 2003, a “gas composed of hydrogen and oxygen obtained by electrolysis under vibratory agitation” was filled in a gas cylinder made of stainless steel (SUS304), with the gas compressed to a high pressure of 100 kgf/cm 2 and further cooled (to such a temperature that does not cause liquidizing). The gas maintained in this state was stored for about half year until Mar. 8, 2004. In this while, 100 kgf/cm 2 was kept pointed on a pressure meter gauge and never changed.
[0096] Screw parts of a pressure meter set on the gas cylinder were sealed with ordinary Teflon (registered trademark) member. It was confirmed that there was no gas leakage at all from those parts.
[0097] Compared with a usual case of pure hydrogen which easily causes leakage to decrease the pressure, a gas composed of hydrogen and oxygen obtained by electrolysis under vibratory agitation is found to have an excellent storage property. This fact also suggests that hydrogen and oxygen are not independently in gas states but there is a possibility of existence of a new compound of hydrogen and oxygen.
<Drop Test>
[0098] A gas composed of hydrogen and oxygen was filled in the gas cylinder made of stainless steel under 1 MPa, and the gas cylinder was dropped from a position at a height of 5 m. No phenomenon like an explosion occurred.
[0099] A gas cylinder (3.8 L) made of stainless steel filled with a gas composed of hydrogen and oxygen and compressed to 10 MPa was put on a car. The car was driven to go round at a circuit track several times in particular premises while applying the same vibration as on ordinary roads until the car reached a velocity of 200 km/hour. No trouble was found concerning the gas cylinder and the pressure of the filled gas.
<Combustion Test>
(1) Combustion Test on High Melting Point Metal:
[0100] FIGS. 9 to 11 represent burning states of metals having a high melting point. A device represented in FIG. 7 was used for the combustion test.
[0101] A photograph in FIG. 8 shows a state of flames of a gas composed of hydrogen and oxygen obtained by electrolysis under vibratory agitation, and shows a sandwich structure in which a blue flame of hydrogen is sandwiched between red flames of oxygen. Flames involved no explosion and calmly showed a bluish white burning state.
[0102] FIG. 9 represents a case that a gas composed of hydrogen and oxygen was burnt with a distance of about 10 mm maintained between a titanium (melting point: 1667° C.) plate and a flame of the gas burning. The titanium plate was melted and gasified instantaneously.
[0103] FIG. 10 represents a case that a gas composed of hydrogen and oxygen was burnt with a distance of about 10 mm maintained between a tantalum (melting point: 2980° C.) plate and a flame of the gas burning. The tantalum plate was melted and gasified in two to three seconds.
[0104] FIG. 11 represents a case that a gas composed of hydrogen and oxygen was burnt with a distance of about 10 mm maintained between a tungsten (melting point: 3380° C.) rod and a flame of the gas burning. The tungsten rod was melted and gasified in two to three seconds.
[0105] Size of the plates and rod used in the test were as follows.
Titanium plate: 15 mm×150 mm×0.5 mm (t) Tantalum plate: 15 mm×150 mm×1.0 mm (t) Tungsten rod: 3.2 mm
These members were cut test pieces, and thicker plates can be cut into pieces by the flame of the gas burning in actuality.
[0109] A burning temperature of the conventional mixture gas of hydrogen and oxygen gases is regarded to be about 1200 to 2500° C. though the burning temperature varies depending on a mixing ratio. At this burning temperature, tantalum or tungsten cannot be melted. In the above combustion test, the burning temperature was set to be higher by 1000 to 2000° C. than that of the conventional mixture gas.
[0110] A burning temperature of this gas composed of hydrogen and oxygen obtained by electrolysis under vibratory agitation is as relatively low as about 600 to 700° C. As described above, the gas can exhibit high energy depending on target objects.
[0111] The gas composed of hydrogen and oxygen obtained by electrolysis under vibratory agitation according to the present invention burns without consuming oxygen in the atmospheric air. As a result, combustion heat generation at a discharge port of a burner was so small that the discharge port could be touched by hands without feeling hot just after the completion of the combustion test. This can be regarded to suggest that, in case of the gas composed of hydrogen and oxygen obtained by electrolysis under vibratory agitation, a chemical reaction occurs from a mechanism different from a mechanism of the conventional combustion reaction of a heat generation type.
(2) Cost Comparison in a Steel Plate Fusion Cutting Test
[0112] For references, Table 1 presents a cost comparison between cases of cutting steel plates (12 mm) respectively by using a gas composed of hydrogen and oxygen obtained by electrolysis under vibratory agitation, and an acetylene gas. The gas composed of hydrogen and oxygen obtained by electrolysis under vibratory agitation was found to result in cost reduction by half, compared with the case of using an acetylene gas.
[0000]
TABLE 1
Manufacturing cost
Cost for
for gas consumed
oxygen used
Total cost
Acetylene gas
¥18.7
¥57.7
¥76.4
(115 liters used)
Gas composed of
¥1.19
¥32.95
¥34.14
hydrogen and
(65.9 liters used)
oxygen obtained by
electrolysis under
vibratory agitation
[0113] Concerning use of oxygen, oxygen in a commercially available oxygen gas cylinder was used when burning the acetylene gas. When burning a gas composed of hydrogen and oxygen obtained by electrolysis under vibratory agitation, oxygen as a component of the gas was used.
[0114] In order to accurately specify components, developments in a dedicated analysis device had to be brought into view. As a temporary measure, as long as liquidizing could be realized at an ultralow temperature, there was a possibility of proving existence of new molecules. A special dedicated cooling device capable of cooling to −260° C. was developed and manufactured, to liquidize the gas composed of hydrogen and oxygen according to the present invention.
[0115] This liquidizing device was designed to display and record a cooling temperature and a pressure of a gas on real time, and had noteworthy features that an inspection window of about 40 mmφ was provided at a lower part of the device, and that a transparent grass tube of about 15 mmφ for containing a liquid was set inside, so that a state of liquidizing start, conditions of a liquid, and color tones could be observed on real time with eyes through the inspection window from the outside of the device.
[0116] Observation with eyes was intended to prevent mistakes in data analysis dependent only on pressures and temperatures because of the new gas.
[0117] Next, a new dedicated liquidizing device was manufactured for the gas according to the present invention, and a preliminary liquidizing test was carried out for each of a single oxygen gas and a single hydrogen gas.
[1] LIQUIDIZING A SINGLE OXYGEN GAS
[0118] 1) Before flowing a pure oxygen gas into the device, the inside of the device was cooled to −150° C. in advance. An oxygen gas was flowed into the cooled device under 0.2 MPa at a gas flow rate of 200 scc/min (standard cc/min). A liquidizing test of oxygen was carried out by decreasing the cooling temperature gradually in steps of 0.01° C.
2) Liquidizing started from −183° C. exactly according to a theoretical value and could be observed with eyes from the inspection window. A liquid thereof looked transparently light blue.
3) As the temperature was further decreased, it was observed with eyes that crystal of liquid oxygen from near −225° C. started depositing, and the entire liquid oxygen crystallized at about −230° C.
4) After confirming the above, the temperature was gradually increased to completely gasify oxygen.
[2] LIQUIDIZING A SINGLE HYDROGEN GAS
[0119] 1) As in the case of oxygen, the inside of the device was cooled to −240° C. in advance. A hydrogen gas was subjected to a hydrogen liquidizing test under 0.2 MPa at a gas flow rate of 200 scc/min while decreasing the cooling temperature gradually in steps of 0.01° C. Then, liquidizing which started from about −252.5° C. exactly according to a theoretical value could be observed with eyes from the inspection window.
2) A color tone of the liquid looked colorless and transparent.
3) After decreasing the temperature to about −255° C., the temperature was increased gradually to gasify all hydrogen. A preliminary test was thus finished.
[3] LIQUIDIZING TEST OF A GAS COMPOSED OF HYDROGEN AND OXYGEN AND REGASIFYING TEST OF THE LIQUIDIZED GAS ACCORDING TO THE PRESENT INVENTION
[0120] 1) As in the preliminary test, the inside of the device was cooled to −150° C. in advance. A gas composed of hydrogen and oxygen according to the present invention was flowed into the device under 0.2 MPa at a gas flow rate of 200 scc/min while decreasing the temperature gradually in steps of 0.01° C. Then, liquidizing started from −178.89° C., and a “colorless transparent liquid” could be observed with eyes.
2) Although the temperature was gradually decreased, the liquid stayed as liquid and caused no deposition of crystal even at −225° C. at which crystal of liquid oxygen starts depositing.
3) Further, the temperature was decreased to −255° C. However, the liquid yet stayed as liquid, and crystal was not observed at all.
4) Thereafter, the temperature was gradually increased to gasify the gas composed of hydrogen and oxygen according to the present invention, which was stored into the gas cylinder. The regasified gas was burnt, and a flame thereof was brought into contact with, for example, titanium metal. Then, the metal was observed to instantaneously sparkle and gasify.
[4] LIQUIDIZING TEST OF A MIXTURE GAS OF HYDROGEN AND OXYGEN
[0121] 1) In order to clarify that the liquid material or gas composed of hydrogen and oxygen according to the present invention differs from a mixture of hydrogen and oxygen, a commercially available hydrogen gas and a commercially available oxygen gas were mixed up in a manner as described below, and were liquidized in a manner as described above. A liquidizing temperature thereof was measured, and a color of the liquidized material was observed. Proper setting of pressures is considered to principally contribute to safe completion of such a test. This fact was a discovery.
2) As in the preliminary test, the inside of the device was cooled to −150° C. in advance. Thereafter, a commercially available hydrogen gas and a commercially available oxygen gas were flowed into the device under 0.2 MPa at gas flow rates respectively adjusted to 200 scc/min for hydrogen and 100 scc/min for oxygen while decreasing the temperature gradually in steps of 0.01° C. Then, liquidizing started from −182.50° C., and a “liquid of light blue which is a color of liquid oxygen” could be observed with eyes.
3) Although the temperature was gradually decreased, the liquid stayed as liquid and caused no deposition of crystal even at −225° C. at which crystal of liquid oxygen starts depositing.
4) Further, the temperature was decreased to −250° C. However, the liquid yet stayed as liquid, and crystal was not observed at all.
5) From the above, as expected, the liquid material or gas composed of hydrogen and oxygen according to the present invention was proved to differ from a mixture of hydrogen and oxygen.
[5] LIQUIDIZING A GAS COMPOSED OF HYDROGEN AND OXYGEN GENERATED BY ELECTROLYSIS OF WATER AND REGASIFYING THE LIQUIDIZED GAS
[0122] Liquidizing and regasifying are not limited to the gas generation unit described above but may be applied to a gas generated from any other gas generation unit.
[6] CONCLUSION
[0123] The followings are features of the liquid material or gas composed of hydrogen and oxygen according to the present invention, which have been confirmed through the above experiments. It is worth notice that the existence of a new compound of hydrogen and oxygen is demonstrated.
[0000] a) A liquidizing temperature thereof is about −179° C. which is a “higher temperature” by about 4° C. than that of oxygen.
b) A liquid thereof has a “colorless transparent” color tone.
c) “No crystallization” occurs at a ultralow temperature of −255° C.
d) The liquid material composed of hydrogen and oxygen according to the present invention starts gasifying when the temperature increases to be higher than the liquidizing temperature. A regasified gas is considered to maintain substantially the same energy as before being gasified.
e) Conventionally, oxygen and hydrogen generated from electrolysis of water are considered to form a mixture gas thereof. However, the gas composed of hydrogen and oxygen according to the present invention is considered to be a compound forming a completely “new bond of oxygen and hydrogen” from the various tests described above. | A liquid material comprising hydrogen and oxygen is produced by electrolyzing an electrolysis solution containing 5 to 30% by weight of an electrolyte in an electrolysis tank using a group of electrodes disposed, within the electrolysis tank, while maintaining a spacing of 3 to 10 mm between adjacent electrodes under conditions of a current density of 5 to 20 A/dm 2 , a bath temperature of 20 to 70° C., and pH 14 or more (strongly alkaline) while applying vibration stirring, bringing the pressure of the resultant gas comprising hydrogen and oxygen to 0.1 to 0.5 MPa, and cooling the gas to −190 to −250° C. to liquefy the gas. The liquid material is stored, is returned to room temperature, and is gasified to produce a regasified gas comprising hydrogen and oxygen. | 8 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to U.S. Provisional Patent Application Ser. No. 61/334,671, filed on May 14, 2010, and entitled “GEP AND DRUG TRANSPORTER REGULATION, CANCER THERAPY AND PROGNOSIS,” the entirety of which is incorporated by reference herein.
TECHNICAL FIELD
[0002] This disclosure generally relates to methods for treating hepatic cancers exhibiting chemoresistance by targeting a growth factor (granulin-epithelin precursor (GEP) and an ATP-dependent binding cassette (ABC) drug efflux transporter (ABCB5 or ABCF1) in connection with chemotherapy.
BACKGROUND
[0003] Liver cancer is the third leading cancer killer in the world, with more than half a million individuals dying globally each year. In China, liver cancer is the second major cause of cancer death. Surgical resection, in the form of a partial hepatectomy or a liver transplant, is the mainstay of curative treatment. Nonetheless, cancer recurrence is still common after curative surgery. In addition, liver cancer is frequently diagnosed at an advanced stage, which precludes curative treatment. No effective therapeutic option exists for the treatment of the majority of liver cancer patients. Chemotherapy is widely used to treat unresectable liver cancer, but with marginal efficiency. There is an urgent need to elucidate the key genes in relation to recurrence and chemoresistance in the clinical situation, and to develop a novel therapeutic approach to sensitize liver cancer cells to chemotherapeutic agents.
[0004] Multidrug resistance can result from distinct mechanisms, e.g., alterations of tumor cell cycle checkpoints impairment of tumor apoptotic pathways, and reduced drug accumulation in tumor cells. Among these, decreased intracellular drug accumulation is a well-studied mechanism of cancer multidrug resistance and has been shown to result in part from tumor cell expression of the ATP-dependent binding cassette (ABC) drug efflux transporter ABCB1 (also named P-glycoprotein, or MDR1). In the human ABC superfamily, ABCB1 and ABCC1 (also named MRP1) have been shown to mediate multidrug resistance, each with distinct yet overlapping efflux substrate specificities and tissue distribution patterns. The multidrug resistance phenotype was reported in liver carcinogenesis long ago. The phenotype is commonly mediated through overexpression of ABC drug transporters, including ABCB1 and ABCC1. These genes enable liver cancer cells to efflux a broad range of chemically diverse chemotherapeutic agents. Nonetheless, the key genes that regulate chemoresistance in clinical situations have yet to be identified for liver cancer patients.
[0005] The contribution of tumorigenic stem cells to hematopoietic cancers has been established for some time, and cells possessing stem cell properties have been described in several solid tumors. Although chemotherapeutic agents would kill most of the tumor cells, they are believed to leave a small population of tumor stem cells behind, which might be an important mechanism of drug resistance. For example, the ABC drug transporters have been shown to protect cancer stem cells from chemotherapy, e.g., ABCB1 in glioblastoma and ABCB5 in melanoma.
[0006] Granulin-epithelin precursor (GEP, also named progranulin, proepithelin, acrogranin, or PC-derived growth factor) is a multi-facet autocrine growth factor with different biological roles, including cancer progression, murine fetal development, and tissue repair. Mutation of GEP affects neuron survival and causes frontotemporal dementia. GEP has been identified as a therapeutic target from the global gene expression profiles of liver cancer. GEP has been shown to be up-regulated in liver cancer tissues and functional experiments have demonstrated that GEP controls proliferation, invasion and tumorigenicity. Thus, GEP is an important molecule for targeted therapy. Nonetheless, targeted therapy alone in clinical settings, in general, is not sufficient to eradicate solid tumors.
SUMMARY
[0007] The following presents a simplified summary of the various embodiments in order to provide a basic understanding of some aspects described herein. This summary is not an extensive overview of the disclosed subject matter. It is intended to neither identify key or critical elements of the disclosed subject matter nor delineate the scope of the subject embodiments. Its sole purpose is to present some concepts of the disclosed subject matter in a simplified form as a prelude to the more detailed description that is presented later.
[0008] Various embodiments are directed to treating liver cancers exhibiting multidrug resistance (also referred to herein as chemoresistance). More specifically, the embodiments relate to targeting and/or suppressing a growth factor and a drug transporter to facilitate the treatment of chemoresistant liver cancer. The specific growth factor targeted can be granulin-epithelin precursor (GEP), which over-expresses in liver cancer cells and regulates proliferation, invasion and tumoriginicity. Suppression of GEP can enhance the apoptotic effect induced by chemotherapeutic agents, while up-regulation of GEP shows opposite trend. GEP has been shown to regulate drug transporters of the ATP-dependent binding cassette (ABC) drug efflux transporter family that play a role in chemoresistance, such as ABCB5 and ABCF1. Accordingly, the drug transporter targeted can be ABCB5 or ABCF1. These methods can further include applying chemotherapeutics in combination with targeting the growth factor and the drug transporter. Targeting the growth factor and drug transporter, in combination with chemotherapy can provide a treatment modality that can eradicate aggressive liver cancer cells.
[0009] According to an embodiment, methods are described for manipulating a growth factor (e.g., GEP) and drug transporters (e.g., ABCB5 or ABCF1) on a cell, as well as related products. In a further embodiment, described are methods for treating cancer cells using growth factor (e.g., GEP) and drug transporter (e.g., ABCB5 or ABCF1) binding molecules and suppression of growth factor and drug transporter molecules. Further described herein are sets of markers whose expression patterns can be used to differentiate different clinical conditions, such as high or low levels of a growth factor (e.g., GEP) and drug transporters (e.g., ABCB5 or ABCF1). Based on the different clinical conditions, a likelihood of cancer recurrence, drug sensitivity, and prognosis can be determined. Also described herein are methods of classifying and treating patients based on the prognosis are also provided herein.
[0010] The following description and the annexed drawings set forth in detail certain illustrative aspects of the disclosed subject matter. These aspects are indicative, however, of but a few of the various ways in which the principles of the various embodiments may be employed. The disclosed subject matter is intended to include all such aspects and their equivalents. Other advantages and distinctive features of the disclosed subject matter will become apparent from the following detailed description of the various embodiments when considered in conjunction with the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 shows GEP level regulated chemoresistance. (A) Hep3B cells were modulated for GEP levels: GEP suppression (−) and GEP overexpression (+). The transfectants were validated for GEP mRNA and protein level modulations (mean fluorescence intensity, MFI). (B) Positive correlation between GEP level and chemoresistance. GEP suppression demonstrated increased apoptotic populations and thus the cells were more sensitive to chemotherapeutic agents. GEP overexpression resulted in decreased apoptotic populations and thus the cells were more resistant to chemotherapeutic agents. GEP conferred chemoresistance to chemotherapeutic agents, including doxorubicin and cisplatin. (C) GEP modulated ABCB5 level. The liver cancer cells modulated for GEP levels were examined for ABCB5 expression. The change of GEP level conferred a moderate effect on the modulation of ABCB5 mRNA level, but a prominent effect on the regulation of ABCB5 protein level. The protein levels of GEP/ABCB5 (solid lines) were shown as mean fluorescence intensity (MFI) after subtraction for the corresponding isotype controls (dotted lines) for the flow overlay diagrams.
[0012] FIG. 2 shows increased ABCB5 in chemoresistant cells. (A) The chemoresistant cells demonstrated an increase of 10 to 16 folds in resistance to chemotherapeutic agents. The liver cancer cells were selected and expanded under different chemotherapeutic agents. These cells with “acquired resistance” were referred to as chemoresistant populations. The cells selected for resistance to doxorubicin were referred to as doxorubicin resistant cells. Similarly, the cells selected under cisplatin were referred to as cisplatin resistant cells. The drug IC50 values were determined by MTT assay. The doxorubicin resistant cells demonstrated an increase in resistance to doxorubicin by more than 16 folds compared to their parental cells (IC50 values were 1.78 and 0.11 μg/ml, respectively). The cisplatin resistant cells demonstrated an increase in resistance to cisplatin by more than 10 folds compared to their parental cells (IC50 values were 8.53 and 0.84 μg/ml, respectively). (B) ABCB5 up-regulation was observed in the chemoresistant cells.
[0013] FIG. 3 shows ABCB5 suppression enhanced doxorubicin uptake and cell apoptosis. (A) The cells were suppressed for ABCB5 expression by the siRNA approach. All of the cells showed decreased ABCB5 mRNA levels with siABCB5 (results of protein level suppression were shown in FIG. 4 ). (B) Doxorubicin content after 24 hours of doxorubicin (0.5 μg/ml) treatment. The majority of the Hep3B cells had doxorubicin uptake (76.4%) after 24 hours of doxorubicin incubation (solid line, compared to dotted line of the control). In contrast, GEP overexpressing cells and doxorubicin resistant cells had reduced populations with doxorubicin uptake (55.4% and 31.1%, respectively). Irrespective of the cells' baseline sensitivity to doxorubicin (middle panel), suppression of ABCB5 by the siRNA approach sensitized them to doxorubicin uptake (right panel). (C) Cell apoptosis after 24 hours of doxorubicin (0.5 μg/ml) treatment. Suppression of ABCB5 enhanced cell apoptosis in cells including the Hep3B, the GEP overexpression transfectants, and the doxorubicin-resistant cells. * P<0.05, ** P<0.01 vs. controls.
[0014] FIG. 4 shows characterizations of hepatic stem cells marker expressions in HCC cells. The double-positive subpopulation, GEP+ABCB5+ cells is shown in the upper right quadrant of the scatter plot at the left panel, gated in R2/The double-positive subpopulation gated in R2 was further distinguished for positivity of CD133 (scatter plot at the middle panel) and EpCAM (scatter plot at the right panel). (A) Hep3B cells. The majority of the ABCB5+ cells were also GEP+(28.0% cells). These GEP+ABCB5+ double-positive cells expressed CD133 and EpCAM. Suppression of ABCB5 by the siRNA approach effectively decreased ABCB5 expression, reduced the population of cells coexpressing GEP, and diminished the cell population expressing the hepatic stem cell markers CD133 and EpCAM. (B) GEP overexpression transfectants. Increased GEP expression level by transfection of GEP full-length cDNA increased the ABCB5+GEP+double positive population (64.6% compared to 28.0% in parental cells), and the majority of these cells were positive for CD133 and EpCAM. Suppression of ABCB5 expression by siRNA decreased the GEP+ABCB5 subpopulation, and reduced the cell population with hepatic stem cell markers CD133 and EpCAM. (C) Doxorubicin resistant cells. Increased ABCB5+GEP+ subpopulation (57.6% compared to 28.0% in parental cells) was observed in the chemoresistant cells, and these double-positive cells expressed the hepatic stem cell markers CD133 and EpCAM. Suppression of ABCB5 expression decreased the GEP+ABCB5+ subpopulation and the cell population expressing hepatic stem cell markers CD133 and EpCAM. * P<0.005, **P<0.001 vs. controls.
[0015] FIG. 5 shows decreased hepatic stem cell marker expression in liver cancer cells with suppression of ABCB5. Cells were examined by flow cytometry and mean fluorescence intensity (MFI) of each protein was shown. (A) Hep3B cells. (B) GEP overexpression transfectants. (C) Doxorubicin resistant cells.
[0016] FIG. 6 shows high recurrence rate of HCC with elevated GEP and ABCB5 expressions. (A) GEP overexpression was significantly up-regulated in HCC compared to the paralleled tumor-adjacent liver tissues (comprised with hepatitis and cirrhotic livers) and the normal livers from healthy individuals. (B) ABCB5 expression was elevated in HCC. The majority of normal livers from healthy individuals and tumor-adjacent livers from HCC patients showed undetectable ABCB5. (C) Kaplan-Meier recurrence-free survival plot according to GEP levels (log-rank test, P=0.028). There were 26 patients in the low GEP group and 36 patients in the high GEP group (median recurrence-free survival of 37.2 months and 8.0 months, respectively). (D) Kaplan-Meier recurrence-free survival plot according to ABCB5 levels (log-rank test, P=0.022). There were 36 patients with undetectable ABCB5 expression and 26 patients with ABCB5 expression (median recurrence-free survival of 32.4 months and 7.4 months, respectively).
[0017] TABLE 1 shows a Cox regression analysis for recurrence-free survival on gene expression and clinicopathological parameters.
[0018] TABLE 2 shows ATP-binding transporter genes. Genes whose expression level differed by at least two fold, in at least one sample, from their mean expression level across all samples were selected for further analysis. Leaving 7836 clones, there were 22 clones, 19 genes encoding the ATP-binding transporters. The genes were ranked according to the correlation coefficient values of their expression levels with GEP.
[0019] FIG. 7 shows microarray data in the first set of liver samples. GEP and ABCF1 expression levels were correlated (P<0.001).
[0020] FIG. 8 shows a validation of GEP and ABCF1 correlation (P<0.001). Independent sample set of liver samples were analyzed by real-time quantitative PCR.
[0021] FIG. 9 shows that ABCF1 mRNA levels in tumor tissue is significantly higher than the parallel non-tumor liver (P<0.001).
[0022] FIG. 10 shows a Kaplan-Meier plot on recurrence-free survival according to ABCF1 levels. Cells exhibiting a low concentration of ABCF1 exhibited a higher recurrence-free survival rate than cells exhibiting a high concentration of ABCF1 (log rank, P=0.001).
[0023] TABLE 3 shows a Cox regression analysis for recurrence-free survival on gene expression and clinicopathological parameters including ABCF1.
[0024] FIG. 11 shows effects of GEP antibody treatment and a chemodrug on enhancement of apoptosis in Hep3B.
[0025] FIG. 12 shows continuous monitoring of tumor size with GEP antibody treatment and a chemodrug. GEP antibody treatment in combination with a chemodrug showed improved growth inhibition compared to either treatment alone.
DETAILED DESCRIPTION
[0026] Various aspects relate to the treatment of liver cancer. Traditional treatments involve curative surgery, such as a partial hepatectomy, and/or chemotherapy. Chemotherapy has marginal efficiency, and patients to exhibit poor survival outcomes. This can be due to a small portion of cells exhibiting multidrug resistance (also referred to as chemoresistance herein).
[0027] Multidrug resistance can result from a decreased intracellular drug accumulation, for example due at least in part to tumor cell expression of an ATP-dependent binding cassette (ABC) drug efflux transporter. The multidrug resistance phenotype in liver carcinogenesis is commonly mediated through overexpression of ABC drug transporters, including ABCB1 and ABCC1. These transporters enable liver cancer cells to efflux a broad range of chemically diverse chemotherapeutic agents.
[0028] Multidrug resistance can also be facilitated by tumorigenic stem cells. The contribution of tumorigenic stem cells to hematopoietic cancers has been established for some time. Although chemotherapeutic agents kill most of the tumor cells, a small population of cancer stem cells can be left behind. These remaining cancer stem cells can be protected from chemotherapy, for example, by ABCB5 and ABCF1.
[0029] Gene expression profiling studies of liver cancer have shown that hepatic cancer cells express GEP. GEP has been shown to be up-regulated in liver cancer tissues, and, functionally, GEP controls proliferation, invasion and tumorigenicity. Accordingly, GEP is an important molecule for targeted therapy. A therapeutic approach of GEP-targeted therapy for liver cancer using anti-GEP monoclonal antibody with an animal model has been previously demonstrated. However, targeted therapy alone in clinical settings is not sufficient to eradicate solid tumors.
[0030] As shown in the Experimental section, overexpression of GEP confers chemoresistance to liver cancer cells, while suppression of GEP renders the lover cancer cells chemosensitive. Additionally, GEP is the upstream from ATP-dependent binding cassette (ABC) drug efflux transporters (ABCB5 or ABCF1), so that GEP can regulate the protein level of ABCB5 and/or other drug efflux transporters, such as ABCF1. Suppression of ABCB5 or ABCF1 can render liver cancer cells chemosensitive. Targeting GEP and the drug efflux transporter, in combination with chemotherapy, can provide treatment modalities to eradicate aggressive, chemoresistant liver cancer cells.
[0031] Moreover, the GEP+ABCB5+ cells coexpressed the hepatic stem cell markers CD133 and EpCAM, and the sternness feature explained the high recurrence rate after curative partial hepatectomy for liver cancer that expressed GEP/ABCB5. Accordingly, GEP regulates chemoresistance through ABCB5, and GEP+ABCB5+ cells express hepatic stem cell markers.
[0032] Suppression of GEP and drug transporters is a viable treatment modality for liver cancer cells. Suppression of GEP and ABCB5 has been shown to increase uptake of chemotherapeutic by at least 20% when compared to suppressing GEP alone. In other embodiments, suppression of GEP and ABCB5 has been shown to increase uptake of chemotherapeutics by at least 40% when compared to suppressing GEP alone. Suppression of GEP and ABCB5 has been shown to increase the uptake of chemotherapeutic by at least 40% when compared to treatment with chemotherapeutics alone. Additionally, treatment suppressing GEP and drug transporters ABCB5 and ABCF1 increases chemotherapeutic by at least 45% when compared to treatment with chemotherapeutic alone. Additionally, treatment suppressing GEP and ABCB5 in combination with chemotherapy increases the apoptotic rate of liver cancer cells by at least 30%. In another embodiment, treatment suppressing GEP, ABCB5 and ABCF1 in combination with chemotherapy increases the apoptotic rate of liver cancer cells by at least 40%. Moreover, suppression of GEP and ABCB5 can reduce the number of drug resistant cancer stem cells by at least 25%. Suppression of GEP, ABCB5 and ABCF1 can reduce the number of drug resistant cancer stem cells by at least 35%.
[0033] Furthermore, treatment suppressing GEP and drug transporters in combination with chemotherapy increases the recurrence free survival time in at least 50% of patients by more than six months. According to a more preferred embodiment, treatment suppressing GEP and drug transporters in combination with chemotherapy increases the recurrence free survival time in at least 30% of patient by more than 12 months. According to a more preferred embodiment, treatment suppressing GEP and drug transporters in combination with chemotherapy increases the recurrence free survival time in at least 10% of patients by more than 24 months.
EXPERIMENTAL
Materials and Methods
Clinical Specimens
[0034] The study protocol was approved by the Institutional Review Board of the University of Hong Kong/Hospital Authority Hong Kong West Cluster (HKU/HA HKW IRB). Between October 2002 and July 2005, 66 patients having curative partial hepatectomy for hepatocellular carcinoma (HCC) at Queen Mary Hospital, Hong Kong, were recruited with informed consent to the study. The same team of surgeons performed all the operations throughout this period. Clinicopathological data were prospectively collected. All patients had been diagnosed with primary HCC. Recurrence-free survival was the endpoint and was calculated from the date of surgery to the date of recurrence. Diagnosis of recurrence was based on typical imaging findings in contrast-enhanced computed tomography scan and an increase of serum alpha-fetoprotein level. In case of uncertainty, hepatic arteriography and post-Lipiodol computed tomography scan were performed, and, when necessary, fine-needle aspiration cytology was used for confirmation. Only 62 patients were included in the recurrence-free survival analysis. Four patients were excluded from the survival outcome analysis because of default follow-up, hospital mortality or concurrent radiofrequency ablation. Up to the date of analysis, the median follow-up time was 66.6 months.
Cell Cultures and Assays
[0035] Human liver cancer cell lines, Hep3B and HepG2, were purchased from American Type Culture Collection (Manassas, Va.). Culture method has been previously described, for example by Ho J C, et al. Hepatology 2008; 47: 1524-1532 and Cheung S T, et al. Clin Cancer Res 2004; 10: 7629-7636. Stable transfectants for GEP overexpression and suppression have also been described. For chemoresistant populations, the Hep3B cells were plated out and selected under various chemotherapeutic agents of various concentrations at 10-fold dilution for 30 days. The highest dose that still had viable cells over the extended selection period was used and the cells expanded for further selection. The one-step selected cells were then plated out again and selected under escalating doses of the respective drug in a 2-fold manner for another 30 days. The two-step selection process could select a population of cells more resistant to chemotherapeutic agents. The cells selected for resistance to doxorubicin were referred to as doxorubicin resistant cells. Similarly, the cells selected under cisplatin were referred to as cisplatin resistant cells. The drug IC50 value was determined by MTT assay. For apoptosis assays, cells were incubated with or without chemotherapeutic agents for 24 to 48 hours. Apoptosis was determined by Annexin V-FITC (AV-FLI) and propidium iodide (PI-FL2) staining using flow cytometry. The total apoptotic population included the early apoptotic cells (high MFI of AV but low PI) plus the late apoptotic cells (high MFI of both AV and PI) of the scatter plot. The bar chart for apoptosis assay showed the net increase of apoptotic cells after designated time of treatment (e.g.=the apoptotic population under doxorubicin treatment for 24 hours minus the control with no doxorubicin). For doxorubicin uptake assays, cells were incubated with or without doxorubicin for 24 hours, and doxorubicin content (FL2) was analyzed by flow cytometry. Pilot studies had examined treatment time-points 0, 1, 3, 6 and 24 hours, and the latter three time-points had similar data profiles. Hence, treatment time-points 0, 1, and 24 hours were examined in the subsequent experiments for doxorubicin uptake and apoptosis assays. There was a time-dependent effect, and thus the data charts presented the data of the 24-hour treatment in comparison with the baseline data. Antibodies against ABCB5 (Everest Biotech Ltd, Oxfordshire, UK), CD133 (Miltenyi Biotec, Bergisch Gladbach, Germany), EpCAM (BD Biosciences, San Jose, Calif.) and GEP (described previously By Ho K C, et al. Hepatology 2008; 47: 1524-1532) were used in the immunofluorescence staining by flow cytometry (FACSCalibur, BD Biosciences).
Real-Time Quantitative RT-PCR
[0036] Real-time quantitative RT-PCR was performed as described previously by Cheung S T, et al. Clin Cancer Res 2004; 10: 7629-7636. Quantification was performed with the ABI Prism 7700 sequence detection system (Applied Biosystems, Foster City, Calif.). Primers and probes for GEP have been described by Cheung S T, et al. Clin Cancer Res 2004; 10: 7629-7636. Primers and probe reagents for ABCB5 and control 18s were ready-made reagents (Pre-Developed TaqMan Assay Reagents, Applied Biosystems). The relative amount of GEP and ABCB5, which had been normalized with control 18s for RNA amount variation and calibrator for plate-to-plate variation, was presented as the relative fold change.
RNA Interference
[0037] Three stealth small interfering RNAs (siRNA) specific to ABCB5 (HSS139171, HSS139172 and HSS139173) and a control siRNA with matched GC content were designed and synthesized by Invitrogen (Carlsbad, Calif.). Transfection was performed using Lipofectamine 2000 (Invitrogen) according to the instructions of the manufacturer. A total of 100 nmol/L of siRNA duplex was used for each transfection. Each set of transfection had three controls, including the cell plus Lipofectamine, the cell plus Lipofectamine and control siRNA, and the cell only control. These three controls had similar data profiles, and thus the data charts presented the average data of the controls. Comparison of the three siRNAs for ABCB5 indicated that HSS139172 had a more consistent effect on mRNA and protein suppression, and thus the data charts presented the average data of siABCB5 HSS139172.
Statistical Analyses
[0038] All statistical analyses were performed by SPSS version 16.0 for Windows (SPSS Inc., Chicago, Ill.). Continuous variables were assessed by the Spearman correlation and compared between groups by Student's t-test. The GEP and ABCB5 mRNA levels were continuous variables, and the data were modeled as categorical variables in Kaplan-Meier and Cox regression analyses. The Youden index, i.e. sensitivity+specificity−I, was used to determine the optimal cutoff point for the prediction of 3-year recurrence-free survival. Other cutoff values, including the mean and the median, were also considered and examined. They were all able to segregate patients with similar clinical implications. The Youden index was employed to simultaneously maximize the sensitivity and the specificity of the prediction. The association of GEP, ABCB5 and tumor stage (AJCC tumor staging system) with recurrence-free survival was examined by univariate and multivariate Cox proportional hazards regression with a forward stepwise selection procedure. A P value less than 0.05 was considered statistically significant.
Results
[0039] Growth Factor GEP Regulated Chemoresistance Through ABCB5
[0040] To examine whether GEP has a role in chemoresistance, transfection experiments were performed to overexpress or suppress GEP in HCC cells ( FIG. 1 (A)). The transfectants were investigated for chemoresponses under doxorubicin and cisplatin treatments. We observed that suppression of GEP (−) sensitized the HCC cells to chemotherapy with enhanced apoptosis, while overexpression of GEP (+) rendered the HCC cells resistant to chemotherapeutic agents with fewer apoptotic cells ( FIG. 1 (B)).
[0041] A number of ABC drug transporters were then screened to examine if GEP would regulate chemoresistance through modulating the drug transporter levels. GEP overexpression enhanced ABCB5 protein expression, while GEP suppression down-regulated ABCB5 protein expression ( FIG. 1 (C)). Notably, the variation of GEP level demonstrated a prominent effect on the modulation of ABCB5 protein level. However, GEP level differences only moderately affected ABCB5 mRNA level in cell lines. Remarkably, the other common ABC drug transporters were not affected by GEP modulations, including ABCB1 (also named P-glycoprotein or MDRI), ABCCI (also named MRP1) and ABCC2 (also named MRP2) (data not shown).
[0042] Chemoresistant HCC cells were used to examine the role of ABCB5. Cells were plated out and selected under different chemotherapeutic agents. The cells selected under doxorubicin were referred to as the doxorubicin resistant population, and they demonstrated increased resistance to doxorubicin compared to their parental cells ( FIG. 2(A) ). The cells selected under cisplatin were referred to as the cisplatin resistant population, and similarly they showed increased resistance to cisplatin. Both the doxorubicin and cisplatin resistant populations showed enhanced ABCB5 expression ( FIG. 2(B) ).
[0000] Cells with Elevated ABCB5 Reduced Doxorubicin Uptake
[0043] The different cell populations were exposed to doxorubicin and examined for drug uptake ( FIG. 3 ). After doxorubicin treatment, GEP overexpression transfectants and doxorubicin resistant cells both demonstrated a lower doxorubicin uptake compared to the parental Hep3B cells (cell populations with doxorubicin were 55.4% and 31.1%, compared to 76.4% respectively). It was also noted that the Hep3B cells showed a lower ABCB5 level compared to GEP overexpression transfectants and doxorubicin resistant cells. Thus, the current data indicated that the ABCB5 level was negatively associated with doxorubicin uptake.
Suppression of ABCB5 Sensitized the Cells to Doxorubicin Uptake and Apoptosis
[0044] The results described earlier showed that GEP regulated chemoresistance, GEP regulated ABCB5 expression level, and ABCB5 demonstrated enhanced expression in chemoresistant populations. To consolidate if ABCB5 has a pivotal role in chemoresistance, ABCB5 expression levels were modulated by the siRNA approach and examined the functional effects. The Hep3B cells, GEP overexpression transfectants and doxorubicin resistant cells were transfected with three siRNAs against ABCB5. All the siRNAs were able to suppress ABCB5 mRNA and protein levels, and the siRNA that had a more consistent effect was shown ( FIG. 3(A) on ABCB5 mRNA levels; FIG. 4 on ABCB5 protein levels).
[0045] In the Hep3B cells, suppression of ABCB5 demonstrated a significant increase in doxorubicin uptake (76.4% to 93.8% population with doxorubicin uptake) ( FIG. 3B ) and enhanced apoptosis (12.5% to 27.9% net increase in apoptotic populations) ( FIG. 3C ). It was further shown that ABCB5 suppression had a similar functional effect on liver cancer cells with a higher ABCB5 level, including the GEP overexpression transfectants and doxorubicin resistant cells. GEP overexpression transfectants demonstrated that ABCB5 suppression could enhance doxorubicin uptake (55.4% to 78.0%) and apoptosis (11.3% to 19.2%). Similarly, doxorubicin resistant cells showed that ABCB5 suppression could enhance doxorubicin uptake (31.1% to 62.0%) and apoptosis (7.7% to 14.2%). These data demonstrated that ABCB5 level regulated chemoresponse, and suppression of ABCB5 level could sensitize liver cancer cells to chemotherapeutic agents with increased intracellular drug content and enhanced apoptosis.
GEP and ABCB5 Elevation in HCC
[0046] The association between ABCB5 was further examined with clinical specimens. GEP transcript and protein levels were reported in a previous study by Cheung S T, et al. Clin Cancer Res 2004; 10: 7629-7636. Herein, an independent patient cohort was recruited. Similar to the observation by Cheung, et al., GEP expression was significantly elevated in HCC compared to the paralleled tumor-adjacent liver tissues in the new sample set (Paired-Sample T-Test, P<0.001) and to the normal livers from healthy individuals (Independent Sample T-Test, P<0.001) ( FIG. 6 ). This served as an independent study to demonstrate GEP is up-regulated in HCC in general. The tumor-adjacent liver tissues were comprised of hepatitis and cirrhotic livers, and the GEP expression level in these tissues was similar to that in the normal livers obtained from healthy individuals, indicating the uniqueness of GEP overexpression in HCC. ABCB5 was undetectable in the majority of the normal livers (90%, 9/10) and tumor-adjacent liver tissues (89.7%, 58/66). HCC tissues demonstrated elevated ABCB5 expression compared to the paralleled tumor-adjacent liver tissues (Paired-Sample T-Test, P=0.033) and to the normal livers from healthy individuals (Independent-Sample T-Test, P=0.022).
[0047] Gene expression levels were compared in the HCC samples, and the expression of GEP and that of ABCB5 significantly correlated (HCC n=66, Spearman's rho correlation coefficient=0.390, P=0.001). All the liver samples, including the tumor, tumor adjacent and normal liver tissues, were then included in the correlation analysis. Expressions of GEP and ABCB5 significantly correlated in the different types of liver samples investigated (n=142, Spearman's rho correlation coefficient=0.428, P=0.022). Accordingly, GEP and ABCB5 expressions significantly correlate in the clinical liver specimens, providing further evidence for the observation on cell models that GEP and ABCB5 were tightly associated.
[0000] Association of GEP and ABCB5 with Poor Prognosis
[0048] GEP protein expression has been shown to be associated with early intrahepatic recurrence by Cheung S T, et al. Clin Cancer Res 2004; 10: 7629-7636. The current patient cohort had extensive follow-up and thus the association between gene expression and recurrence-free survival was examined. Kaplan-Meier plot was used to examine patient outcome in association with gene expression. The patients were segregated into GEP low and GEP high groups with the Youden index maximized to determine the optimal cutoff value ( FIG. 6(C) , TABLE 1). There were 26 patients in the GEP low group (median recurrence-free survival 37.2 months) and 36 patients in the GEP high group (median recurrence-free survival 8.0 months). Patients with high GEP levels were found to have poor recurrence-free survival (log-rank test, P=0.028).
[0049] Prognosis analysis was performed based on ABCB5 expression. The optimal cutoff value for ABCB5 was determined by maximizing the Youden index, and the patients were segregated into ABCB5 absent and ABCB5 present groups ( FIG. 6(D) , TABLE 1). There were 36 patients in the ABCB5 absent group (median recurrence-free survival 32.4 months) and 26 patients in the ABCB5 present group (median recurrence-free survival 7.4 months). Patients with ABCB5 expression were shown to have poor recurrence-free survival (log-rank test, P=0.022).
[0050] To examine the prediction power for recurrence-free survival, Cox regression analysis was employed to compare the gene expression data and tumor stage (TABLE 1). By univariate Cox regression analysis, high GEP level [hazard ratio (HR)=2.3; 95% confidence interval (95% Cl)=1.2-4.6; P=0.016], ABCB5 expression (HR=2.3; 95% Cl 1.2-4.4; P 0.009) and advanced tumor stage (HR=2.7; 95% Cl=1.4-5.2; P=0.002) were significantly associated with poor recurrence-free survival. By multivariate Cox regression analysis, only ABCB5 expression (HR=2.1; 95% Cl=1.1-4.0; P=0.024) and advanced tumor stage (HR=2.5; 95% Cl=1.3-4.7; P=0.006) were found to be independent prognostic factors for recurrence-free survival. This part of the study showed that ABCB5 expression influenced the prognosis of liver cancer patients having curative partial hepatectomy.
Expression of GEP/ABCB5 and Stem Cell Markers
[0051] Cancer stem cells have been known to express ABC drug transporters to protect themselves from chemotherapy. In addition, with the tumor bulk removed by curative partial hepatectomy, the high recurrence rate of liver cancer could be explained by the presence of cancer stem cells/tumor-initiating cells. The stem cell signature of hepatic cancer cells was further characterized. The majority of the GEP+ABCB5+ cells coexpressed hepatic cancer stem cell markers including CD133 and EpCAM in Hep3B cells ( FIG. 4(A) ). Increased GEP expression in the GEP overexpression transfectants increased the GEP+ABCB5+ population, and these cells coexpressed the stem cell markers ( FIG. 4(B) ). The doxorubicin resistant cells also showed an increased population of GEP+ABCB5+ with CD133 and EpCAM expressions ( FIG. 4(C) ).
[0052] To further study the association between GEP/ABCB5 and stem cell properties, the cells were then suppressed for ABCB5 by the siRNA approach. All the cells, including Hep3B, GEP overexpression transfectants and doxorubicin resistant cells, demonstrated decreased ABCB5 expression. Notably, the population of GEP+ABCB5+ cells was decreased by siABCB5, and the majority of these double-positive cells coexpressed the hepatic cancer stem cell markers CD 133 and EpCAM. Importantly, suppression of ABCB5 not only decreased the triple positive cell populations ( FIG. 4 ) but also the overall populations with hepatic stem cell markers CD133 and EpCAM expressions ( FIG. 5 ). Thus, the GEP+ABCB5+ population was highly associated with the hepatic cancer stem cell population. The data supported the observation that GEP+/ABCB5+ HCC was associated with increased cancer recurrence after curative surgery.
GEP Regulation of Other Drug Transporters
[0053] Since only 45% of HCC shows detectable ABCB5, it was hypothesized that GEP may regulate other drug transporters in addition to ABCB5. Liver cancer gene expression profiles were re-examined, and, as shown in TABLE 2, the ATP-binding transporters were ranked by the correlation coefficient values of their expression levels with GEP. The microarray data were validated in an independent sample set and independent research approach real-time quantitative RT-PCR.
[0054] One such ATP-binding transporter is ABCF1. GEP and ABCF1 expression levels were significantly correlated (P<0.001) ( FIGS. 6-7 ). ABCF1 expression was up-regulated in the tumor as compared with the adjacent non-tumor liver (P<0.001) ( FIG. 9 ). The increased ABCF1 expressions were associated with poor recurrence-free survival (log-rank test, P=0.001) ( FIG. 9 , TABLE 3).
[0000] GEP Antibody in Combination with Chemodrug
[0055] Liver cancer Hep3B cells received different cell assay treatments. Control received no treatment. A23 received treatment with 100 μg/ml GEP antibody A23. Cis received a treatment of 4 μg/ml of the chemotherapeutic cisplatin. Cis+A23 received a combination treatment of GEP antibody A23 (100 μg/ml) plus cisplatin (4 μg/ml). Cells were harvested, stained with Annexin V (AV) and propidium iodine (PI), then flow analysis. The total apoptotic population included the early apoptotic cells (high mean fluorescence intensity of AV but low PI) plus the late apoptotic cells (high mean fluorescence intensity of both AV and PI). GEP antibody treatment in combination with chemodrug enhanced cancer cell apoptosis compared to chemodrug alone ( FIG. 11 ).
[0056] In an animal model, Hep3B cells were injected subcutaneously into nude mice and tumor growth was allowed to 0.3 cm 3 . Tumors were treated for one month with intra-peritoneal injection of GEP antibody A23 (0.1 mg twice per week), or cisplatin (0.1 mg, once per week), or a combination of A23 plus cisplatin, or control saline. Nude mice body weight 20-25 gm. Tumor size was continuously monitored. Tumor size was calculated according to the formula AB 2 /2, where A and B were the largest and smallest dimensions, respectively. GEP antibody treatment in combination with chemodrug showed improved growth inhibition compared to either treatment alone ( FIG. 12 ).
Discussion
Biological Functions of GEP and ABCB5
[0057] GEP is a growth factor involved in tumorigenesis of human cancers of the prostate, bladder, ovary, and breast. GEP has been implicated in murine fetal development and wound response. Furthermore, GEP promotes neuronal cell survival, and mutation of GEP causes frontotemporal dementia. Thus, GEP is an important growth factor involved in many physiological situations. GEP regulates proliferation, invasion and tumorigenesis of liver cancer. Neutralization of GEP by the antibody approach inhibits tumor growth.
[0058] In the current study, we observed that overexpression of GEP conferred liver cancer cells chemoresistance while suppression of GEP rendered the cells chemosensitive. In addition, GEP modulated ABCB5 protein level, and suppression of ABCB5 level rendered the liver cancer cells chemosensitive. Furthermore, the GEP+ABCB5+ cells coexpressed the hepatic stem cell markers CD133 and EpCAM, and the sternness feature explained the high recurrence rate after curative partial hepatectomy for liver cancer that expressed GEP/ABCB5. This is the first study to demonstrate that GEP regulates chemoresistance through ABCB5, and that GEP+ABCB5+ cells express hepatic stem cell markers.
Drug Resistance
[0059] Increasing evidence had revealed the role of GEP in mediating resistance to a number of clinical drugs in a variety of cancer types. Overexpression of GEP had been shown to render breast cancer cells resistant to tamoxifen and trastuzumab, multiple myeloma cells insensitive to dexamethasone, and ovarian cells resistant to cisplatin. However, the exact signaling whereby GEP confers drug-resistance had not been elucidated and whether GEP regulates drug transporters was not known from the literature. In this study, GEP was discovered to have a prominent effect in modulating ABCB5 protein level ( FIG. 1 (C)). Thus, GEP has a positive effect in stabilizing ABCB5 protein or affecting the ABCB5 translation rate. In addition, suppression of ABCB5 by the siRNA approach resulted in reduced GEP protein levels ( FIG. 4 ) but had no significant effect on GEP transcript levels (data not shown). The observation further supports that GEP protein and ABCB5 protein are able to stabilize each other.
Cancer Stem Cells and Drug Resistance
[0060] ABCB5+ melanoma cells were known to be capable of self-renewal and differentiation and to possess greater tumorigenic capacity compared to the ABCB5− subpopulation. ABCB5 was known to express in CD133+ progenitor cells of melanocytes and mediate resistance to doxorubicin. Furthermore, the ABCB5+ subpopulation are known to have T-cell modulatory functions that may allow the subpopulation to evade host antitumor immunity. However, the signaling molecule that regulates ABCB5 protein level was previous unknown. This study demonstrates that GEP modulates ABCB5 protein level, and that enhanced GEP increased ABCB5 protein level while suppression of GEP decreased ABCB5 protein level. Importantly, suppression of either GEP or ABCB5 sensitized the cancer cells to chemotherapeutic agents.
[0061] Accordingly, chemoresistance and poor survival outcome are dictated by a subset of GEP+ABCB5+ liver cancer cells. Targeting the specific growth factor/drug transporter, in combination with chemotherapy, can provide treatment modalities to eradicate the aggressive liver cancer cells.
GEP Regulation of Other Drug Transporters
[0062] To elucidate the signaling mechanism of how GEP regulates chemo-resistance, a number of common ATP-dependent binding cassette (ABC) drug efflux transporters reported in the literature have been examined. GEP was shown to modulate the expression of the drug transporter ABCB5, and blockage of ABCB5 sensitized the liver cancer cells to chemotherapeutic agents and attenuated the expression of hepatic cancer stem cell markers CD133 and EpCAM. Furthermore, GEP and ABCB5 expression levels were significantly correlated in clinical samples, and were associated with recurrence of hepatocellular carcinoma after partial hepatectomy. GEP controls growth, regulates chemo-resistance through the drug transporter ABCB5 and hepatic cancer stem cell marker expressions, partly explaining the rapid recurrence after tumor resection and features associated with chemo-resistance in liver cancer.
[0063] The current study reports the genomic approach to systematically examine GEP-associated genes in relation to chemo-resistance. Notably, GEP expression is detectable in all liver cancer tissues while only 45% show detectable ABCB5 transcript. Thus, GEP regulates chemo-resistance through ABCB5 only in a subset of liver cancer. Therefore, GEP may regulate other drug transporters in addition to ABCB5.
[0064] The liver cancer gene expression was re-examined, and the ABC drug transporter family members were ranked in association with GEP expression patterns (TABLE 2). The ABC genes that have shown high correlation with GEP expressions in the microarray hybridization datasets were further validated in an independent cohort of clinical specimens using the independent research platform real-time quantitative RT-PCR. The expression levels of drug transporter ABCF1 were significantly up-regulated in the tumor as compared with the adjacent non-tumor liver (P<0.001), and that the increased expressions were associated with poor disease-free survival (log-rank test, P=0.001). In summary, chemo-resistance and poor survival outcome are dictated by a subset of GEP+ABC+ liver cancer cells. Targeting the specific growth factor/drug transporter (e.g., ABCB5 or ABCF1), in combination with chemotherapy, could provide treatment modalities to eradicate aggressive liver cancer cells.
[0000] GEP Antibody in Combination with Chemodrug
[0065] Treatment of liver cancer with a combination of GEP antibody A23 and a chemodrug exhibited greater apoptotic effect than either the GEP antibody A23 or the chemodrug alone. Accordingly, targeting the specific growth factor in combination with chemotherapy can provide a more effective treatment modality to eradicate aggressive liver cancer cells.
[0066] With respect to any figure or numerical range for a given characteristic, a figure or a parameter from one range may be combined with another figure or a parameter from a different range for the same characteristic to generate a numerical range.
[0067] Other than in the operating examples, or where otherwise indicated, all numbers, values and/or expressions referring to quantities of ingredients, reaction conditions, etc., used in the specification and claims are to be understood as modified in all instances by the term “about.”
[0068] The embodiments as disclosed and described in the application are intended to be illustrative and explanatory, and not limiting. Modifications and variations of the disclosed embodiments, for example, of the processes and apparatuses employed (or to be employed) as well as of the compositions and treatments used (or to be used), are possible; all such modifications and variations are intended to be within the scope of this application. | Described herein are methods for manipulating GEP and/or drug transporters (e.g., ABCB5 and/or ABCF1) on a cell, as well as related products. Also described herein are methods for treating cancer cells using GEP and/or drug transporter and/or their binding molecules and suppression thereof. Methods of cancer treatment targeting the GEP and/or drug transporters, alone or in combination with chemotherapy are also described herein. Also provided herein are sets of markers whose expression patterns can be used to differentiate clinical conditions, such as high or low levels of GEP and drug transporters. Based on the levels of GEP and drug transporters, the likelihood of cancer recurrences, drug sensitivity, and prognosis can be determined. Methods of classifying and treating patients based on the prognosis are also provided herein. | 2 |
BACKGROUND OF THE INVENTION
The invention disclosed herein pertains to attaching literature to articles including containers such as bottles of various sizes and shapes. The literature is called an "outsert" herein because it is customarily attached to an outside surface of an article. The common form of an outsert for a bottle comprises a long strip of paper containing printed matter. The paper is folded repeatedly to produce a compact multiple-page packet whose width is less than the width of the surface of the article to which the outsert is adhered. Although the new machine can adhere literature to a variety of articles, one important use of the invention will be described herein in connection with adhering outserts to bottles.
The pharmaceutical industry, for example, is a beneficiary of being able to attach outserts to bottles. It is, of course, common knowledge that conventional practice has been for bottles containing liquid and solid pharmaceuticals to be contained within a box or carton before being placed on sale in a drug store or other retail store. Thus, the information a purchaser of the pharmaceutical should know about, such as dosage, side effects, timing of the dosage, contraindications and others ought to be provided by way of a box, carton, by a printed insert or by means of an outsert without using a box or carton.
Some cartons are too small for application of outserts in which cases the containers must still be packaged in cartons or boxes along with the printed matter that explains to the purchaser how to properly use the contents of the container.
Vendors of bottles containing pharmaceuticals can provide much of the information a purchaser needs by way of an outsert that is attached to a bottle. One of the advantages of informing a purchaser by way of an outsert is that the traditional box or carton containing the bottle may be dispensed with since cartons or boxes have been used primarily as media to provide printed information to purchasers. Hence, the number of cartons that are destined to become unrecyclable trash can be reduced by using outserts.
Preexisting machines for attaching outserts to bottles have disadvantages. One disadvantage is that many of such machines conduct time-consuming operations such as transferring outserts from a vacuum transport drum to an adhesive-coated tape. These sequential operations take time and limit productivity of the machine. Moreover, releasable adherence of outserts to adhesive tape introduces a measure of instability and uncertainty in high speed handling and transporting of the outserts.
SUMMARY OF THE INVENTION
The new outsert attaching machine described herein avoids the disadvantages mentioned above and other disadvantages too. The new machine maintains a positive physical grip on the bottle or article before and after the outsert is attached and until the bottle is discharged from the machine. The machine is designed for being easily converted for processing bottles and other articles having widely different sizes and shapes.
The new machine uses some features which are conventional such as a circular turntable driven rotationally about a vertical axis. The top of the turntable has several equiangularly spaced apart rotationally oscillating bottle support plate assemblies arranged for moving in a circular orbital path under the influence of the rotating turntable. Although oscillating bottle plate support assemblies about a vertical axis is known, the oscillation protocol in the new machine differs from prior practice. A basically conventional bottle infeed starwheel places bottles on the support plate assemblies as they orbit on the turntable past the transfer station at the infeed starwheel.
In the new machine, according to the invention, oscillation of the support plates is carried out in a manner such that the orbiting bottles arrive consecutively at a station for applying glue to the bottle meeting the glue roller in perfect tangency and with rolling contact pressure while the bottle is rotating at a predetermined angular velocity due to the controlled oscillatory motion. Thus, the glue is applied in a roll-on motion rather than a wiping motion. After a column of glue spots are applied to a bottle, it is transported in orbit to an outsert dispenser from which an outsert is picked up by rolling the glue spots on the bottle onto the first outsert that is presented from the stack of outserts by the dispenser gate. At this time, according to the invention, the plate assembly oscillating mechanism maintains the peripheral velocity of the outsert application surface at the same velocity as the previously mentioned predetermined velocity which the bottle surface had when the glue spots were being applied so the machine functions in a stable, repeatable and predictable fashion.
The oscillating bottle holding and support plate assemblies actually comprise bottle support disks which have vertically downwardly extending shafts to provide for oscillating the disks and the uniquely configured bottle holding plates that are superimposed on and fixed to the respective disks. The new bottle holding plates are provided with a cavity in which the base of the bottle fits as it is pressed down by a bottle hold down device which is commonly called a centering bell. According to the invention, the cavity in the bottle holder plate in which the base of the bottle registers, is in a position on the holder plate such that the outside surface of the bottle wall on which the outsert is to be attached is always set at the same radial distance from the center of rotation of the bottle support disk shaft regardless of bottle width. This distance is calculated to assure that the outsert attachment surface of the bottle will develop the desired contact pressure with the glue roller and with the outsert as it is taken from the outsert dispenser. This radial distance is the same for bottles of all sizes and shapes within limits of the bottle sizes that the bottle holder plates can handle. If the user desires to make a run of bottles of a different size, it is necessary to exchange the bottle holding plates to plates that have cavities shaped complementary to the bottom of the bottle holding plates and to also exchange quick release subassemblies of the bottle centering bells, which are otherwise called the bottle hold-down devices herein as will be further explained later. For example, assuming a relatively small bottle that is square in cross-section is having outserts attached in a production run and it is desirable to convert the machine for applying outserts on a bottle that is more oblong or has a different diameter than the bottles currently being processed by the machine. In such case, the bottle holder plates for the previously processed smaller bottles are removed and plates having a cavity for accommodating the base of the larger oblong bottles are substituted. However, in accordance with the invention, the longer bottle cavity for the substitute oblong bottles is simply positioned on the holder plate with the bottle axis offset from the axis of bottle plate rotation such that the outsert application surface of the larger bottle will be at the same radial distance from the axis of the bottle support disks as was the case with the smaller bottles. It makes no difference as to what is the shape of a bottle as long as it has a surface or a wall which provides an area to which an outsert may be applied. Bottles may be elliptical or circular in cross-section, for example, but it is still possible to provide a holder plate with a cavity that positions the bottle with its outer application surface at the same radial distance from the bottle holder shaft axis for bottle sizes or widths that are smaller than the width or diameter of the bottle holder plates. The term "bottle" is used herein as a generic name for the article to which an outsert can be applied with the machine.
How the objectives and features of the new outsert attachment machine are implemented will be evident in the ensuing more detailed description of a preferred embodiment of the invention which will now be set forth in reference to the accompanying drawings.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagrammatic top plan view of the new machine showing the large circular turntable on which there are a plurality of smaller circles representing article or bottle holder plates in various angular positions for the bottles supported thereon to undergo certain processing steps, although it should be understood that in the actual machine the bottle support plates and holders are equiangularly spaced apart and lie on a common circle at a predetermined radial distance from the rotational axis of the turntable;
FIG. 2 is a vertical sectional view taken through the center of the turntable depicted in FIG. 1;
FIG. 3 is a plan view of an illustrative circular bottle holder plate which is adapted for retaining a bottle having a square base with the radially outermost surface of the bottle to which the outsert is to be attached maintained at a predetermined distance(D) from the center of rotation of the bottle support disk and the holder plate thereon;
FIG. 4 shows a substitute bottle holder plate having a rectangular recess for retaining the base of an oblong or rectangular bottle whose radially outermost surface to which the outsert is attached is also at the same radial distance(D) from the rotational axis of the bottle support disk and the holder plate thereon as in the preceding FIG. 3;
FIG. 5 is a sectional plan view of the space underneath the top plate of the turntable, taken on a line corresponding to 5--5 in FIG. 6, but with the top plate of the turntable removed to reveal the mechanisms which are involved in oscillating the support disks on which the bottle holder plates are mounted;
FIG. 6 is a partial vertical sectional view of two of the bottle support disks having bottle holder plates mounted thereon and the mechanism for oscillating them;
FIG. 7 is a diagrammatic showing of the acquisition, processing and discharge of a bottle from the turntable where the bottle centering and hold down devices and their control mechanisms are shown in various operating stages identified as parts 7A-7F of FIG. 7;
FIG. 8 is a vertical sectional view of one of the bottle hold-down devices and its associated mechanism for showing how the bottles are pressed down onto their holder plates while the bottles are being processed;
FIGS. 9 and 10 show a cam and a cam follower arrangement in different operating positions, the arrangements being part of the hold down devices depicted in FIG. 8;
FIG. 11 shows a glue roller and the manner in which a bottle in a cavity of a holder plate would approach and depart from the periphery of the glue roller;
FIG. 12 is a diagram for showing the path followed by the outsert application surface of an article such as a bottle as it orbited by the turntable depicted in FIG. 1;
FIG. 13 shows a bottle to which three glue spots have been applied by the glue roller depicted in FIG. 11;
FIG. 14 is a diagram showing how the application surface of a square bottle approaches the foremost outsert in the row of outserts dispensed from a magazine;
FIG. 15 is a diagram showing the position of a bottle immediately after it has picked up an outsert by adhesion;
FIG. 16 shows the bottle in another stage of oscillation after it has picked up an outsert by adhesion;
FIG. 17 is a diagram that is useful for showing the motion which the bottle executes as it approaches and departs from an outsert that is withdrawn from the outsert dispenser;
FIG. 18 is a vertical sectional view of a bottle hold-down device as it appears when holding down a bottle; and
FIG. 19 is similar to the preceding figure except that the hold-down device has been operated to release the bottle.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 is a diagrammatic plan view of the machine for attaching labels and outserts to bottles. The machine comprises a turntable 10 which is driven rotationally about a vertical axis coincident with the point marked 11. The means for driving the turntable rotationally about a vertical axis are not shown in FIG. 1 since they are conventional. Bottles are provided to the machine by a conventional infeed screw, not shown. The bottles are transferred consecutively to pockets 12 of an infeed starwheel 13. The bottles are discharged from starwheel 13 to an oscillating bottle support disk and plate assembly. A typical assembly is indicated generally by the reference numeral 14. The assembly comprises an exchangeable bottle holder plate 15 in which there is a hole or cavity 16 that has a shape selected to complement the shape of the bottom or base of any bottle or article fed to the machine for the purpose of having an outsert attached. There is a support disk 55 beneath bottle holder plate 15 which is not visible in FIG. 1 but which will be shown and discussed in reference to other figures later. In FIG. 1, the bottle support plate assembly 14 which is in the lowermost position between infeed starwheel 13 and outfeed starwheel 17 does not have a bottle 18 inserted in its cavity 16 as yet. In other words, its bottle support assembly is presently unloaded and is conditioned for orbiting to its next angular position where it can accept a bottle 18 from infeed starwheel 13. It should be understood that in the actual machine, the bottle support assemblies 14 are equiangularly spaced apart around the machine axis 11. The bottle support assemblies 14 are shown in FIG. 1 spaced apart at unequal angular positions to facilitate describing various operations the bottles experience as they orbit with turntable 10 until they are finally removed from the machine by the outfeed starwheel 17.
In FIG. 1, an illustrative square bottle 18 has just been transferred from a pocket 12 of infeed starwheel 13 and the square base of the bottle is registered in the square cavity 16 of bottle holder plate 15. Observe that the center of the bottle holder cavity 16 is offset radially from the center or vertical axis of rotation of circular bottle holder plate 15. In this way, according to the invention, the periphery of a circular bottle or the wall of a square or oblong bottle or any bottle of another shape to which an outsert is to be attached is held at a constant distance from the central axis of the support plate for any size bottle. The bottle holder plates 15 are exchangeable for applying outserts to different bottle sizes and the exchanged plates will have a cavity 16 that is complementary to the size and shape of the base of the larger or smaller or otherwise-shaped bottles.
The machine is also provided optionally with well known means for applying pressure-sensitive adhesive labels to the bottle before the outsert is applied. A conventional label applicator device is used and is generally designated by the numeral 20. The label applicator is not part of the present invention. The pressure-sensitive adhesive labels are fed to the device on a web 21 which has a release material coating on it. The adhesive-coated side of the labels interfaces with the release material coating on the web. The web is drawn over a peeler 22 which has a beveled edge 23 about which the web is compelled to make a sharp turn which releases the label 24 and allows it to adhere to bottle 18. After leaving the pressure-sensitive adhesive label applicator device 20 with the label attached to the side opposite of the bottle to which the outsert will be attached, the holder plate rotates in the direction indicated by the arrow 25 and arrives at the next station or angular position where a brush 26 is positioned. Brush 26 wipes one end of the label 24 into adhesive contact with a side of the bottle 18. The bottle continues in its orbiting and rotational motion for arriving at the next station at which there is another brush 27 which wipes the other end of the self-adhering label onto the bottle.
After the self-adhering label 24 is attached to the bottle, turntable 10 carries the oscillating and orbiting bottle support 14 to proximity with a glue roller 30. The roller is comprised of resilient material which can yield radially by a small amount when the wall 31 of the bottle 18 is pressed against it so there is a positive application of glue to the bottle. It is the outer surface of wall 31 of the bottle onto which the outsert 34 will be adhesively attached. The glue applicator roller 30 has several annular axially-spaced apart grooves indicated by the dashed lines 32 so the full diameter periphery of the roller on axially opposite sides of the grooves deposit a plurality of axially separated glue spots on the bottle such as the three spots 33 shown in FIG. 13.
After application of the glue spots, the bottle in FIG. 1 orbits to the next station where the glued outside surface 31 of bottle 18 adheres to the foremost outsert 34 in an outsert dispenser 35, thereby attaching the outsert to the bottle. The bottle is then transported by turntable 10 past an optical bar code reader 36 which reads the bar code, not visible, on self-adhering label 24. Next the bar code on the outsert 34 is read by bar code reader 37. Finally, the bottle 18 arrives in alignment with a pocket 12 in output starwheel 17 which results in the bottle being removed from the turntable.
The consequence of the turntable 10 being driven rotationally about the vertical axis of rotation 11 as shown in FIG. 1 will now be discussed further in reference to FIG. 2. In this figure the machine bed is marked 40. Beneath bed 40 there is a conventional turntable drive system, not shown, comprised of a gear system, not shown, that drives a central machine shaft 41 about a vertical axis coincident with axis 11 in FIG. 1. Shaft 41 extends through a collar 42 which is fixedly mounted to machine bed 40. A plurality of equiangularly spaced apart radially extending arms 43 are clamped at 44 to collar 42. The radially outward end portions 45 of the arms are integral with member 46 having an annular channel or chamber 52 that is for containing the bottle support and holder plate driving mechanisms that will be described later. Because lubricating oil is sprayed on the mechanism in the non-rotating channel 46, a drain tube 47 is provided for recirculating oil that drips from the mechanism back to a sump, not shown, for a lubricant circulation pump which is also not shown.
Turntable 10 in FIG. 2 comprises a large circular plate 48 which is a light weight cast aluminum part which extends radially from a hub 49. There are also a plurality of radially extending reinforcement ribs 50 cast on circular plate 48 which ribs also extend radially from hub 49. At their radial outward extremities, plates 48 and ribs 50 join integrally with and support an annular channel member 51 which is part of the turntable, and which, in conjunction with the lower stationary annular channel member 46 define a chamber 52 for containing mechanism that will be discussed later primarily in reference to FIGS. 5 and 6. FIG. 2 that lower stationary channel member 46 has a cam groove 53 which extends part way around the machine and is shown occupied by one of a plurality of cam follower rollers 54. The bottle support plate assembly is shown to comprise a substrate disk 55 on which bottle support plate 15 containing cavity 16 is mounted for holding a bottle 18. FIG. 2 shows that the cam follower roller 54 mounts to a gear segment 111 which will be discussed in more detail later in reference to FIGS. 5 and 6. FIG. 2 also shows one of the shafts 57 on which the bottle support plate assembly 14 is supported. Shafts 57 and, of course, the centers of substrate disks 55 and bottle holder plates 15 lie on a circle that is coincident with the machine circle. That is, shafts 57 are located at a constant distance from the center of rotation 11 of central shaft 41. FIG. 2 shows that the hub 49, which is aluminum in the actual machine, is cast on a collar 58 that is preferably made of steel. Collar 58 is keyed with keys 59 to power main turntable shaft 41 so that when shaft 41 turns, the turntable 10, comprised of plate 48 and ribs 50 along with upper annular channel member 51, turn together as a unitary turntable. A sleeve 60 is positioned concentrically to driven turntable shaft 41. Sleeve 60 does not rotate. It has a bearing 61 in its upper end. This bearing along with bearing 68 near the lower end of the shaft, support the shaft for rotation. A plurality of radially extending arms 62 support at their outermost ends bottle centering and hold down assemblies such as the typical assembly which is identified generally by the reference 63. Arms 62 are preferably composed of aluminum cast on a steel collar 64. Keys 65 are provided for enabling the shaft 41 to drive the collar rotationally. At the top of the machine, there is a plate member 70. A shroud having downwardly depending sides 80 is support from plate member 70. Plate 70 supports upper and lower cam tracks 71 and 75 having edges 71 and 74 which are spaced apart to define a cam groove 73. Plate member 70 has an open-ended cylinder 76 mounted to it by means of a machine bolt 77. A ball bearing 78 is arranged in cylinder 76 and provides further support for shaft 41 by way of a sleeve 79. Each of the centering and bottle hold-down devices 63 have a cam follower roller 85 which cooperates with cam groove 73 to raise and lower bottle a bottle hold-down element 94 at required times as will be explained later.
A general identification of the parts of the typical bottle hold-down and centering device 63 will now be given in reference to FIG. 2 although more details of the device and its operation will be given later. There is one hold-down device 63 above each bottle support disk 55 having a bottle holder plate 15 thereon. For the time being it is sufficient to observe that the hold-down assembly 63 comprises a cylindrical body 86 that is supported from radially extending arm 62 by a clamp 87 which is secured to arm 62 by means of a bolt 88. The body 86 has a plunger sleeve 89 that is moved up and down by reason of the cam follower 85 following cam groove 73 as the devices 63 orbit with the turntable. A shaft 90 projects out of plunger sleeve 89 and a collar assembly 91 is freely rotatable on that shaft. The collar assembly has a cam 92 mounted to it. Sleeve 91 also has a crank arm 93 mounted to its lower end. Crank arms are used for different bottle sizes. The crank arm has a downwardly extending force transmitting rod element 94 which engages the cap 95 of a bottle for stabilizing the bottle on its holder plate 15. A cam follower roller 96 is mounted to the end of a shaft 97 which is laterally retractable by use of a knob 98 which is involved in exchanging the entire assembly comprised of cylindrical collar 91, cam 92, crank 93 and hold-down element 94. These parts are exchanged when a changeover to a different bottle size or shape is made. Plunger 89 transmits a force to the bottle cap 95 under the influence of a spring 99 so the force applied to a cap 95 on a bottle 18 is not so great as to crush the cap or bottle. The vertical rotational axis of crank arm 93 aligns with the vertical axis of support disk 55 and its shaft 57 but the axis of hold-down element 94 is offset from the axis of the crank arm, as alluded to earlier, to have the surface of any size bottle to which an outsert is applied always at the same from the vertical axis of shaft 57.
The mechanism for oscillating the bottle support plate assemblies 14 will now be discussed in reference to FIGS. 5 and 6, primarily. First of all, consider the actuators 105 which are involved in oscillating the bottle support assemblies 14 about the axes of bottle disk 55 shafts 57. Shafts 57 have pinions 106 fixed to them by way of a key 107 and retainer plate 108. The shafts 57 are journaled in ball bearings 109 that are overlaid by a flexible seal 110. The actuators include a gear segment 111 which was previously mentioned while describing the turntable in reference to FIG. 2. The angular position of the gear segment is governed by the follower rollers 54 cooperating with the cam groove 53. Follower rollers 54 run on bushings 112. The gear segment is mounted to an arm 56 which also carries the follower roller 54. The arm swings on a shaft member 113 which is provided with a bushing 114. The shaft member 113 is secured to the turntable by means of screws 115. All of the shafts 113 are at an equal radial distance from the center of rotation or vertical axis of the turntable axis 41 and these shafts 113 do not move laterally of their respective axes. The shafts 57 on which the bottle support plate assemblies 14 are mounted have pinions 106 mounted to them. The teeth on the gear segments 111 mesh with these pinions. As the turntable rotates about its vertical axis, the follower rollers 54 follow the cam track groove 53 which results in the gear segments swinging in various directions, indicated by arrows next to them. The direction in which the gear segments 111 swing depends upon the distance of the cam groove 53 from the center of rotation 11 of the machine in which the follower is positioned at the moment.
Observe in FIG. 6 that the bottle holder plates 15 are secured on the underlying disks 116 with screws 117. To switch the machine for handling different bottle sizes, the bottle holder plates 15 are removed by removal of screws 117 and different holder plates are installed which have a cavity 16 that has the configuration of the base of the bottles that are to be processed next.
The benefit of using the bottle support plate actuating mechanism described in reference to FIGS. 5 and 6 can be appreciated by viewing FIGS. 3 and 4. In FIG. 3, the bottle holder plate 15 has a cavity 16 occupied by a square bottle 18. The distance from the center of rotation of the plate to the wall 31 of the bottle at which the outsert is to be applied is indicated by the distance D1. In FIG. 4, the plates 15 for the square bottles in FIG. 3 have been replaced by plates 15 for a typical oblong bottle 18. Because the cavity for the bottle base is simply shifted relative to the axis of rotation, one may see in FIG. 4 that the distance from the center of shaft 57 to the outside wall 31 of the bottle where the outsert is to be attached remains the same for all bottle sizes that fit within the circumference of the holder plate 15.
FIG. 11 shows how the bottle 18 on holder plate 15 approaches and departs from the glue roller as the bottle is transported or orbited by the turntable 48 in the direction of the arrow 120. Note, how the surface 31 of the bottle to which the glue is applied for holding the outsert translates and rotates as it goes in and out relative to the periphery of glue roller 30 and then proceeds with the plate 15 turning in the same direction as the bottle draws away from the periphery of the glue roller. The positions of the center line or line of symmetry D1 are exhibited in FIG. 12. In FIG. 12, the line which is followed by the center axis of the bottle support plate shaft axis 57 is given the same number 57 to indicate how the surface to which the outsert is applied is always at an equal distance from the center of rotation of the bottle support for any bottle size.
FIG. 17 is for illustrating that the bottle 18 executes the same motions as it approaches and departs from an outsert 31 as it executed when approaching and departing from the glue roller.
FIGS. 14-16 show in more detail how the surface 31 to which the outsert 34 is attached cooperates with the outsert dispenser which is generally designated by the numeral 35. The outserts are stored in a channel-like dispenser tray 120 with a soft spring, not visible, and are biased toward the bottle so that the foremost outsert 34 will always be positioned in the tray as shown in FIG. 14. The dispenser tray 120 is slightly yieldable in opposition to a minor spring force. A tongue 121 extends from the tray and it terminates with a small interference to the outserts at the point marked 122. Another small interference is obtained with a small hook member 123. Thus, unless the outserts are pulled out of the dispenser tray, they will remain therein. FIG. 14 shows that the adhesive spots 33 on bottle wall 31 are beginning to roll onto a surface of the leading outsert 34. In FIG. 15, the bottle surface 31 is now adhered to an outsert 34 and the line of symmetry 124 is presently perpendicular to the outsert surface so that there is uniform contact by the surface of the outsert over the glue spots. Note also in FIG. 15 that, because the leading outsert 34 is backed up by other spring biased yieldable outserts, that the bottle can exert a slight compressive force on the leading outsert to assure that good adhesion of the outsert to the bottle is obtained before the bottle support plate 15 moves away. In FIG. 16 observe that the translating and oscillating bottle support plate 15 is rotating in a direction after an outsert is picked up by the bottle that assures the outsert will clear the next outsert in the dispenser 35 and will not be rubbed off the bottle as the bottle support translates.
The exchangeable bottle centering and hold-down device 63 was mentioned in connection with FIG. 2. A more detailed discussion of the structure and function of the exchangeable part of the device will now be set forth in reference to FIG. 8. The crank arm 63 at the lower end swings around the central axis of a stub shaft 130 to which the crank arm is fastened by a pin 131. Bottle hold-down element 94 extends vertically from crank arm 93 and has an elastic friction insert 132. Hold-down element 94 presses centrally of the cap 95 on the bottle. Thus, a crank arm 93 having a different radial length is required for each bottle of different size because the center of support shaft 57 for disk 55 will not ordinarily coincide with the center of the offset. The crank arms are free wheeling about a vertical axis as they must be for the pressing elements 94 to stay centered on the caps 95 which are oscillating offset about the axes of the support plate assemblies 14. Changing crank arms 93 is accomplished by removing from shaft 90 everything mounted to it and replacing what is removed with a similar device having a different radial length crank arm 93. For releasing the device from shaft 90, a spring biased releasable latch lever 133 is provided. Pressing lever 133 into a groove 134 in cylinder body 91 of the device releases sleeve 91 for removal. A spring that biases the release lever 133 to its holding position as is presently the case in FIG. 8, is not shown. However, it will be observed that the release lever 133 controls a pin 135 that registers in an annular groove 136 in shaft 90. Thus, when the release lever 133 is pressed in FIG. 8, pin 135 is retracted from groove 136 and the whole body 86 is in readiness for being disconnected from shaft 90. A cam follower roller 96 cooperates with cam 92 as will be elaborated later. Follower roller 96 rotates on a stem 97 which is slidable in a hanger member 101. A clamping screw 102 holds stem 97 against unintended axial movement. Hanger member 101 is supported on arm 100 whose end is clamped to plunger sleeve 89. The entire device can be removed from shaft 90 by moving cam roller 96 out of interfering position relative to cam 92. This is done, after loosening set screw 102, by grasping knob 98 and pulling it to the left for the cam to clear the follower roller and then, while holding pin 135 in a retracted state, the device can be slid off shaft 90. Note that cam 92 is fastened to stub shaft 130 by means of a pin 137. When a vertical thrust force is applied by the hold-down device through shaft 90, the force is transmitted to a ball 138 which constitutes a thrust bearing.
The bottle hold-down and centering control device 63 construction and operation will now be discussed in reference to FIGS. 18, 19 and 7 additional to the parts just discussed. The device 63 is known per se but will be described briefly as it is used in the environment of present concern. FIG. 18 shows in phantom lines a bottle that is assumed to be presently pressed and stabilized in a bottle receiving cavity of a bottle plate 15 which is not shown in FIG. 18 but is shown in FIG. 7. The device 63 has a generally cylindrical body 86 which is fixedly mounted to a radial arm 62 of the turntable 10 by way of a bolt 88. There is one such body 86 above each bottle holder plate 15. The body 86 has a bore in which the plunger sleeve 89 is axially movable. The upper end of plunger sleeve 89 has a bushing 161 fitted on it. Bushing 161 can move biaxially with plunger sleeve 89. A split clamp 162 has a bolt 163 which is tightened to fasten the clamp to bushing 161 and plunger sleeve 89. Clamp 162 has a shaft 163 pinned to it. Cam follower roller 85 is rotatable on shaft 163 as the roller follows cam groove 73. Cam follower roller 85 is at its lower limit position in FIG. 18. Thus, plunger sleeve 89 is at its lower limit position too. The desirable consequence is that the lower cam follower roller 96 is held securely spaced from its cooperating cam 92. The outer fixed cylindrical body 86 has a longitudinally extending guide slot 163 in it. A guide member 164 can move up and down in the guide slot. Guide member 164 is fastened to plunger sleeve 89 with machine screws 165. Plunger sleeve 89 is prevented from rotating by the guide member. Hence, lower cam follower roller 96 can move up and down with plunger sleeve 89 but the follower roller cannot swing about a vertical axis. The upper end of fixed outer cylinder 86 is configured to receive a spring 99. The spring 99 exerts a lifting force on clamp 162 and on plunger sleeve 89 for the purpose of assuring that the cam follower roller 85 stays in contact with cam member 71.
Vertical shaft 90 is arranged concentrically within plunger sleeve 89. A C-ring 168 is fitted on shaft 90. A coil spring 169 is interposed between C-ring 168 and bushing 161. Since clamp 162 is undergoing a downward force by reason of upper cam roller 85 being at the lowest level in cam groove 73, a resilient compressive force is transmitted from clamp 162 and plunger sleeve 89 through spring 169 to shaft 90. This force is conducted through cylinder 91, crank arm 93, and hold-down element 94 to bottle cap 95 so the bottle 18 is held in its complementarily shaped cavity 16 in circular holder plate 15.
The state of the centering and bottle hold-down device 63 in FIG. 18 corresponds to the state of the device in part 7A of FIG. 7. Part A of FIG. 7 is illustrative of the situation where bottle 18 has just been placed in the bottle cavity 16 of a bottle holder plate 15 by the infeed starwheel 17. It is at this moment that cam follower roller 85 arrives in the lowermost level of cam groove 73 so bottle pressing element 94 on free wheeling crank 93 grips the cap on bottle 18.
In FIG. 19 the cam follower roller 85 is assumed to have moved onto the highest level of cam groove 73 so that plunger sleeve 89 is lifted away from the bottle 18 as shown. This event is coincident with the bottle having been received in a pocket 12 of the outfeed starwheel 17 so the bottle remains upright and in a stable state while being conveyed away from the outfeed starwheel 17. This operational state corresponds to part 7C of FIG. 7 where plunger sleeve 89 is at its upper level limit so as to hold lower cam follower roller 96 against the beveled surface of cam 92 under the influence of spring 99. In parts 7B and 7C of FIG. 7 the lower cam follower roller 96 has registered in the detent notch 140 of cam 92 which is visible in FIG. 9. Thus, the crank parts 93 and 94 are stabilized against rotation.
Because crank arm 93 is free wheeling, measures must be taken to assure that crank arm 93 will be in the proper angular position for the axis of hold-down element 94 to be aligned with the vertical axis of bottle 18 when element 94 is ready to come down on cap 95 of the next bottle to come along on the infeed starwheel 13. When, as in part C of FIG. 7, the bottle has been removed to the outfeed starwheel, cam roller 85 in cam groove 73 and plunger sleeve 89 are at their highest level, spring 89 in FIG. 19 is exerting a downward force on shaft 90. This force is applied through lower cam 92 to cam roller 96. Roller 96 is on the inclined plane of cam 92 so a component of force develops that causes the cylinder on which cam 92 is fastened to rotate. Hence, crank arm 93 swings to the position in which it appears in part D of FIG. 7. At this time a bottle 18 is being transferred from infeed starwheel 13 to bottle holder plate 15 and the axis of hold-element 94 is centered above the bottle cap. Then, as in part 7F of FIG. 7, as upper cam roller 85 descends toward its lowermost level in cam groove 73, plunger sleeve 89 is shifted downwardly in which case crank arm 93 is able to swing freely again so the hold-down member 95 stays on the bottle cap as the bottle oscillates on its axis while bottle holder plate 15 turns to facilitate application of glue to the bottles and pickup of inserts.
Although a preferred embodiment of the invention has been described in detail, such description is intended to be illustrative rather than limiting, for the invention may be variously embodied and is to be limited only by interpretation of the claims which follow. | A machine for applying outserts to articles such as bottles has a turntable driven about a vertical axis. A glue roller and an outsert dispenser are positioned in that order of turntable rotation adjacent the periphery of the turntable. A circular array of bottle support assemblies are mounted concentric to the turntable axis. A closed loop cam groove positioned below the turntable surrounds its rotational axis. Cam followers in the groove are connected to mechanisms that drive shafts on which the bottle support assemblies are mounted rotationally in response to turntable rotation. The support assemblies have a bottle holder plate on them in which plate there is a cavity for holding the bottle to which an outsert is to be adhered on a given outside wall area. The wall area is held at constant distance from the glue roller and the foremost outsert in the dispenser for all bottle sizes and shapes by having sets of holder plates in which the bottle cavity is off center by a sufficient amount for said wall area to be at the constant distance from the roller and dispenser. | 8 |
RELATED APPLICATIONS
This application is based in part upon provisional patent application No. 60/274,898, filed Mar. 9, 2001, entitled “Secure Dredging System for Contaminated Sediment Clean-up,” provisional patent application No. 60/309,731, filed Aug. 2, 2001, entitled “Hydropneumatic Sheet Pile Seal,” the examinable application entitled “Contaminated Sediment Removal Vessel,” Ser. No. 10/094,064, filed Mar. 8, 2002 and this application is a continuation of PCT/US01/09025, filed Mar. 20, 2001.
TECHNICAL FIELD OF THE INVENTION
This application relates to a process for isolating sections of the lakes, reservoirs, rivers, streams, and other water bodies so that contaminated sediments may either be removed or treated in-situ, while at the same time containing and preventing the release of particulate and soluble matter to the ambient water environment.
BACKGROUND OF THE INVENTION
Removal of sediments that accumulate on the bottom of natural and artificial water bodies is commonly practiced to permit navigation of ships and/or to maintain designated water depths. This type of sediment removal is commonly referred to as maintenance or navigational dredging. Sediments are sometimes removed to clean up the bottom of these water bodies when such sediments are found to be contaminated and pose a threat to public health and/or the ecosystem. This type of sediment removal is commonly referred to as environmental dredging. In some cases the objectives of the sediment removal activity are both maintenance and environmental. The in-situ treatment of contaminated sediments to render contaminants inert without the need to remove the sediments from the waterway is another remediation approach that is being researched as an alternative to dredging. At the present time, however, sediment removal or dredging is the primary remediation method commercially practiced.
Current methods of maintenance or environmental dredging can be divided into two general categories. They include mechanical dredging and hydraulic or vacuum dredging. The fundamental difference between these categories is the equipment used and ultimately the form in which the sediments are removed. Mechanical dredges typically remove the sediments directly with clamshell-type buckets at a relatively low liquid to solid ratio (i.e., relatively little water is entrained in the sediments compared to hydraulic dredging operations). Hydraulic or vacuum type dredges agitate the bottom channel to dislodge the sediment, and pump (vacuum) the sediment from the waterway. In hydraulic dredging operations the sediment is transported in a slurry with water acting as the transportation medium. This results in a water sediment mix with a high liquid to solid ratio. The sediment in the slurry must later be segregated from the water carrier. This is typically accomplished using large impoundment areas where the sediment is extracted by settling and the water (effluent) is returned to the originating waterway.
The removal of bottom sediments, whether by a mechanical or by a hydraulic dredging operation, involves some form of raking, grabbing, penetrating, cutting, or hydraulically scouring of the waterway or channel bottom. During such operations, sediments are readily suspended into the water column, dispersed and lost. In addition to sediment loss due to sediment disturbance and resuspension, in the case of mechanical dredging operations, sediment loss will occur when the bucket leaks sediments due to improper bucket closure resulting from debris stuck in the bucket, inadequate bucket sealing mechanisms, and the displacement of water contained within the bucket that occurs when solids enter the bucket during the excavation. While hydraulic dredging operations may have the advantage of a vacuum system that can assist in capturing some resuspended solids during bottom scouring operations, the large volumes of water that must be withdrawn and processed during such operations limit the feasibility of hydraulic dredging operations to areas where large impoundments are available. In addition, the presence of tides and currents can be expected to significantly reduce the efficiency of capture of resuspended solids by vacuum dredges when compared to operations that occur in quiescent waters.
Sediment resuspension and loss during dredging is a particular concern in environmental dredging operations where sediments are contaminated and the resuspension and dispersion of such sediments can result in ecological and human health impacts. This concern is underscored by the fact that most contaminants are generally associated with or bound to the fine particles, which are also those particles that are most easily resuspended and dispersed during the dredging operation. In addition to particulate resuspension, the potential release of soluble contaminants that may be present in the pore space of contaminated muds or may be subject to dissolution from the mud particle upon resuspension during dredging operations is also a concern.
Other problems associated with environmental dredging operations include the lack of suitable methods to monitor the actual loss of sediment that occurs during the excavation process, the lack of appropriate methods to monitor and ensure that the cleanup is being properly effected, and the absence of suitable methods to make certain that the handling of such sediments, during marine-to-land transfer and land-based transfer of such materials, do not result in liquid leakage or loss of sediments.
Current approaches for monitoring sediment loss during the excavation typically involve the use of discrete upgradient and downgradient subsurface sampling stations. Water samples collected at these stations are used to assess the increase in solids or turbidity loading to the waterway during the excavation. Given the unpredictability of subsurface currents, the discontinuous dredging operation, and discrete (spike) loadings that can be expected during dredging operations, the collection of representative samples is difficult. In addition, a determination of sediment loss can only be made after the release has already occurred.
To achieve target cleanup goals at a contaminated sediment site, due to the resuspension and the redeposition of sediment that occurs during conventional mechanical and hydraulic dredging operations, second and third passes to clean the contaminated area are routinely common. Even with multiple passes of a contaminated area, targeted specifications are still difficult to achieve. Current methods to assess the effectiveness of the cleanup of the subsurface sediments after the excavation typically involve the collection of core samples at discrete locations in the dredge area. Due to the expected variability in the spatial distribution of contamination in bottom sediments, particularly after the sediment is disturbed in a dredging operation, the collection of representative bottom sediment samples is also a difficult proposition. If the remediation effort has not met the required specifications, dredging equipment must be remobilized and returned to the location for additional cleanup at significant expense.
The removal and management of contaminated sediments during environmental dredging operations is best accomplished by collecting the sediments in a secure manner, dewatering the sediments, and transferring the sediments in such a way that there will be little risk for spills or loss of material. In mechanical dredging operations, sediments are typically placed in solids barges that require off-loading facilities that make use of additional cranes and buckets to remove the sediments from the solids barge for land-based management. Such operations are extremely messy and difficult to manage, and present a relatively high risk for further environmental contamination. Hydraulic dredging operations, as previously noted, require the construction of facilities for collecting the slurry and segregating the solids from the slurry, and thickening and/or dewatering the collected solids prior to transport to the disposal site. These facilities must be constructed in close proximity to the dredging operation and also increase the risk of local environmental contamination.
Most of the advances in environmental dredging technology in recent years have focused on the development of improvements in the design of buckets or vacuum dredges that tend to reduce or control the disturbance of the bottom of the waterway during the sediment excavation process (Ouwerkerk, R. and H. Greve (1994). “Developments in Dredges During the Last Decade.” Pages 690-699 in Dredging '94, Proceedings of the Second International Conference on Dredging and Dredged Material Placement, Edited by: E. C. McNair, Jr., American Society of Civil Engineers. 1994; Zappi, P. A. and D. F. Hayes. “Innovative Technologies for Dredging Contaminated Sediments.” Improvement of Operations and Maintenance Techniques Research Program, U.S. Army Corps of Engineers, Waterways Experiment Station, Vicksburg, Miss. Miscellaneous Paper EL-91-20. September 1991; and Herbich, J. B. Handbook of Dredging Engineering, McGraw Hill, Inc., New York. 1992).
The primary objective of most mechanical bucket modifications has been to create as tight a seal as possible on the bucket through the installation of rubber backing compressible seals and sensors (proximity switches) to ensure the bucket is closed prior to lifting in the hope of minimizing spillage. A dredging apparatus referred to as a “cable arm clamshell bucket,” advertised by Cable Arm Incorporated of Trenton, Mich., claims to reduce turbidity levels through its use of electronic sensors to detect bucket closure and compressible seals. While these types of systems offer improved designs, they do not eliminate the impact due to raking, upswell, and water displacement that will occur on excavation. In addition, such systems are incapable of effectively addressing leakage that will occur when debris is caught in the bucket and prevents full bucket closure.
Numerous modifications and subcategories of hydraulic dredges have been developed to attempt to mitigate problems associated with hydraulic dredging particle resuspension (Cleland, J. Advances in Dredging Contaminated Sediment, Scenic Hudson, Inc., 1997). Many have specific features that are designed to reduce sediment dispersion resulting from cutterblade, jetting, or raking mechanisms. None of these methods, however, have proven to be highly effective in areas where currents are present, nor do they significantly reduce or have suitable provisions for managing large volumes of contaminated water that are generated in the process. Large impoundment areas and suitable treatment methods are still needed to contain fine contaminated particulates that are drawn up with these sediments.
In addition to the use of improved mechanical or vacuum dredge systems, physical barriers such as silt curtains (flexible, impermeable canvas or rubber-like sheets that are deployed by attaching ballast to the bottom of the fabric and floats to the top to hold the curtain in a vertical configuration) or sheet piles have been employed during environmental dredging operations in attempts to isolate the area of dredging and contain contaminated particulates that are dispersed into the water column during the excavation process. These physical barriers do not prevent the migration of soluble contaminants. Silt curtains can provide some temporary particulate containment, but lack secure containment due to the porous nature of joints and curtain underflow, and their use in waterways with currents or tides is, in most cases, impractical. The application of fixed sheeting along the periphery of a dredge area is costly and, due to the porous joints of sheet piles, cannot guarantee complete particulate containment. Finally, while the referenced physical barriers provide some containment, once the barriers are removed the resuspended particles that were temporarily contained are free to migrate from the dredge area.
Although some advancement has been made in bucket or vacuum dredging, little progress has been made in developing physical barriers that effectively contain resuspended particulates or soluble contaminants during a dredging operation.
Smith, in his U.S. patent, Dredge Environ Protection Assembly, U.S. Pat. No. 4,386,872, Jun. 7, 1983, does describe an approach for temporarily isolating an area within a waterway during a dredging operation to prevent disturbed sediment from spreading. Smith proposes the use of a barge-mounted assembly where the barge (an open hopper barge) system is floated over the area to be dredged and a series of separate large side panel members (preferably ⅜ inch thick steel, 24 feet long, and 18 feet high) are lowered from the barge to the river channel to isolate the dredge area. Smith's invention requires that the area within the panels be pumped dry prior to the excavation. Smith further describes the use of panel support columns that would be lowered to a depth below the bottom necessary to resist the water pressure that would be exerted on separate side panel members. Smith's invention provides for the use of a series of support column caissons (preferably 4 feet in diameter) that would be lowered to the bottom to support the entire vessel when the inner panel area is dewatered. Smith describes these caissons as “stilts” to support the barge above the channel. Smith makes no mention as to how these caissons would support the barge on a soft muddy foundation, but does state that the columns would be lowered to a depth below the bottom surface of the waterway that would be required to support the barge. Smith describes in his patent how the panels would be lowered and set up end to end until they reach the bottom with fluid-tight seals located between the side panels and the panel support columns. Smith describes these fluid tight seals as “rubber sealing strips” to prevent infiltration of water through the panels into the dredge area.
Although Smith in his invention proposes equipment to physically separate the dredge area from the ambient water environment, Smith's invention lacks practical utility. His plan to pump the area dry would exert significant hydrostatic pressure on his proposed sliding panel wall and its support structure. Smith fails to recognize that continuous pumping will almost certainly be required to maintain his dredge zone in the dry condition that his invention requires, and he does not address the disposition of the water that would be pumped from his dredge zone, which can be expected to contain contaminants.
Smith's invention requires caissons to support the entire weight of the barge. This would necessitate that his support caissons be driven to a firm foundation such as bedrock. Such a foundation could be well below the bottom of the channel, further complicating the practicality of the invention. Smith does not describe any means to drive the panels below the initial placement depth in the event it becomes necessary to excavate deeper to remove additional contaminated sediment during a dredging operation. His proposed use of rubber sealing strips sandwiched between his panel support columns and panels, to prevent water infiltration, is theoretically plausible, but Smith fails to address how these strips would be attached nor how they would be sufficiently secure to withstand the abrasive forces they would encounter during deployment and redeployment of the side panels (if his system is to be mobile as implied). Smith does not address how the joints between multiple panels that lay one upon another, if needed, would be sealed.
Smith implies in his patent that an inclined non-horizontal bottom channel, which would result in a gap between the bottom panel and the inclined bottom surface, could be mitigated by attaching one or more extension panels to the bottom panel to block the flow of water. Smith states that such lower extension panels could be attached to the upper panels with bolts. Smith fails to address how these gaps would be identified, how the extension panels would be sized, and how bolts would be attached. One can only assume that Smith is considering the use of divers to bolt extension panels to all locations where gaps in the bottom seal are identified. Even so, Smith fails to address how these lower extension panels would be made watertight. Smith's invention fails to account for debris such as logs, rocks, etc. that will invariably be encountered at the bottom of the channel at most dredge locations, preventing a side panel from fully penetrating the subsurface, thereby resulting in additional gaps under the panel. Large gaps would result in an inability to pump the inner dredge area dry, which is a key feature of Smith's invention. In summary, the authors believe that Smith's invention lacks the means to make it a practical mobile vessel for removing contaminated sediments in a dredging application.
Other inventors have focused their efforts on the development of physical barriers in the marine environment to contain spills or to provide dry areas for construction.
Santamaria, in his U.S. patent, Barrier for Water Treatment, U.S. Pat. No. 6,089,789, Jul. 18, 2000, describes a curtain barrier system that can be deployed to isolate two bodies of water for the purpose of treating the water contained on one side of the barrier without mixing of the two water bodies. Santamaria's invention includes two flexible water impermeable curtains, similar to conventional silt curtains, that are deployed vertically, joined to a bottom web that contains ballast material to hold the barrier to the lagoon bottom and end anchors (on shore) to prevent the movement of the barrier.
While Santamaria describes in his invention a system to isolate two water bodies, Santamaria does not relate his system to a contaminated sediment dredging operation. His invention is intended to provide for the treatment of water on one side of an area of a lagoon that is separated from the remaining lagoon locations. Santamaria's invention is similar to commercially available silt curtains that are held in place by a ballasted bottom and a buoyed float at the top. Santamaria describes features of his impermeable flexible curtain that differentiate it from silt curtains used in commercial applications. While Santamaria's invention does provide some measure of separation, it cannot be used in the center of a channel where it cannot be anchored, nor would it be effective in sealing in a location where there are currents, and as such its application is primarily intended for a quiescent lagoon.
Strange, in his U.S. patent, Marine Pollution Containment Device, U.S. Pat. No. 4,889,447, Dec. 26, 1989, describes a containment barge consisting of two self-propelled semi-circular hulls that can be oriented in a manner that contains marine spills. The device described by Strange is designed as a rapid deployment device and provides for the mobile containment of oil spills at the surface. It does not extend vertically to the bottom of a channel, which would be necessary to address contaminated sediment dredging containment issues.
McClellan, in his U.S. patent, Mobile Cofferdam, U.S. Pat. No. 5,277,517, Jan. 11, 1994, describes a mobile cofferdam vessel that consists of a watertight rectangular shell that can be filled with water to submerge the cofferdam vessel in place, or have the water evacuated to float the vessel. The submerged vessel is designed to replace conventional stationary cofferdams that establish a zone that could be dewatered for use in constructing on the bottom of a waterway. McClellan describes the use of a pump to dewater the interior of the cofferdam to define a dry working environment.
McClellan's invention is intended for construction of elongated structures (such as tunnels or piles) below a waterway where a physical barrier is submerged by sinking a physical structure at a desired location and dewatering the area inside the physical structure so that construction can take place. The application is not designed nor intended for contaminated sediment excavation and removal.
It is relevant to this invention that interlocking sheet piles are commonly used in the construction industry to act as barrier walls to prevent soil movement or to prevent or minimize liquid permeation. Typical sheet piles are comprised of individual steel plates that are vertically aligned with one another as they are sequentially driven into the ground. Interlocking joint connections are used to connect the sequentially aligned sheets.
While interlocking joint connections of conventional sheet piles effectively hold and align the sheets, they are not specifically designed to prevent seepage of water through the interlocking joint connection.
Reducing sheet pile seepage is important in applications where at least one of the objectives of the installation is to divert, intercept or control water flow. In most applications this flow is usually subsurface or groundwater flow. In the marine environment where contaminated sediments must be excavated and sheet piles are used as physical barriers to segregate the excavation area from the main water body, reducing sheet pile seepage rates is important.
There are several known methods for sealing sheet piles. Most of these methods make use of sealants, which are cement-based, bituminous-based, or consist of low permeability materials, such as bentonite or combinations of the above, to seal the voids in the sheet pile joint connection. Some related patents include Hunsucker (U.S. Pat. No. 3,302,412), Zanelli et al. (U.S. Pat. No. 5,163,875), Cherry et al. (U.S. Pat. No. 5,437,520). While many of the above inventions have the potential for sealing sheet pile joints, they also require special sheet pile construction and in addition cannot be reused once the sheet piles are removed (i.e., piles must be cleaned and the sealant applied each time the piles are used).
Wheeler and Harvey (U.S. Pat. No. 5,938,375) describe a method in which sealant material is inserted into a form-like housing that is designed to vertically align with the seam between adjacent sheet piles. Sealant material is inserted into this housing to reduce seepage. The housing is designed so that it may be installed on conventional sheet piles without the use of specialized sheets. While such is an advantage claimed by the authors of the patent, the use of applied sealants limits the potential for reusing the sheet pile if redeployment is required without having to clean and completely reseal the system.
Others have proposed the use of specially designed sheet piles with a variety of interlocking surfaces to increase the surface area contact between adjacent sheets and hence reduce seepage through the sheets. Some related patents include U.S. Pat. No. 5,320,454 and Wickberg and DeGrout (U.S. Pat. No. 5,921,796). While increasing surface contact will undoubtedly reduce seepage, once installed the removal of such sheets are extremely difficult so they tend to weld together and bind. Such an approach is not practical in applications that require installation and reuse of the sheet piles in a continuous operation.
As will be shown, the invention being disclosed in this application incorporates a novel approach that makes use of a new sealing system that can reduce flow through the seam of sheet piles installed in the water environment, and has particular application in the cleanup of contaminated sites where sheet piles are used to segregate the dredge zone from the ambient water body.
At the present time, essentially all contaminated sediment remediation strategies involve the removal of contaminated sediments via one or more of the aforementioned dredging methods. There are presently ongoing research efforts being conducted to seek methods for treating sediments in-situ. The primary objective of an in-situ treatment strategy is to chemically or biologically render the offending contaminants within the sediments inert, thereby eliminating the need for dredging. One of the major impediments to the implementation of such an in-situ treatment strategy is a system that can deliver and contain chemical or biological additives that might be used in such a treatment strategy and to prevent the migration of sediments that may be disturbed if the aforementioned additives are mixed with the sediments.
In addition to ongoing efforts to develop in-situ treatment technology, dredge muds present at the bottom of waterways are at times in a fluff-like form, making the mechanical excavation of such sediments extremely difficult. This is because a mechanical bucket will be scooping mostly water when attempts are made to excavate such a material. Just as the introduction of chemical or biological reagents can assist in rendering contaminants inert, it is possible to introduce conditioning agents that will promote the densification of fluff-like bottom muds to permit the more effective excavation of such sediments. Such a strategy, however, is also limited by systems that can isolate the area to be conditioned to avoid the loss of conditioning agents and disturbed sediments during the chemical delivery and mixing process.
In contrast to the prior art, the invention being disclosed herein relates to the development of a system that isolates a contaminated sediment area and produces a negatively pressurized control zone into which mechanical or hydraulic dredging apparatus can be placed and used to remove contaminated sediment or additives can be introduced to treat or condition the sediments. The invention does not require the dewatering of the subject dredge area. The invention does not require the use of large columns to support a vessel. The invention is not susceptible to large gaps in the barrier that would result in major water infiltration, and the invention provides a practical means to deploy and redeploy the vessel during continuous operations along a waterway. As will become apparent, the maintenance of this negatively pressurized control zone ensures a secure zone that prevents the release of both particulate and soluble matter, and can be readily monitored and evaluated to establish or certify that the operation (dredging or treatment) has met its specified objectives. These features are not included in the prior art. In addition to the establishment of the control zone, the inventors have included a new method for managing dredge solids removed by securing and stabilizing said solids at the dredging site to minimize the opportunity for spills associated with conventional solids management approaches.
OBJECTS OF THE INVENTION
It is therefore an object of the invention to provide for the removal or the in-situ treatment or conditioning of contaminated sediments from the bottom of lakes, rivers, reservoirs, and other water bodies in a manner that prevents the release and transport of particulate matter, soluble matter or additives from a contaminated site during dredging, treatment or conditioning operations.
It is also an object of the invention to establish boundaries of a control zone where the excavation, treatment or conditioning of sediments can occur in a contained manner.
It is a further object of this invention to make such a control zone mobile to permit redeploying the invention along a contaminated waterway.
It is a further object to establish a negative differential pressure between said control zone and the ambient water environment.
It is yet another object of the invention to establish such a negatively pressurized control zone by deploying a sealed, vertical barrier wall beneath a marine vessel and by pumping water from the inner volume of the control zone to establish a differential pressure gradient between the control zone and the ambient water environment.
It is also a further object of the invention that such a sealed, vertical barrier consist of sheets and sheet pile joint seals to respectively define the surface area and volume of the control zone, and to reduce the permeability through the joints of the sheets and hence the rate of flow required to establish said negatively pressurized control zone.
It is still a further object of the invention to treat water collected from the control zone, if necessary, during the pumping process with a polymeric membrane filtration treatment system to enable the discharge of this purified water back into the ambient environment.
It is yet a further object of the invention that such a polymeric membrane filtration treatment system be incorporated into a mobile water treatment vessel, to avoid the need for land-based facilities.
It is also a further object of this invention to incorporate mechanical and/or hydraulic dredging equipment for use within this control zone, if sediment removal is desired, to improve the effectiveness of the subsurface cleanup.
It is a further object of this invention to provide the means to contain all contaminated matter within said control zone and remove such matter until such time as the contaminated area can be certified as complying with the desired specification of the cleanup.
It is a further object of the invention to incorporate a dredge solids stabilization and transportation vessel that can manage the contaminated solids that are removed in a dredging process, and transport such solids to an off-loading facility in an environmentally sound manner.
SUMMARY OF THE INVENTION
In keeping with these and other objects of the invention, a system is described that provides for the containment of particulate and soluble matter within an isolated zone by the use of a specially designed marine vessel that establishes a negatively pressurized control zone that can be used with either mechanical or hydraulic dredging equipment to remove contaminated sediment, or with systems that can introduce and mix reagents into the contaminated sediments for in-situ treatment or conditioning purposes. The physical boundary of the control zone is established by deploying a vertical barrier wall in the form of sheet piles and impermeable sheet joint seals located within and below an open barge-like vessel.
While the use of sheet piles and impermeable sheet joint seals can assist in establishing the physical boundary of the control zone in which suspended contaminants are contained, the driving force used to ensure that neither soluble nor particulate matter is released from this zone during dredging, in-situ treatment or in-situ conditioning operations is provided by the introduction of a pumping system located inside the control zone. This pumping system withdraws water from the control zone to establish a negative pressure gradient directed toward the inside of the control zone from the ambient water environment. Development of this negative pressure gradient between the ambient water surface and the control zone water surface elevation ensures that all flow through the vertical barrier is into the control zone, thereby preventing the release of any liquid or particulate matter contained within the confines of the control zone into the ambient water environment.
Liquid pumped from the control zone, where agitation due to dredging, treatment or conditioning occurs, can be expected to contain contaminated particulate matter and, in some cases, soluble contaminants that must be treated prior to release into the ambient water environment. To achieve the appropriate degree of treatment for the collected water, the invention makes use of a polymeric membrane treatment system capable of removing particulate matter in the range of 0.01 to 10 microns, and soluble contaminant removal, if warranted.
Most polymeric membrane filtration systems in commercial operation at the present time utilize positive pressure as a driving force to pass liquids through the membrane. In recent years, immersed vacuum-driven hollow fiber membranes have been introduced commercially. An immersed hollow fiber membrane filter operating under negative pressure is a polymeric filter that achieves filtration by drawing water through a thin fiber (membrane) surface into the hollow annular inner core of the fiber. Either pressurized or immersed hollow fiber membrane filtration systems are suitable for use in the subject application.
Once the subject control zone is established, dredging can be undertaken using either mechanical or hydraulic dredging techniques, or reagents can be introduced and mixed with bottom sediments with assurance that any suspended material or soluble contaminants will be confined to the control zone or pumped out to the membrane treatment system for removal. As will subsequently be described, the preferred dredging operational mode makes use of both mechanical and hydraulic dredging equipment to remove contaminated sediments. The preferred in-situ delivery and treatment mode makes use of pumping and sediment agitation equipment to deliver the treatment reagent to the subsurface sediment, simultaneously mixing and disbursing the reagent within the sediment layer to be treated.
To minimize the pumping rate required to maintain a differential elevation and hence a negative pressure gradient between the control zone and the ambient water environment, the inventors have developed a specially designed sheet pile joint seal that is designed to reduce the flow of water through the joint between the individual sheet piles. The sheet pile joint seal included in the invention consists of a flexible shroud and a sealing tube that is deployed from the vessel and slides down the outer portion of the vertical barrier wall to secure each sheet pile joint. Pressurization of the sealing tube, by use of water pressure or air pressure or both, is used to achieve a seal that substantially reduces seepage through sheet pile joints deployed in a water column. The effectiveness of the seal is enhanced by the established pressure gradient, which acts to force the flexible shroud and sealing tube into the sheet pile joint, thereby reducing the flow of water through the joint.
To provide the means to effect the removal, treatment or conditioning of contaminated sediments, and to treat the collected water and manage all sediments without the need for land-based facilities in the vicinity of the cleanup, the inventors have further developed a system in which all components of the subject invention are adaptable to mobile marine vessels. This includes the specially designed control zone vessel, referred to as a contaminated sediment remediation vessel, the membrane water treatment system, and the solids stabilization and transportation system.
The system and vessels included in the invention are designed to provide mobile platforms that can readily be deployed and redeployed in order to provide for ongoing remediation over an extended length of contaminated waterway.
While other inventors have proposed physical barriers for separating a dredging area from an ambient waterway to prevent the escape of contaminated particulates, no prior inventions consider the use of a low pressure control zone that is not dewatered to achieve said objective. No prior invention considers the possibility of treating water pumped from said control zone to remove soluble contaminants that may be released during the excavation. No prior invention makes use of sheet piles deployed from a mobile vessel as the vertical barrier wall with the means to penetrate the channel bottom and bottom debris if necessary to achieve a bottom seal. No prior invention provides for individual sheet pile joint seals that can readily be deployed to the desired depth, and can assist in sealing the low pressure control zone to prevent the outflow of contaminants and reduce the inflow of water into said zone. No prior invention provides the means to readily deploy and redeploy a vertical, low permeability barrier in a practical manner during a cleanup operation. No prior invention provides the means to introduce and mix additives to treat or condition sediments, in-situ, in a contained manner. No prior invention provides the means to manage solids without land-based solids handling facilities near the dredge site.
DESCRIPTION OF THE DRAWINGS
The present invention can be best understood in conjunction with the accompanying drawings in which:
FIG. 1 is a conceptual perspective of a control zone within and below an open-bottom vessel;
FIG. 2 is a conceptual perspective of a continuous wall of discrete sheet piles deployed within and below said open-bottom vessel to define the limits of the control zone;
FIG. 3 is a conceptual schematic showing the deployment of a sheet pile joint seal system design to reduce the flow of water through the sheet pile joints;
FIG. 4 is a schematic illustrating a floating skimmer-pumping system used to establish an elevation difference and hence pressure gradient between the inner control zone and external water environment;
FIG. 5 is a plan drawing of a contaminated sediment remediation vessel.
FIG. 6 is a profile drawing of a contaminated sediment remediation vessel.
FIG. 7 shows Section A—A and FIG. 8 shows Section B—B from FIG. 5, both of which depict views of one possible gantry arrangement for deploying sheet piles from the contaminated sediment remediation vessel.
FIG. 9 is Detail 1, referred to in FIG. 5, which shows a plan view of the vertical barrier comprised of individual sheet piles connected at the joints.
FIG. 10 is Detail 2, referred to in FIG. 9, which shows the configuration of the inner hull falsework on the contaminated sediment remediation vessel.
FIG. 11 presents a plan view of the joint seal shroud deployed at an interlocking sheet pile-joint.
FIG. 12 shows a plan view of the sealing tube deployed inside the joint seal shroud.
FIG. 12A shows a profile view of a deployed shroud and sealing tube.
FIGS. 13, 14 , 15 , and 16 present a series of plan, profile and sectional views of a membrane water treatment system deployed on an independent vessel.
FIG. 17 is an isometric view of the individual vessels used in an integrated contaminated sediment dredging operation.
FIGS. 18, 19 and 20 present a series of plan, profile and sectional views of an in-situ contaminated sediment treatment operation.
FIG. 21 is an isometric view of a plurality of vessels used in a contaminated sediment treatment operation deployed on a water body, showing a water treatment system deployed on a contaminated sediment remediation vessel.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The present invention consists of a contaminated sediment remediation vessel that is comprised of an open bottom barge vessel 101 , shown in FIG. 1 in a perspective view, beneath which a low pressure control zone 102 is established. As shown in the perspective view in FIG. 2, sheet piles 103 connected along the inner hull of said vessel are deployed and vibrated into place on the bottom of the waterway from the interior four sides of the rectangular opening to define the physical boundary of said control zone.
An additional feature of the invention, shown in the perspective view in FIG. 3, is the use of individual sheet pile joint seals 104 designed to reduce the flow of water through the sheet pile joints from the ambient water environment into the control zone. Such a sealing system can be readily deployed from the vessel. The sheet pile-seal system is used in conjunction with a water pumping operation to induce a negative pressure gradient inside of the control zone, relative to the external hydrostatic pressure outside the control zone. Inducing a negative pressure gradient prevents any liquid or particle migration from inside the control zone to the external water body during the remediation operation.
To achieve this negative gradient, as shown in the perspective view in FIG. 4, a pumping system including a floating suction well or pump 106 is located within the control zone 101 and is connected by piping or hoses 107 to a water treatment system located on a separate vessel, of if convenient, on the contaminated sediment remediation vessel. FIG. 4 illustrates the development of a differential head or differential water elevation 108 between the ambient water surface 109 and the control zone water surface elevation 110 . Such a differential head supplies the energy to induce the negative pressure gradient. The floating suction well provides the means to select the depth below the surface from which water is pumped by either skimming water from the top of the control zone or by extending piping below the surface to the desired depth.
FIGS. 5 and 6 show plan and profile views, respectively, of the contaminated sediment remediation vessel. FIG. 5 shows a plan view of the limits of the control zone 102 within the vessel 101 . FIG. 5 also shows the location of a gantry 141 and gantry rails 142 used to direct the movement of a vibratory driver that assists in deploying and removing individual sheet piles during vertical barrier deployment and removal operations. While in many instances individual sheet piles can be suitably deployed by simply dropping the sheet piles into the subsurface, the use of a vibratory driver provides the means to set the sheet piles to the desired depth and to penetrate subsurface debris, such as logs and rocks, should they be located in the subsurface at a location that might interfere with the penetration of the sheets.
Mooring winches 143 and spud wells 144 , designed to establish the location of the vessel over the dredge zone, are also shown in FIG. 5 . FIG. 6 shows the plurality of individual sheet piles 103 , connected to the inner hull of the vessel floating atop of the water surface 109 above the river bottom 145 to be remediated.
FIGS. 7 and 8 show views of Section A—A and Section B—B (from FIG. 5 ). These figures provide sectional views of the gantry 141 , directing movement of a vibratory driver 146 traveling along the gantry rails 142 . The vibratory driver 146 attaches to the tops of sheet piles 103 after having been moved into place by the trolley and hoist 147 having a hoist wheel 148 . Also shown in FIG. 8 is a diesel hydraulic power pack mounted on the gantry 149 and motorized wheels 150 .
FIG. 9 shows a plan view of a continuous wall of individual sheet piles 103 joined together by sheet pile joint interlocks and attached to the inner hull 121 by means of a falsework. FIG. 10 shows a detail of the inner hull 121 and said falsework 122 , which consists of clips 123 and an H-beam 124 that is connected to an individual sheet pile 103 . The individual sheet piles are shown connected side by side by an interlocking system. Said interlocking system typically consists of interlocking U-shaped sockets 125 , as shown in FIG. 10 .
To assist in sealing the seams of the interlocking sheet pile joints, which can be a source of water infiltration into the control zone, the inventors have developed a joint seal system capable of being deployed from the top of the vessel during mobilization of the vertical barrier. Reducing water infiltration into the control zone is necessary to reduce the pumping rate required to maintain the negative pressure gradient between the control zone and ambient water environment. The subject joint seal system, shown in FIGS. 11, 12 and 12 A, consists of a flexible shroud and a sealing tube system, together referred to by the inventors as a hydropneumatic seal.
To permit deployment of said sealing tube system from the deck of the contaminated sediment remediation vessel, two circular rods 131 , shown in FIG. 11, are welded onto the edge of a flat plate 132 . Each rod and plate is welded to the edge of each sheet pile 103 where the U-shaped sockets 125 from adjacent sheet piles are attached. The circular rod and plate run the entire vertical length of the sheet pile. The two circular rods 131 at each joint, shown in FIG. 11, act as shroud guides and provide a sliding and locking mechanism over which slotted shroud tubes 133 , shown in FIGS. 11 and 12, can slide over the circular rods 131 to deploy the seal shroud 134 . The seal shroud 134 is a flexible rubber membrane (such as neoprene) that is attached to the ends to the two hollow rods 133 . Metal brackets framing the shroud 134 provide rigidity to the shroud, provide a means to bolt the shroud 134 to the slotted shroud tubes 133 , and provide support to permit the shroud 134 to penetrate the subsurface bottom 145 . The seal shroud 134 provides a form into which a sealing tube 135 , shown in FIG. 12, is deployed and also functions as a protective cover to prevent damage to the sealing tube by external debris, such as floating logs. The sealing tube 135 is comprised of a heavy flexible material, preferably rubberized, that expands and contracts if pressurized or depressurized.
FIG. 12 presents a cross sectional view of the sealing tube 135 deployed and pressurized. Pressurization of said tube is accomplished by filling the tube with water and, if necessary, pressurizing the tube with air. FIG. 12 shows a cross section of the sealing tube cap 136 , which is located at the top end of the sealing tube and into which a water-fill tube 137 and air-fill fitting 139 are fabricated. The water-fill tube 137 provides the means to introduce water into the sealing tube in order to fill and pressurize it. A water-fill tube cap 138 is available to seal the tube after it is filled. The air-fill fitting 139 , shown in FIG. 12, is used as a means to introduce compressed air into the sealing tube 135 . Introducing compressed air into the sealing tube 135 provides the means to adjust the tube pressure to whatever value is necessary to tighten the seal. This additional pressurization is accomplished by closing the water-fill tube cap 138 and introducing compressed air through the air-fill fitting 139 . Total pressure levels of less than 10 pounds per square inch are suitable for such an application.
The combination of deployed shroud and sealing tube system comprise the hydropneumatic seal, which is capable of substantially reducing flow through the vertically aligned sheet piles deployed in a water column with a pressure differential between the outer and inner zones. The introduction of either water, air or both provides the means to pressurize the sealing tube 135 , which expands and penetrates into the sheet pile's knuckle joint thereby cutting off the flow of water through said joint. The pressure differential between said inner and outer zones provides additional means for the shroud 134 to force and hold the pressurized sealing tube 135 into the seam between the two sheets.
FIG. 12A presents a profile view of a vertically aligned sheet pile 103 extending into the bottom of a waterway 145 with the shroud 134 and sealing tube 135 extending the length of sheet. When such a system is deployed, seepage from the outer zone to the inner zone is limited for the most part to that which permeates through the subsurface soil, under the sheet pile.
The subject sheet pile sealing system can readily be deployed, demobilized, and redeployed using the same sheet piles and sealing system without any modifications to the existing sheet piles or hydropneumatic sealing system.
Deployment, as previously outlined, requires attachment of the shroud 134 to the shroud guides 131 that are welded to the sheets to provide the means to slide the shroud down the length of the sheet. The sealing tube can readily be deployed by inserting the bottom of the sealing tube into the deployed drape and pushing down on the water-fill tube 137 . This water-fill tube 137 is constructed from a rigid material, such as PVC plastic, and extends the length of the sealing tube 135 , as shown in FIG. 12 A. The sealing tube 135 readily slides down the length of the shroud, penetrating the bottom sediment 145 . The bottom of the sealing tube is sealed with two metal brackets located on each side of the bottom of the sealing tube 135 bolted together. The metal brackets located at the bottom of the sealing tube provide rigid support to the tube that enables its penetration into the bottom sediment 145 . One bracket 140 is shown in FIG. 12 A. The introduction of water through the water-fill tube 137 , during deployment, can be used to assist deploying in the sealing tube by overcoming the buoyant forces that may resist deployment.
Demobilization of the sealing tube 135 , shroud 134 and sheet piles 103 , respectively, involves injecting air through the air-fill fitting 139 , to force water back up the water-fill tube 137 , where it can be collected, raising the sealing tube 135 and shroud 134 , and lifting the sheet piles 103 . The entire contaminated sediment remediation vessel 101 can then be moved to another location where the vertical barrier wall can once again be redeployed.
While FIGS. 9, 10 , and 11 depict a flat sheet pile section, a U-shaped interlocking mechanism, and a clip and H-beam falsework pile arrangement, the presentation of such configurations is not intended to limit the fact that alternative sheet pile sections, interlocking mechanisms, and falsework arrangements could be employed to establish the vertical barrier wall and to permit deployment of the hydropneumatic seal in the manner outlined above without departing from the objectives and essence of the invention.
To treat the water pumped from the control zone, the inventors have supplemented the dredging process with a membrane water treatment system, adapted for deployment on the contaminated sediment remediation or a separate water treatment vessel. Those who are versed in the art of membrane filtration design will recognize that complete rejection of all micron-sized and submicron sized particles (for example, greater than 0.1 micron) can readily be attained by using such membrane filtration technology. The referenced water treatment system is capable of treating soluble contaminants, if needed, utilizing microfiltration or ultrafiltration membrane technology or alternative commercial methods for soluble contaminant removal such as chemical precipitation for soluble metals or activated carbon treatment for soluble organics or reverse osmosis. Since most contaminants (particularly organics) are tightly bound to free particulate matter, microfiltration should, in most cases, be capable of effecting adequate treatment.
FIGS. 13, 14 , 15 , and 16 show design views through a separate mobile water treatment vessel containing a low pressure hollow fiber membrane treatment system. FIG. 13 shows the main deck plan view of such a vessel 151 and includes an equipment room 152 , a main deck enclosure 153 to house the membrane module racks (four shown) 154 , and tank hatch covers 155 that cover the equalization and pretreatment tanks, located below deck, as shown in FIGS. 14, 15 , and 16 . Also shown in FIG. 13 is a hydraulic crane 156 used to remove the hatch covers and to lift and offload solids collection containers from the vessel.
FIG. 14 shows a plan view of the hold level, highlighting the location of the equalization and pretreatment tanks 157 (nine shown) and fuel tank 158 . Also shown in FIG. 14 is the location of a solids thickening tank 159 that is used to thicken settled solids, collected from the pretreatment membrane treatment systems, a solids stabilization tank 161 where solids are mixed with a cementitious stabilization reagent (such as Portland cement) to improve its handleability, and the anchor chain locker 162 .
FIG. 15 shows a profile view of the vessel depicting the aforementioned equipment room 152 , the membrane module racks 154 , the equalization and pretreatment tanks 157 , and equalization and pretreatment tank hatch covers 155 . Also depicted in FIG. 15 are a tug push notch 163 and an anchor windlass 164 .
FIG. 16 shows a section through the water treatment vessel further highlighting the main deck enclosure 153 , the membrane module racks 154 located below deck, and the equalization and pretreatment tanks 157 .
The design layout shown in FIGS. 13 through 16 can be readily modified to accommodate the installation of an immersed pressurized membrane system or supplementary treatment operations. Its presentation is in no way intended to limit the scope of the application to either low pressure or immersed membrane systems and is intended only to illustrate additional detail associated with the barge mounted treatment vessel concept.
An isometric view in FIG. 17 shows an integrated dredging system, which includes a water treatment vessel 151 , a contaminated sediment remediation vessel 101 , an excavator barge 171 with a supporting hydraulic excavator 172 , a solids stabilization and transportation vessel 173 with a hopper screening plant 174 and containment ramps 175 (to connect the contaminated sediment remediation vessel 101 with the excavation barge 171 , and the excavation barge 171 with the solids vessel 173 ) to prevent spillage of sediment during the excavation process. Also shown in FIG. 17 on the solids stabilization and transportation vessel 173 are storage containers 176 , and a conveying system 177 . Screened sediments, from the hopper screening plant 174 , and a cementitious stabilizing reagent (such as Portland cement), which is stored in a silo 178 , are introduced into the conveying system 177 , mixed (using screw conveyors) and transported (using flite conveyors) for distribution to the storage containers 176 through the conveying 177 and hopper distribution system 179 .
While FIG. 17 depicts the introduction of both the stabilizing agent and the screened contaminated sediments into a conveyor to effect a mixing process, an alternative mixing approach makes use of a blade mixer attached to a telescoping crane with a pump to inject and mix the stabilizing agent with the contaminated sediments after the contaminated sediments are distributed to the storage containers 176 onboard the solids stabilization and transportation vessel 173 . Such an approach would permit the mixing process to occur while the solids stabilization and transportation vessel is in transit to the land-based transfer station.
The multiple vessel arrangement and the equipment shown in FIG. 17 depict one potential vessel and equipment configuration for dredging operations. Its presentation is in no way intended to limit the manner in which vessels can be deployed at a cleanup site, which vessel might support a specific piece of equipment or operation, nor the type of dredging equipment that may be employed to remove the sediment, since this will, in most cases, be dictated by the size of channel or other site-specific issues. For example, where channel space is limited, the vessels could be configured linearly or the excavator could be deployed on the contaminated sediment remediation vessel 101 , eliminating the need for an excavator barge 171 . It may also be desirable in certain instances to utilize a crane and bucket as opposed to a hydraulic excavator as the preferred equipment in the excavation process. The presentation shown is also not intended to limit the preferred number of each vessel located at a particular dredge site. For example, it may be desirable to locate the water treatment process directly on each contaminated sediment remediation vessel 101 , or deploy one water treatment vessel 151 to support multiple contaminated sediment remediation vessels 101 in order to reduce the number of vessels required for the dredging operation. Deploying several contaminated sediment remediation vessels 101 is advantageous, from an operational viewpoint, since it provides the means for the excavator barge 171 to move from one control zone 102 , located within each contaminated sediment vessel 101 , to the next control zone 102 without slowing the excavation process (waiting to redeploy the contaminated sediment remediation vessel 101 ). Neither is the depiction of one control zone 102 within a given contaminated sediment remediation vessel 101 intended to limit the number of control zones 102 that might be established on one vessel. For example, it might be advantageous to have several control zones 102 on one large contaminated sediment remediation vessel 101 .
While the above description emphasizes equipment used in a dredging operation, it should be apparent that where in-situ treatment or conditioning of the bottom sediments is the desired activity, the excavator barge or solids vessel would be unnecessary. In such an operation these vessels would be replaced by a means to introduce and mix the additives with the bottom sediments.
FIGS. 18, 19 and 20 , respectively depict a plan, profile and sectional view of a reagent delivery and sediment mixing system for the in-situ treatment of contaminated sediments within a control zone 102 , inside the contaminated sediment remediation vessel 101 . Establishing the low pressure control zone prevents both the release of contaminants that may be suspended or released during the mixing operation and the loss of reagent from the control zone. FIGS. 18 and 19 show a plan and profile view of a separate vessel 191 supporting a hydraulic excavator 192 and a slurry and pumping system 193 used to deliver stored reagents 194 to the sediment surface 145 . Delivery of the reagents to the sediment is provided through hoses and piping 195 . The reagent is uniformly distributed into the subsurface sediment through a sediment agitation and mixing device, shown in FIG. 20 as a horizontal auger 196 , located at the end of the excavator. The horizontal auger is lowered to the bottom surface by the hydraulic excavator to simultaneously mix and deliver the reagent. Churning of the bottom sediments by the auger provides the necessary mixing over the cross section of the control zone. Reagent distribution is effected by a manifold system 197 used to distribute the reagent along the section of the auger 196 . The horizontal auger 196 shown in FIG. 20 is one possible sediment agitation and mixing device. Other methods of agitating the sediment in order to mix the sediment with the reagent can be used. These could include but are not limited to vertical augers, plows, vibratory mixers or jet type mixers that would inject the reagent into the subsurface sediment. A mobile water treatment vessel 151 provides the pressure control and water treatment necessary to maintain the control zone 101 and treat the control zone water.
FIG. 21 shows a plurality contaminated sediment remediation vessels 101 and a plurality of control zones 102 deployed along a water body with a plurality of water treatment systems 254 shown on the deck 251 of a plurality of floating contaminated sediment remediation vessels 101 .
In summary, in a preferred embodiment for the secure dredging embodiment shown in FIGS. 1 through 20 and 12 A, operation of the overall system involves the following activities:
1. positioning of the contaminated sediment remediation vessel 101 over the zone 102 to be dredged;
2. lowering and inserting of sheet piles 103 , attached to the inner hull 121 , into the bottom 145 of the waterway and driving them into the subsurface formation with the driver, such as the vibrating hammer 146 , if necessary;
3. for each sheet pile, lowering the impermeable shroud 134 located on the external side of the sheet pile 103 , inserting the sealing tube into the shroud 134 and pressurizing the sealing tube 135 ;
4. initiating flow into the water treatment system 151 to induce a negative pressure gradient into the control zone 102 ;
5. initiating and completing a mechanical dredging operation to remove contaminated sediments from the control zone 102 ;
6. continuing to pump and treat control zone water after the completion of the excavation to maintain the negative pressure gradient, and to reduce suspended solids and/or soluble contaminants in the water column within the control zone to specified levels;
7. permitting the solids to settle for an extended period (e.g., 6 to 24 hours) after dredging of the control zone 102 is completed;
8. vacuum dredging the bottom 145 of the control zone 102 using a cutterless vacuum head to remove residual lightweight sediment (fluff) that has settled, and directing the vacuumed slurry to the water treatment system 151 ;
9. monitoring the water column and bottom sediments to ensure adequate cleanup;
10. withdrawing the shroud 134 and sealing tube 135 , and raising the sheet piles 103 ;
11. relocating the contaminated sediment remediation vessel 101 to the next area to be dredged using mooring winches and spuds,
12. redeploying the vertical barrier and hydropneumatic sealing system in order to reestablish the new control zone,
13. processing the contaminated dredge solids on a solids stabilization and transportation barge 173 involving conveying and mixing the finer-grained dredge muds with a cementitious stabilizing reagent and distributing the mixed materials to storage containers 176 , using a conveying 177 and hopper distribution system 179 ; and
14. covering storage containers 176 and securely transporting stabilized muds to an off-loading facility.
In summary, the preferred embodiment for an in-situ treatment or conditioning operation involves the following activities:
1. positioning of the contaminated sediment remediation vessel 101 over the control zone 102 to be treated or conditioned;
2. lowering and inserting of sheet piles 103 , attached to the inner hull 121 , into the bottom 145 of the waterway and driving them into the subsurface formation with the driver, such as the vibrating hammer 146 , if necessary;
3. for each sheet pile, lowering the impermeable shroud 134 located on the external side of the sheet pile 103 , inserting the sealing tube 135 into the shroud 134 and pressurizing the sealing tube 135 ;
4. initiating flow into the water treatment system 151 to induce a negative pressure gradient into the control zone 102 ;
5. introducing by means of a pumping and delivery system, and mixing treatment or conditioning reagents with the bottom sediments using a horizontal auger 196 or alternative sediment agitation and mixing device;
6. continuing to pump and treat control zone water after the introduction of reagents to reduce suspended solids loadings and/or soluble contaminants in the water column to specified levels;
7. maintaining the control zone in place, and continuing to mix, if necessary, until the desired treatment or conditioning of the sediments are achieved;
8. redeploying the vessel to the next location.
Although the aforementioned particular embodiments are shown and described herein, it is understood that various other modifications may be made without departing from the scope of the invention, as noted in the appended claims. | A method is described for containing dispersed particulate or soluble matter during contaminated sediment remediation operations in the marine environment. The preferred method comprises the use of a specially designed marine vessel that establishes a negative differential pressure gradient between a defined remediation control zone and the external ambient water environment, thereby preventing the release of contaminants dispersed during the remediation process. The preferred method also includes the use of marine vessels to remove contaminants contained within said control zone and to provide for the management of solids collected in the process. | 4 |
This application is a continuation in part of application Ser. No. 07/155,609 filed Feb. 12, 1988 and now U.S. Pat. No. 4,815,652, issued Mar. 28, 1989.
BACKGROUND OF INVENTION
The present invention pertains to the art of casting and forming composite metal articles, and more particularly to the containment of a molten metal in a metal shell which is engaged by one or more forming dies and formed to a desired shape.
Heretofore, steel and other metals with the desired characteristics of high strength, hardness, and corrosion resistance have been cast in molds of sand or ceramic because of the high temperature melting point of these metals. The molds required for these processes must be made on an individual basis using labor intensive methods. The casting process, itself, is likewise labor intensive and extensive secondary operations to clean and trim the castings are required. The furnaces and attendant equipment must operate at very high temperatures which makes for high equipment cost and high maintenance costs. All of which, when combined with the high cost per pound of heavy casting materials, result in castings of high cost and excessive weight.
The die casting of low melting temperature metals such as aluminum and zinc alloys is a widely used process that addresses some of the problems by utilizing resusable steel dies operated at lower temperatures. While this produces castings of light weight with closer dimensional control and better surface finish, the use of such low melting temperature materials is much restricted by low strength, lack of wear resistance, and poor corrosion resistance.
Attempts have been made to cast steel alloys in metal dies made of very high melting temperature metals in processes similar to that of die casting low melting temperature materials, but the charge of molten steel must be cast at so high a temperature that the surfaces of the dies are severely stressed by thermal shock and the dies breakdown after limited use. Also, the very high melting temperature metals from which the dies are made, are expensive and are difficult to machine into the required die shapes. Accordingly, such processes for casting high temperature metals have not met with wide acceptance.
Efforts have been made to overcome these problems by casting bimetallic products. Some examples are die casting of aluminum around steel inserts; rolling or explosion bonding of aluminum and steel in flat bimetal pieces or sheets; and electroplating or hot dipping a molten metal on a base metal. These methods are each servicable in a limited range of application but are severely limited in one or more areas of performance such as product size and shape, structural strength, and corrosion protection.
Heretofore, methods for casting bimetallic products have only been successful in obtaining a structurally sound metallurgic bond between those metals having nearly the same coefficient of thermal expansion or in those articles in which the metal with the lower coefficient of thermal expansion is positioned interior to the metal with the higher coefficient of thermal expansion. This relative position will cause the outer metal to shrink more upon cooling and in so doing, tighten upon the inner metal to form a secure joint. Composite metal forms in which the metal with the higher coefficient of thermal expansion is the interior metal, result in the interior metal drawing away from the exterior metal thus creating stress and possible voids at the bonding interface of the two metals.
Another limitation of present methods of die casting is that the dies are required to come in direct contact with the molten metal to contain and form it. This requires dies with precise dimensions, smooth surface finish, and full enclosure of the molten metal. Therefore, the dies are expensive.
Yet another problem with present methods is that of removing oxides from the bonding surfaces of the metals to be joined. The highly reactive nature of such metals as aluminum and the high melting temperature of its oxide makes oxide removal and the prevention of its subsequent formation an expensive and difficult operation.
SUMMARY OF THE INVENTION
Accordingly, it is an object of the present invention to provide a method of producing a composite metal article with an improved metallurgical bond between an inner core metal and an outer metal shell in which the metal comprising the core has a higher coefficient of thermal expansion and a lower melting point than the metal comprising the shell. It is another object of the present invention to provide a cost effective, manufacturing method of removing oxides from the bonding surfaces of companion metals. It is yet another object of the present invention to provide a rapid, low cost method to cast and form containerized ingots. It is a further object of the present invention to provide a method which will allow a final use manufacturer to select from a range of containerized ingot sizes and shapes furnished by a primary supplier to simplify the process requirements at final use. It is yet a further object of the present invention to provide a manufacturing method that will utilize dies of low cost construction.
In accordance with the present invention a composite metal article is made by placing a low melting temperature metal to serve as a core within a shell of a high melting temperature metal and containing and sealing the core within the shell. The core may be placed in the shell either by pouring it as a molten metal or placing it as a solid within a part of the shell previously shaped to contain it and then covering it with the remaining part of the shell to make up a containerized ingot which is then transported to a forming die where the containerized ingot is heated to soften the core and is then formed to the shape imposed by the die.
Alternately , the core metal may be injected in a molten condition or extruded in a plastic condition into a shell which has been shaped with entry and exit ports and configured so that the molten or plastic core metal may pass through the cavity of the shell, scour the inner surfaces of the shell and discharge the loosened oxides through the scavenging ports with the excess of core metal. The scavenging ports and the injection ports are thereafter closed to make a containerized ingot which is then transported to a forming die where it is heated and formed to a shape for final use.
In yet another method, the core metal may be injected into the shell which has been placed and contained in a forming die such that when subjected to hydraulic pressure generated during the injection of the molten metal the shell expands to form against the die.
After a containerized ingot having a core with a higher coefficient of thermal expansion than the shell has been formed to the approximate shape required for final use, the shell is reformed by the forming die or by auxiliary dies to be compressed in upon the core as it shrinks in cooling. Depending on the complexity of the casting, this may be done over the whole surface of the shell or may be done in localized areas only.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an exploded perspective view of the parts used to make a containerized ingot
FIG. 2 is a perspective view of the assembled containerized ingot and of fastening methods to secure the cover.
FIG. 3 is a perspective view of the apparatus and parts used in a method to make a containerized ingot.
FIG. 4 is a partials sectional view showing key parts of an apparatus with a containerized ingot in place to be formed by a compressive force.
FIG. 5 is a partial sectional view showing key parts of an apparatus with a shell in place to be filled and formed by hydraulic pressure.
FIG. 6 is a partial section showing a portion of a forming die with a plunger reforming a spot indentation in the shell.
FIG. 7 is a partial section showing a portion of a forming die with a plunger reforming a close pattern of indentations in the shell and core.
FIG. 8 is a face view of the reforming plunger shown in FIG. 7.
FIG. 9 is a partial section showing portions of the forming die with integral reforming projections, and with shell and core after forming has taken place but before solidification of the core.
FIG. 10 is a partial section showing portions of the forming die with integral reforming projections, with the shell and core after cooling of the core and after reforming has taken place.
FIG. 11 is partial section of the forming die with integral reforming projections in a close pattern.
FIG. 12 is a face view of the reforming projections shown in FIG. 11.
FIG. 13 is a partial sectional view showing key parts of an apparatus injecting molten core metal into a shell with provision for the discharge of excess core metal from the shell.
FIG. 14 is a partial sectional view showing key parts of an apparatus extruding plastic core metal into a shell with provision for the discharge of excess core metal from the shell.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIG. 1, there are shown an open container 1, formed from a thin sheet of a relatively high melting point material, such as an alloy of stainless steel with a melting point of approximately 2600 F. deg., a core 2, composed of a metal with a relatively low melting point such as an aluminum alloy having a melting point of approximately 1220 F. deg., and a cover 3 composed of a relatively high melting point metal which may be of the same metal as that of the container. The container 1, and cover 3, cooperating together constitute a shell 4, which encloses the core 2. FIG. 2 shows the parts of FIG. 1 assembled to make a containerized ingot 5. The cover 3 may optionally be fastened to container 1 with spot welds 6 or continuously welded at joint 7 or soldered at joint 7 with a low melting temperature material. A scavenging port 8 is preshaped in the cover and is closed with a plug 9 of low melting temperature material.
The containerized ingot 5 is used in the forming process of a composite metal article now to be described.
A method to make the containerized ingot 5 of FIG. 2, is illustrated in FIG. 3 in which the whole apparatus is placed in an enclosure 10 containing an argon atmosphere. Wherein a ladle 11 containing molten aluminum from which surface oxides have been skimmed, pours molten aluminum 12 into cavity 13 of container 1 until the cavity is filled. After which, cover 3 is placed on top of container 1 and is pressed firmly to it until the aluminum has solidified. A plug 9 of a suitable low temperature material such as aluminum is then placed in scavenging port 8 and the exposed joints may then be optionally coated with a resin to seal the joints or the cover may be spot welded 6 or continuously welded 7 as previously described and illustrated in FIG. 2. Aluminum and stainless steel will join together under heat and pressure by an action which consists of the diffusion of molecules to create a bond at the interface of the two metals. This action when structurally supported by firm and continuing mechanical contact through the cooling period of the casting permits a cohesion of the two metals which is referred to in this application as a metallurgical bond. The compound of these two metals is brittle and of low strength, therefore it is desirable to keep the casting temperature low and the cooling period as short as possible.
For those bimetallic articles requiring a metallurgic bond between the shell and core, the stainless steel container 1 and cover 3 may be treated with a solution of muriatic acid to remove surface oxides and placed within enclosure 10 which contains an inert atmosphere such as argon to prevent the formation of oxides. Molten aluminum is then poured into cavity 13 from ladle 11 which has before been skimmed free of oxides while in the confines of enclosure 10.
The container 1 and cover 3, together, make up a shell 4 which, when filled with molten metal, constitutes a containerized ingot 5 which may immediately be formed in a die or, alternately, may be allowed to cool to a solid form to permit transportation to a die in another location where it is then reheated to permit forming.
The reheating of the containerized charge, when suitably sealed, may take place in a conventional controlled atmosphere furnace in the presence of an endothermic atmosphere operating at 1500 F. deg. in which the atmosphere constituents are approximately 20% carbon monoxide, 40% hydrogen, 39% nitrogen, and 1/2% methane.
In an alternate method the containerized ingot 5 shown in FIG. 2 is assembled with a core made by die casting or by cutting from an extruded shape the aluminum ingot 2 shown in FIG. 1. which is placed, in solid form, in container 1 and enclosed in cover 3.
In those castings requiring a metallurgic bond between the shell and core of the composite metal article, the stainless steel container 1 and cover 3 are treated with a solution of muriatic acid to remove the surface oxides and are immediately placed within enclosure 10 which contains an inert atmosphere such as argon to prevent the formation of additional oxides. The aluminum ingot is cleaned and deoxidized in an electrolytic bath and then plated with 40-50 microinches of silver. The ingot is then placed in container 1 and cover 3 is placed on the container and is sealed while still in the argon atmosphere by welding a continuous stainless steel seam along the juncture between cover and container. A short section of the juncture is left unwelded with stainless steel and this is sealed with a suitable low melting temperature material such as aluminum.
The containerized ingot 5, in a heated condition and in place to be formed, is shown in FIG. 4 with flange portions clamped between clamping mechanisms 14 and 15, by which the containerized ingot is held in position for shaping and by which it may also be sealed to prevent unwanted loss of molten metal through the joint formed by container 1 and cover 3 if that joint has optionally been left unwelded. A separate clamping member 16 is actuated independently to allow scavenging port 8 in cover 3 to remain open when plug 9 removes under heat and pressure until purging is completed whereupon clamping member 16 is actuated to press against cover 3 to depress that portion of the cover at scavenging port 8 tight against the surface of container 1 to close and seal the port.
The shaping dies 19 and 20 are then activated to press against containerized ingot 5, causing some portions of it to be indented and some portions to be distended, thus acquiring a shape imparted by the die configuration and die motion. The initial shaping by a die with the core at full heat and prior to solidification of the core is the process step defined by the terms form, formed andforming in this description and in the claims of this invention. FIG. 5 shows an alternate method of forming in which the container 21 and the cover 22 are preshaped to cooperatively establish a filling port 23 to receive molten metal. The container and cover are placed in a die and clamped by means 24 and 25 making together a sealed shell 26 to enclose a molten charge. The shell is engaged with and sealed to a molten metal injection nozzle 27 at filling port 23 through which molten aluminum is injected under hydraulic pressure generated by piston 28 slidably acting in cylinder 29. Depending on the composition and shape of the composite metal article to be formed, casting temperature may range from 1220 F. deg. to 2200 F. deg. and injection pressure may range upward from 4000 psi. Also preshaped in cover 22 is scavenging port 30 to allow escape of gases and of contaminants carried in the molten metal. After this occurs, the scavenging port is closed off by compressive action of the port closing plunger 33 which causes pressure to build up in the shell and initiates forming. The hydraulic pressure of the molten metal then expands shell 26 to press against and form to dies 31 and 32, which remain in fixed position during the forming operation.
Due to differences in the coefficients of thermal expansion, after the aluminum core solidifies it will continue to shrink and draw away from the stainless steel shell during the cooling period. For those castings with a suitably simple shape and with a thin enough shell, the forming dies 31 and 32 are acted upon with increased pressure to cause them to advance in upon the formed containerized ingot in a continuing manner throughout the cooling period to generally reform the shell so that it will press in upon and tightly fit the core. The terms reform, reformed, and reforming specifically define the shaping process of dies compressively acting on the containerized charge after forming and after solidification of at least part of the core and continuing throughout at least part of the cooling period thereafter.
For those conditions in which oxides have been excluded from the containerized ingot by the methods previously described and in which contact under pressure is continuously maintained during cooling, the aluminum and stainless steel diffuse together at their interface to create a metallurgic bond between the shell and the core of the composite metal article.
Those castings with a more intricate shape and with thicker shells may only permit reforming to be accomplished locally in spot indentations 34 as shown in FIG. 6 where such indentations are reformed by independently actuated plungers 35 mounted in the forming die 20 to indent the stainless steel shell 4 below the surface 36 formed at the moment of casting so as to seat the inner surface 37 of the spot indentation against the core 2.
In a variation of the spot indentation method, indentations reformed in the surface 36 in shell 4 in FIG. 6 are tightly grouped as shown in section in FIG. 7. The pressing face of plunger 38, shown in FIG. 8, is shaped with a pattern 39 of projections and depressions that is impressed on the stainless steel shell; the projections on the plunger face serve to reform indentations 40 in the shell 4 and the depressions 41 on the plunger face allow for spaces between the indentations, which spaces are defined as the interstices 18 in the pattern of the indentations reformed in the shell and the core. The plunger 38, shown in FIG. 7, is activated to press in upon the shell 4 during the cooling period after initial forming and casting, and is actuated with sufficient force so as to reform both the shell and the surface layer of the core. The indentations reformed in the outer surface of the shell become projections on the inner surface of the shell that extend into the core and displace material in the surface layer of the core to plastically flow laterally and outwardly from the inner surface shell projections to fill the intertices 18 in the pattern of indentations and thereby establish an area of continuous contact between the shell and the core in the area of the pattern.
An alternate shaping means, shown in FIG. 9 consists of integral form/reform dies 42, contoured to impart the final general configuration desired in the composite metal article on which fixed height, integral projections 43 of relatively small cross sectional area have been established on the shaping faces 44. The projections are spaced apart at a distance small enough to allow the shell structure to bridge the gap 45 without appreciable deflection between the projections when forming is performed at a relatively low pressure, and at a distance large enough to permit plastic deflection 46 of the shell shown in FIG. 10 as the relatively high pressure used for reforming is applied. The spacing of the projections,forming temperature, and forming and reforming pressures are interactive factors that vary with the shell thickness and the shape of the formed article. Therefore, these factors must be individually determined for each formed article
The integral form /reform shaping means may also be constructed with the integral projections in die 47, shown in section in FIG. 11, and grouped in a pattern 48 as shown face view in FIG. 12.
Another method for making containerized ingots is shown in FIG. 13. In this method a molten metal charge 49 of a low melting temperature metal such as aluminum is injected under pressure by a piston 50 from a cylinder 51 into a shell 52 shaped as a closed channel with injection port 53 and scavenging port 54. The shell is held in position by clamps 55 and 56. The molten charge is injected into the shell in excess such that the molten charge moves through the closed channel of the shell and scours the inner surfaces of the shell removing oxides and other contaminants which are carried in the charge and are discharged with the excess molten metal through the scavenging port. After scavenging is completed, The scavenging port is closed by scavenging port cut off 57 and 58. The pressure in the charge is built up by continued action of the piston which causes the charge to fill out and seat into the shell cavity after which the injection port is closed by injection port cut off 59 and 60. The resulting containerized ingot is then cooled and the closed injection and scavenging ports may optionally be sealed by one of the methods previously described.
Another method for making containerized ingots is shown in FIG. 14. In this method a plastic metal charge 61, of a low melting temperature metal such as aluminum is injected under pressure by a piston 62, from a cylinder 63, through an extrusion die 64, into a shell 65, shaped as a closed channel with injection port 66,and scavenging port 67. The shell is held in position by clamps 68 and 69. The charge is extruded into the shell in excess such that the charge moves through the closed channel of the shell and scours the inner surfaces of the shell removing oxides and other contaminants which are carried in the charge and are discharged with the excess extruded metal through the scavenging port. After scavenging is completed, the scavenging port is closed by scavenging port cut off 70 and 71. The pressure in the charge is built up by continued action of the piston which causes the charge to fill out and seat into the shell cavity after which the injection port is closed by injection port cutoff 72 and 73. The resulting containerized ingot is then cooled and the closed injection and scavenging ports may optionally be sealed by one of the methods previously described. | A composite metal article is made by placing a low melting temperature metal to serve as a core within a shell of a high melting temperature metal and by containing and sealing the core within the shell. The assembly constitutes a containerized ingot which is then transported to a forming die where the containerized ingot is heated to soften the core and is then formed to the shape imposed by the die. During the cooling period, the shell is reformed to the core to maintain tight contact and to promote bonding. | 8 |
FIELD OF THE INVENTION
The present invention relates to optical fiber delivery systems, and more particularly to optical fibers used to deliver the optical output from laser diodes to end user applications.
BACKGROUND OF THE INVENTION
A multi-emitter laser diode produces a plurality of optical beams, one from each emitter. A common method of delivering the laser diode optical output to an end user application includes coupling the output beams into a plurality of transport optical fibers. The input ends of the transport fibers are aligned with the laser diode emitters. The output ends of the transport fibers are arranged into a tightly packed circular array to minimize the spot size of the composite optical beams (overall laser diode output) exiting the transport fibers. Coupling optics are placed between the laser diode emitters and the transport fiber input ends to properly focus the laser diode output beams into the array of transport fibers.
It is known to enclose the laser diode, coupling optics and transport fiber input ends inside a sealed laser diode housing to prevent the contamination thereof. It is also known to place an optical fiber connector at the laser diode housing wall for coupling the optical output out of the laser diode housing while maintaining the seal of the housing. The transport fibers terminate at the optical fiber connector. A delivery fiber from outside of the laser diode housing is butted against the ends of the transport fibers (butt coupled) by the fiber optic connector. The delivery fiber is a single optical fiber having a diameter matched to the diameter of the entire circular array of transport fibers in order to capture all of the optical output exiting the transport fibers.
The spot size of the laser diode optical output at the optical connector is at least as large as the diameter of the circular array of transport fibers. It is desirous to minimize the spot size at the optical connector so that a smaller diameter delivery fiber can be used, which results in a smaller emission diameter at the output end of the delivery fiber. A smaller emission diameter can simplify the design of optical systems at the intended end user application. Further, an optical fiber with a smaller diameter is less expensive and has a smaller bend radius.
The circular array of transport fibers, however, can be packed only so tight to achieve a smaller overall fiber array diameter. Further, the selected diameter of the transport fibers can be reduced only so far without either requiring complicated coupling configurations at the laser diode emitters, or resulting in coupling losses at the transport fiber input ends.
Complicated and expensive fiber core fusing techniques have been used to further reduce the diameter of the transport fibers. For example, U.S. Pat. No. 4,820,010, issued to Scifres et al on Apr. 11, 1989, describes heating the end of a bundle of fibers beyond the fibers' melting point to form a tapered output rod having a smaller diameter than the overall diameter of the fiber bundle. However, the molten tapered rod contains both the core and clad materials which, unless thoroughly mixed, will cause light scattering. Further, there is no cladding left around the tapered rod, which will result in the leakage of light if the rod surface is not perfectly smooth and/or there is any surface contamination.
There is a need for a simple and inexpensive laser diode delivery system that reduces the spot size of the laser diode output, even while combining a plurality of optical outputs together, while coupling the laser diode output into a delivery fiber of reduced diameter to utilize smaller delivery fibers and achieve smaller laser output emission diameters.
SUMMARY OF THE INVENTION
The present invention solves the aforementioned problems by changing the emission diameter of the laser diode output near the laser diode housing connector in a guided-wave format with low optical loss.
The optical fiber delivery system of the present invention includes a semiconductor light source that produces an optical output. A first optical fiber has an input end and an output end, with the input end positioned to receive the optical output. A second optical fiber has an input end and an output end. A quick disconnect optical connector removably butt couples the input end of the second fiber to the output end of the first fiber, to receive the optical output from the first fiber. One of the first and second fibers has a tapered segment with a core and a cladding tapered down smoothly in diameter. The diameters of the core and cladding at the input end of the one first and second fiber are larger than core and cladding diameters respectively at the output end of the one first and second fiber.
In another aspect of the present invention, the optical fiber delivery system includes a semiconductor light source that produces an optical output. A plurality of first optical fibers each has an input end and an output end. The input ends are optically coupled to the semiconductor light source to receive the optical output. The output ends are bundled together. A second optical fiber has an input end and an output end. An optical connector positions the second fiber input end, relative to the first fiber output ends, to receive the optical output from the first fibers. At least each of the first fibers, or the second fiber, has a tapered segment with a core and a cladding tapered down smoothly in diameter.
In yet another aspect of the present invention, the optical fiber delivery system includes a plurality of laser diode assemblies. Each laser diode assembly includes a laser diode having a plurality of emitters that each emit an optical beam, and a plurality of first optical fibers with input ends each positioned to receive one of the optical beams from the emitters and output ends that are bundled together. A plurality of second optical fibers each have an input end and an output end. The second fiber output ends are bundled together. A plurality of first optical connectors each of which butt couple one of the second fiber input ends to one of the bundles of the first fiber output ends. Each of the second fibers have a tapered segment with a core and a cladding tapered down smoothly in diameter. The diameters of the core and cladding at each of the second fiber input ends are larger than core and cladding diameters respectively at each corresponding second fiber output end.
Other objects and features of the present invention will become apparent by a review of the specification and appended figures.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a cross-sectional side view of the laser diode enclosure with the tapered fibers of the present invention.
FIG. 2 is a top view of the laser diode enclosure with the lid removed illustrating the tapered fibers of the present invention.
FIG. 3 is an end cross-sectional view of the circular array configuration of the output ends of the transport fibers.
FIG. 4 is a perspective view of the optical fiber array butt coupled to the delivery optical fiber.
FIG. 5 is a side view of the tapered transport fiber of the present invention.
FIG. 6 is a top view of the laser diode enclosure with the lid removed illustrating a single tapered fiber.
FIG. 7 is a side view of the tapered transport fiber of the present invention fused to a second fiber.
FIG. 8 is a top view of the laser diode enclosure with the lid removed illustrating multiple laser diodes coupled to the array of tapered fibers.
FIG. 9 is a top view of a plurality of laser diode assemblies with tapered delivery fibers bundled together.
FIG. 10 is a top view of the laser diode enclosure with the lid removed illustrating the untapered transport fibers therein.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention is a laser diode assembly 1 that couples the optical output from a plurality of individual light sources into a single optical fiber while reducing the overall optical output emission diameter (spot size) in a guided-wave format with minimal optical loss. The laser diode assembly 1 includes a laser diode housing 2, and an optical connector 4 for coupling an array of transport fibers 6 to a delivery fiber 8, as illustrated in FIGS. 1-2. The transport fibers 6 transmit the optical output out of the laser diode assembly, and the delivery fiber 8 transmits the optical output from the transport fibers to the intended application.
The laser diode housing 2 includes a base plate 10, side walls 12 and a lid 14, which define a sealed space 16 therein. Optical connector 4 is mounted through a hole in one of the walls 12, and forms a seal therewith.
Inside the sealed space 16, a heatsink 18 is mounted to the base plate 10. A laser diode bar 20 is mounted to the heatsink 18 so that there is good thermal and electrical conduction. The laser diode bar 20 produces an optical output 22 that exits the laser diode bar 20 through a plurality of emitters 24.
The array of transport fibers 6 is attached to a support block 26, preferably by solder or glue, such that the input ends 28 of the fibers 6 are each aligned to one of the emitters 24. A cylindrical lens 30 disposed across the input ends 28 of transport fibers 6 collimate and/or focus the optical output from each laser diode emitter 24 into the corresponding fiber 6. In the preferred embodiment, the cylindrical lens 30 is spaced approximately 30 μm from the diode emitters 24.
The transport fibers 6 extend to and terminate at the optical connector 4. As illustrated in FIG. 3, the output ends 29 of the transport fibers 6 are bundled together in a tightly packed circular configuration (i.e. a closed pack hexagonal array if seven transport fibers 6 are used as illustrated in FIG. 3) having an overall diameter D (that does not include the fiber claddings) to produce a single composite optical output from the individual output beams exiting the output ends of fibers 6. The output ends 29 are butted up against (butt coupled with) the input end 33 of delivery fiber 8 inside optical connector 4, as illustrated in FIGS. 1-2 and 4. Output ends 29 and input end 33 are preferably anti-reflection coated for efficient optical butt coupling. With this configuration, the input end 33 of delivery fiber 8 ideally has a diameter approximately equal to or greater than diameter D in order to efficiently capture all the optical power exiting the bundle of transport fibers 6.
The optical connector 4 is ideally a quick disconnect SMA #905 connector, FC connector, or any equivalent thereof that removably butt couples output end 29 of transport fiber 6 to the input end 33 of delivery fiber 8. Alternately, connector 4 could be any permanent device, such as a glass sleeve glued to the fibers 6 and 8, etc., that permanently butt couples these fibers together.
It is desirous to minimize the diameter of the delivery fiber 8 to reduce the spot size of the optical output exiting therefrom, and to utilize cheaper delivery fibers having a smaller bend radius. Since delivery fiber 8 ideally has a diameter approximately equal to or greater than the overall diameter D of the transport fiber array, diameter D is minimized in accordance with the present invention by individually tapering down the diameter of transport fibers 6.
Each transport fiber 6 has a tapered section 38 so that output end 29 has a smaller diameter than input end 28. Each fiber 6 has a core 34, surrounded by a cladding 36, both of which having diameters that smoothly taper down in the tapered section 38, as best illustrated in FIG. 5. The reduced diameters of the output ends 29 results in a reduced overall diameter D of the circular bundle of transport fibers 6 at the optical connector 4. Ideally, the overall diameter D of the fiber array is approximately equal to or slightly less than the diameter of delivery fiber 8 to ensure efficient coupling and decrease losses due to mechanical alignment tolerances and manufacturing variances at the connector 4.
To form a tapered section 38, any buffer present is stripped off of a predetermined length of each fiber 6 from the output end 29. Heat is evenly applied to each predetermined length of fiber 6, while the output end 29 of each fiber 6 is pulled, to form tapered section 38. The amount of heat applied must be sufficient to raise the core 34 and cladding 36 to a high enough temperature so that they will stretch, thus resulting in a longer, but narrower, section of fiber. A simple method of pulling the fiber is to mount a small weight (a few ounces) to the output end 29 of the fiber while the predetermined length is being heated. The heat is applied evenly to form a tapered section 38 that evenly and concentrically tapers down to smaller diameters over its length. The heating and pulling of the fiber 6 continues until the desired core diameter at the output end 29 is achieved. Ideally, the fiber 6 is heated and pulled until a core diameter is achieved that is slightly smaller than the desired core diameter at the output end 29. Thereafter, the output end 29 of the fiber 6 is cleaved and polished back to achieve the actual desired core diameter value. Any conventional heat source can be used, such as a torch, a laser source, etc., that can evenly heat the predetermined length to produce an even, circular, tapered core diameter through the tapered section 38 of fiber 6. Once the fibers 6 have been tapered, they are bundled and attached to optical connector 4.
The tapering method described above is advantageous because it preserves the cladding 36 around core 34 throughout the tapered section 38, thus preventing any light from escaping out the side of optical fiber 6. The tapered section is a gradual, or adiabatic, taper made of low loss optical materials which preserves the intrinsic brightness of the emission pattern through the taper fiber section. The length of the tapered section 38 and the diameter of the core 34 at the output end 29 are such that, given the refractive indices of the materials used to make the core/cladding, and the optical properties of the propagating beam, the numerical aperture of the propagating beam does not exceed the intrinsic numerical aperture of the tapered section 38.
A further advantage of tapering the transport fiber 6 as described above is that the emission divergence of the laser energy exiting the laser diode housing can be matched to that of the lowest cost delivery fiber without any degradation in brightness. Further, matching the emission divergence at output 29 to the acceptance divergence of the delivery fiber 8 will minimize shifts in the light distribution associated with bending and flexing the fiber.
It should be noted that it is well within the scope of the present invention to use a laser diode 20 having a single emitter 24 optically coupled to a single tapered transport fiber 6, as illustrated in FIG. 6. Further, tapered section 38 need not terminate at output end 29 of transport fiber 6, but can be formed in a mid-fiber position, as illustrated in FIG. 7. In this embodiment, a smaller diameter fiber 40 is fused onto the output end 29 of the tapered fiber 6 using standard fiber fusing techniques, where the output end 42 of fiber 40 is butt coupled to delivery fiber 8. In addition, fibers 6 could originate from a plurality of different laser diodes 20, using a different cylindrical lens 30 for each transport fiber input end 28, as illustrated in FIG. 8.
The optical output from a plurality of laser diode assemblies 1 can be coupled together in a spot size reducing, guided wave fashion similar to that described above. FIG. 9 illustrates a plurality of sealed laser diode assemblies 1 with the output ends 44 of delivery fibers 8 bundled together in a tightly packed circular configuration to produce a single optical output therefrom. A second optical connector 45 butt couples the output ends 44 of delivery fibers 8 to the input end 48 of a second delivery fiber 50. Each delivery fiber 8 has a tapered section 38 so that output end 44 has a smaller diameter than input end 33. The reduced diameters of the output ends 44, and therefore the reduced overall diameter of the circular bundle of delivery fibers 8, result in a reduced optical output spot size at the second optical connector 45. Ideally, the overall diameter of the circular bundle of delivery fiber output ends 44 is approximately equal to or slightly less than the diameter of the input end 48 of fiber 50 to ensure efficient optical coupling. If an additional reduction in the optical output spot size exiting second delivery fiber 50 is desired, delivery fiber 50 can also have a tapered section 38, as illustrated in FIG. 9.
It should be noted that while FIGS. 2 and 9 illustrate fibers 6, 8 and 50 all having tapered sections 38, the scope of the present invention includes any combination of just one or more of fibers 6, 8 and 50 having a tapered section 38, depending upon the desired spot size and divergence of the optical output exiting fiber 50. Further, fiber 50 and connector 45 can be omitted from the embodiment shown in FIG. 9. In such a case, the composite output beam exiting the bundled output ends 44 of delivery fibers 8 is directly applied to the intended application.
For example, a high powered fiber-delivered laser source having seven laser diode assemblies is illustrated in FIGS. 9-10, where each laser diode assembly 1 includes a laser diode bar 20 having nineteen emitters 24 and nineteen corresponding transport fibers 6, as illustrated in FIG. 10. The transport fibers 6 have 150 um diameter cores and 165 um diameter claddings. The transport fibers 6 are untapered, thereby not having any tapered sections 38. The output ends 29 of the transport fibers 6 are bundled together into a circular array having an overall effective diameter of about 810 um at the optical connector 4. The input end 33 of delivery fiber 8 has a diameter of 825 um and is butt coupled to the transport fibers 6 by the connector 4. The delivery fiber 8 has a tapered section 38 such that the output end 44 of delivery fiber 8 is 275 um core diameter (290 um cladding diameter), yielding a factor of three reduction in the emission diameter of the laser output. The seven output ends 44 of the delivery fibers 8 are bundled together into a circular array having an approximate overall effective diameter of about 855 um. A 1.0 mm core diameter fiber 50 is butt coupled to the array of delivery fibers 8 by the connector 45. With the present embodiment, a 100 watt optical output from 133 emitters in seven laser diodes bars 20 can be captured by 133 optical fibers each having a 150 um core, and are coupled into a single optical fiber 50 having a 1.0 mm diameter in a low loss guided-wave fashion.
It is to be understood that the present invention is not limited to the embodiments described above and illustrated herein. For example, the scope of the present invention includes any variation in the numbers of laser diode assemblies 1 and delivery fibers 8 used with any number of laser diodes 20 and emitters 24 and transport fibers 6 in each laser diode assembly 1, and any number of second delivery fibers 50, and with any combination of one or more of the fibers 6, 8 and 50 having, or not having, tapered sections 38. | An optical fiber delivery system having a semiconductor light source that produces an optical output. A plurality of first optical fibers each has an input end and an output end. The input ends are optically coupled to the semiconductor light source to receive the optical output, and the output ends are bundled together. An optical connector positions the input end of a second fiber, relative to the first fiber output ends, to receive the optical output from the first fibers. Either each of the first fibers, or the second fiber, have a tapered segment with a core and a cladding tapered down smoothly in diameter to reduce the spot size of optical output. | 6 |
This is a continuation of co-pending application Ser. No. 805,966 filed on Dec. 5, 1985, now abandoned.
FIELD OF THE INVENTION
The invention relates to a cabin-like cover which is particularly suitable for covering machine tools, but also for many other industrial purposes.
BACKGROUND OF THE INVENTION
Cabin-like covers are known in which the supporting framework is formed by a plurality of horizontal and vertical beams which are screwed or welded together and on which cover plates are placed. The essential disadvantage of these constructions lies in the comparatively high expenditure on assembly. It is a further disadvantage that maintenance and repair work in the cabin-like cover (for example replacement of large assemblies) generally requires substantial dismantling of the cover.
A known cabin-like cover in which the panels forming the side walls of the cover are constructed so as to be self-supporting represents a significant improvement over this prior art. In such a construction the arrangement of a base frame and a top frame is sufficient in order for the side walls of the cover to be kept free of troublesome intermediate members.
In this way not only is the assembly of the cabin-like cover considerably simplified, but in case of need (particularly for maintenance and remodelling purposes) free openings which extend over the total height of the cover can be created by removing individual panels. In the last-mentioned known construction the base frame has a U-shaped cross-section which is open towards the top and into which the panels are inserted from above. The gaps between the panels and the base frame must be sealed on the interior and the exterior of the cabin-like cover against the entry of fluid and/or foreign bodies. Furthermore, in the known construction the baffles which are in many cases required on the inside of the cover (to deflect cooling agent or shavings) must--in order to have a sufficiently steep inclination--be mounted on the panels which, however, do not generally have sufficiently thick walls for such mounting. At the same time such mounting of the baffles on the panels creates problems of sealing.
A further disadvantage of the previously known cabin-like covers is that detachment of individual panels requires a more or less complete dismantling of the whole cover. Consequently in the known construction it is not generally possible for later alterations in the side walls to be carried out in a simple manner, for example altering the position of a window or a door or producing a larger opening in a side wall in a short time for assembly purposes.
SUMMARY OF THE INVENTION
The object of the invention, therefore, is to construct a cabin-like cover in such a way that the junction of the panels with the base frame is well protected in a structurally simple manner against the entry of fluid and foreign bodies and that it is also possible for baffles to be mounted on the inside of the cabin-like cover so as to be mechanically stable and satisfactorily sealed at the mounting point.
In a further embodiment of the invention a cabin-like cover is constructed in such a way that later alterations in the construction of the side walls can be carried out in a particularly simple manner, particularly without dismantling the whole cover.
BRIEF DESCRIPTION OF THE DRAWINGS
Some embodiments of the invention are illustrated in the drawings, in which:
FIG. 1 shows a schematic representation of a cabin-like cover according to the invention,
FIG. 2 shows a horizontal section (along the line II--II in FIG. 1) through two panels which interengage with their side edges,
FIG. 3 shows a vertical section along the line III--III in FIG. 1,
FIG. 4 shows a horizontal section (along the line IV--IV in FIG. 1) through a closure element,
FIG. 5 shows a section (similar to FIG. 4) through a further embodiment of a closure element,
FIG. 6 shows a horizontal section through some panels and a closure element arranged between them,
FIG. 7 shows a vertical section through a variant of the base frame,
FIG. 8 shows a section through a further closure element.
DETAILED DESCRIPTION
The cabin-like cover illustrated quite schematically in FIG. 1 is intended for example for covering a machine tool (and possibly also serves as a sound-insulation cabin), and contains a base frame 1, a top frame 2, corner pieces 3, panels 4 and a closure element 5 in the region of each side wall.
One embodiment of the panels 4 forming the side walls is illustrated in FIG. 2. The panels have an outer coating 6 and 7 made for example from sheet metal on the two broad sides and 8 and 9 on the end edges. The outer coating of the panels encloses an insulating material 10.
The end edges of the panels 4 are constructed so as to be complementary to each other. As can be seen from FIG. 2, one end edge (of the left-hand panel 4) has a U-shaped cross-section, whilst the end edge of the other (right-hand) panel has a plug-like cross-section. A sealing element 11 is arranged between the two panels which interlock with their complementary end edges.
The base frame of the embodiment illustrated in FIG. 3 contains one single beam 31 of box-shaped cross-section which is supported on the ground by supports 12 which are adjustable in height and constructed as adjusting screws. The lower edge 13 of the panels 4 which is constructed with a U-shaped cross-section engages over the beam 31 of the base frame 1. The internal breadth B of the U-shaped cross-section of the lower panel edge is at least as great as the outer breadth B' of the base frame beam 31.
In the illustrated embodiment there is a clear distance a between the outer coatings 6 and 7 of the panels 4 and the beam 31 of the base frame 1.
The top frame 2 has a U-shaped cross-section which is open towards the bottom and engages over the panels 4. There is also a certain clearance b provided between the outer coatings 6, 7 of the panels 4 and the side walls of the top frame 2.
The upper edges of the panels 4 have a spacing c relative to the top frame 2 which is greater than the dimension d by which the panels 4 engage over the beam 31 of the base frame 1. Consequently the panels 4 can be raised relative to the top frame 2 to such an extent that the lower edge of the panels 4 is freed from the base frame 1. The clearance b between the panels 4 and the side walls of the top frame 2 also facilitates tilting of the panels 4 within the top frame 2 so that the raised and tilted panels 4 can be detached from the top frame 2 and from the base frame 1 by pulling them out at an angle downwards.
A baffle 21 which serves to deflect cooling agent and shavings is provided on the inner face of the base frame beam 31, and the U-shaped cross-section of the lower edge of the panels 4 engages over the upper part 21a of the baffle whilst the lower part 21b thereof projects into the interior of the cabin-like cover.
An attachment 2a which serves to support top elements 22 is also provided on the inside of the top frame 2.
FIG. 4 shows an embodiment of a closure element 5 which is preferably provided in each side wall of the cabin-like cover. This closure element 5 has a U-shaped cross-section in the region of both side edges and is divided in the vertical longitudinal central plane 14. Thus the closure element 5 consists of two parts 15 and 16 which are releasably connected to each other by connecting elements 17, 18 (for example screws).
The two panels 4 adjacent to the closure element 5 have a plug-like cross-section on their side edges facing the closure element 5. The closure element 5 closes off these two panels 4 flush with the broad sides.
In the embodiment illustrated in FIG. 4 the two parts 15, 16 of the closure element 5 also have an outer coating (for example made from sheet metal) and an insulating material arranged in between. In vertical section the closure element 5 can be constructed in the same way as the panels 4 (cf. FIG. 3). After the connecting elements 17 and 18 have been released the part 16 of the closure element 5 located on the outside of the cabin-like cover can then be removed towards the exterior; for this purpose it is raised slightly and tilted somewhat and can then be detached from the base frame 1 and from the top frame 2. The other part 15 of the closure element 5 can then also be removed without difficulty either towards the interior or the exterior.
If the closure element 5 is removed in this way then--as can be seen from FIG. 6--one of the two panels 4 adjacent to the closure element 5 can be moved in the longitudinal direction of the side wall of the cabin-like cover to the extent that the engagement between the side edges of this panel 4 and the next panel 4' is released. For this purpose the core dimension e (FIG. 6) of the closure element 5 must be somewhat greater than the dimension f with which the side edges of adjacent panels 4, 4' engage in one another.
If after the closure element 5 has been released and the adjacent panel 4 has been moved the engagement of this panel 4 with the next panel 4' is released in this way, then the panel 4 can be removed from the base frame 1 and the top frame 2 in the manner already explained in FIG. 3 by raising and tilting. In this way all the required panels of the side walls can be removed one after the other without the basic structure of the cabin-like cover, particularly the base frame 1, the top frame 2 and the corner pieces 3, having to be dismantled.
Thus in this way all later alterations in the side walls of the cabin-like cover can be very simply and quickly carried out: windows and doors can be inserted and changed in position. In addition a larger opening can be created for assembly purposes by removing some panels.
In the further embodiment which is schematically illustrated in FIG. 5 the closure element 5 consists of two flat plates 19, 20 which are connected to each other by the releasable connecting elements 17 and 18. Thus in this simplified embodiment no insulation is provided in the region of the closure element 5. However, apart from this the closure element has the same advantages as have already been explained above for the variant according to FIG. 4.
FIG. 7 shows a second embodiment of the base frame 1 of of the cabin-like cover according to the invention. This base frame 1 contains an upper beam 31 of box-shaped cross-section and a further beam 32 which is parallel to the upper beam 31 and spaced from it and supported on the ground. The U-shaped cross-section of the lower edge of the panels 4 engages over the upper beam 31 in the manner already explained with the aid of FIG. 3.
The beams 31 and 32 are connected to each other at certain intervals by vertical connecting elements 33. The free space between the two beams 31, 32 is covered towards the exterior by removable cover elements 34 which are connected to the beams 31, 32 for example by screws 35.
A part 21a of a baffle 21 which delivers shavings which land on it to a shavings conveyor 36 arranged in the interior of the cabin-like cover is also mounted on the upper beam 31.
By the use of two beams 31, 32 with the clear space between them covered towards the exterior by coating elements 34, it is possible in spite of the light construction which saves on material for the base frame 1 to have a sufficiently great height H (for example 1000 mm) for the baffle 21 mounted on the beam 31 to have the desired steep inclination. The mounting of the baffle 21 on the beam 31 does not create any problems. It is advantageous that the outer coating 6 of the panel 4 partially engages over the upper part 21a of the baffle 21 which is mounted on the beam 31.
In the construction of the base frame 1 illustrated in FIG. 7 it is possible by removing one or more coating elements 34 to provide access to the ground region of the cabin-like cover from the exterior without having to remove panels 4 of the side walls for this purpose. In this way it is in particular possible for small components of the cabin-like cover to be installed and removed in a very simple manner.
FIG. 8 shows as a further embodiment a closure element 5' which in contrast to the embodiments described previously is constructed without a division. The closure element 5' has a cross-section which is graded in breadth and is broader on the outside of the cabin-like cover which is assumed to be on the top in FIG. 8 than on the inside. The outer skin 5'a and 5'b of the closure element 5' forms on the outside of the cabin-like cover a fold 5'c which rests on the corresponding fold 4c of the two adjacent panels in such a way that the outer surface of the closure element 5' is closed flush with the outer surface of the panel 4.
On the surface facing the inside of the cabin-like cover the closure element 5' is provided with a step 5'd which rests via a seal 42 on a fold 4d of the panels 4.
The closure element 5' is provided with swivelling connecting elements 40, 41--indicated by broken lines which--are accessible from the outside of the cabin-like cover and by means of which the closure element 5 can be locked with the two adjacent panels 4.
After swivelling of the connecting elements 40, 41 into the unlocked position the closure element 5' can be raised in the manner already described to such an extent that the engagement between the closure element 5' and the base frame 1 is released so that the closure element 5' can be detached from the base frame 1 and the top frame 2. Then one of the two adjacent panels 4 can be moved in the longitudinal direction of the side wall until the engagement between the side edges of this panel 4 and those of the next panel 4' (cf. FIG. 5) is released and the panel 4 which has been moved sideways can be raised and detached from the base frame and the top frame.
Within the scope of the invention "panels" should be understood to mean not only assembled wall elements of the construction described in the embodiments but also for example simple plates made from sheet metal or plastics material. | The invention relates to a cabin-like cover, in particular for covering machines, in which the panels of the side walls have a U-shaped cross-section which is open towards the bottom and engages over a base frame so that the junction of the panels in the base frame is well protected against the entry of fluid and foreign bodies. In at least one side wall of the cabin-like cover a closure element is also provided and after it has been detached the individual panels of the side wall can be removed and thus later alterations to the side walls can be carried out without complete dismantling of the cabin-like cover. | 4 |
FIELD OF THE INVENTION
The present invention relates generally to skylight collimators.
BACKGROUND OF THE INVENTION
Briefly, a tubular skylight such as those mentioned in U.S. Pat. Nos. 5,896,713 and 6,035,593, both of which are owned by the same assignee as is the present invention and both of which are incorporated herein by reference, includes a tube assembly mounted between the roof and ceiling of a building. The top end of the tube assembly is covered by a roof-mounted cover, while the bottom end of the tube assembly is covered by a ceiling-mounted diffuser plate. With this combination, natural light external to the building is directed through the tube assembly into the interior of the building to illuminate the interior.
As understood herein, the tube with vertical sides reflects light in the same angle each reflection, which angle depends on the sun's elevation in the sky and thus varying throughout the day, limiting the efficiency and effectiveness of the diffuser in controlling the distribution of light in the building.
SUMMARY OF THE INVENTION
The present invention has recognized that to optimize the light transmission through the cover, a collimator may be provided above the diffuser, and furthermore the collimator need not be specular.
Accordingly, a skylight assembly includes a skylight shaft and a collimator assembly operably engaged with the shaft. The collimator assembly includes an axial series of multiple collimator segments. In the limit in which the number of segments in the series approaches infinity, the collimator assumes a curved shape in longitudinal cross-section. A first collimator segment defines a first collimating angle with respect to an axis of the collimator assembly and subsequent collimating segments define respectively different (and steeper) collimating angles with respect to the axis. The collimating angles can be oblique. The collimating angles (and in the limiting case, the curve of the assembly) can be established by the desired degree of collimation, the expected range of angles at which sunlight enters the assembly, and the diameter of the entrance to the collimator.
In some examples, the collimating assembly includes a third collimating segment defining a third collimating angle different from the first and second collimating angles. The collimating segments can be successively less flared than each other. An upper collimating segment can be more flared than a lower collimator segment. The inside surface of the collimating assembly may be non-specular.
In another embodiment, a skylight collimator assembly has a first frustum-shaped collimator segment defining a first cone angle and a second frustum-shaped collimator segment connected to the first segment and coaxial therewith. The second segment defines a second cone angle more acute than the first cone angle.
In another aspect, a skylight has a skylight tube defining an upper end and a lower end, a skylight cover disposed above the upper end and permitting light to enter the tube, and a collimator assembly disposed below the lower end to receive light therefrom. The collimator assembly has a non-specular inside surface. A diffuser is disposed below the lower end of the collimator assembly. In some embodiments the assembly has multiple collimator segments.
The details of the present invention, both as to its structure and operation, can best be understood in reference to the accompanying drawings, in which like reference numerals refer to like parts, and in which:
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side view in partial cross-section of an example non-limiting tubular skylight showing an example environment of the collimator;
FIG. 2 is a cross-sectional view of the collimator as seen along the line 2 - 2 in FIG. 1 ;
FIG. 3 is a side schematic view showing collimator parameters;
FIG. 4 is a side schematic view of an alternate collimator assembly in which the number of segments approaches infinity, effectively establishing a collimator that is continuously curved at ever-steeper tangents in the longitudinal dimension;
FIG. 5 is a perspective view of an alternate collimator having a round-to-square configuration;
FIG. 6 is an elevational view of the collimator shown in FIG. 5 ; and
FIG. 7 is a top plan view of the collimator shown in FIG. 5 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring initially to FIG. 1 , a tubular skylight made in accordance with the present invention is shown, generally designated 10 , for lighting, with natural sunlight, an interior room 12 having a ceiling dry wall 14 in a building, generally designated 16 . FIG. 1 shows that the building 16 has a roof 18 and one or more joists 20 that support the roof 18 and ceiling dry wall 14 .
As shown in FIG. 1 , the skylight 10 includes a rigid hard plastic or glass roof-mounted cover 21 . The cover 21 is optically transmissive and preferably is transparent.
The cover 21 may be mounted to the roof 18 by means of a ring-like metal flashing 22 that is attached to the roof 18 by means well-known in the art. The metal flashing 22 can be angled as appropriate for the cant of the roof 18 to engage and hold the cover 21 in the generally vertically upright orientation shown.
As further shown in FIG. 1 , an internally reflective hollow metal shaft assembly, generally designated 24 , is connected to the flashing 22 . The cross-section of the assembly 24 can be cylindrical, rectangular, triangular, etc. Accordingly, while the word “tube” is used from time to time herein, it is to be understood that the principles of the present invention are not to be limited to a tube per se.
The shaft assembly 24 extends to the ceiling 14 of the interior room 12 . Per the present invention, the shaft assembly 24 directs light that enters the shaft assembly 24 downwardly to a light diffuser assembly, generally designated 26 , that is disposed in the room 12 and that is mounted to the ceiling 14 or to a joist 20 as described in the above-mentioned '593 patent.
The shaft assembly 24 can be made of a metal such as an alloy of aluminum or steel, or the shaft assembly 24 can be made of plastic or other appropriate material. The interior of the shaft assembly 24 is rendered reflective by means of, e.g., electroplating, anodizing, metallized plastic film coating, or other suitable means.
In one example embodiment, the shaft assembly 24 is established by a single shaft. However, as shown in FIG. 1 , if desired, the shaft assembly 24 can include multiple segments, each one of which is internally reflective in accordance with present principles. Specifically, the shaft assembly 24 can include an upper shaft 28 that is engaged with the flashing 22 and that is covered by the cover 21 . Also, the shaft assembly 24 can include an upper intermediate shaft 30 that is contiguous to the upper shaft 28 and that can be angled relative thereto at an elbow 31 if desired. Moreover, the shaft assembly 24 can include a lower intermediate shaft 32 that is slidably engaged with the upper intermediate shaft 30 for absorbing thermal stresses in the shaft assembly 24 . And, a collimator-like lower shaft 34 can be contiguous to the lower intermediate shaft 32 and join the lower intermediate shaft 32 at an elbow 35 , with the bottom of the lower shaft 34 being covered by the diffuser assembly 26 . The elbow 35 is angled as appropriate for the building 16 such that the shaft assembly 24 connects the roof-mounted cover 21 to the ceiling-mounted diffuser assembly 26 . It is to be understood that where appropriate, certain joints between shafts can be mechanically fastened and covered with tape in accordance with principles known in the art.
As shown in FIG. 2 , the collimator-like lower shaft 34 referenced in FIG. 1 is presented in greater detail. As may now be appreciated, in non-limiting embodiments the collimator-like lower shaft 34 has an axial series of multiple collimator segments. It may further be appreciated that each collimating segment of the shaft 34 is successively less outwardly-flared from top to bottom than the one immediately above it.
The collimator-like lower shaft 34 shown in FIG. 2 has a top 36 and a bottom 38 . The top 36 of the shaft 34 may be contiguously engaged to the lower intermediate shaft 32 as described in reference to FIG. 1 above. The bottom 38 of the shaft 34 may be covered by the diffuser assembly 26 as also described above. The bottom of the collimator may also be left open without a diffuser assembly engaged therewith.
Also as stated above, the shaft 34 has multiple collimating segments. In some embodiments the collimating segments are frusto-conical. In other embodiments they may assume other collimating shapes, e.g., frusto-pyramidal.
Thus, there may be a first frustum-shaped collimating segment 40 defining a first collimating angle α 1 with respect to an axis of the collimator assembly 34 and a second frustum-shaped collimating segment 42 connected to the segment 40 and defining a second collimating angle α 2 that is less than the first collimating angle with respect to an axis of the collimator assembly 34 . Furthermore, in non-limiting embodiments there may also be a third frustum-shaped collimating segment 44 connected to the segment 42 and defining a third collimating angle α 3 that is less than the first and second collimating angles. It is to be further understood that each collimating angle referenced in the present application may be oblique. Additional segments may be provided in accordance with disclosure below.
Still referencing FIG. 2 , the collimating segment 40 is more flared than the collimating segment 42 . Similarly, in non-limiting embodiments that include a third collimating segment 44 , the collimating segment 42 is more flared than the third collimating segment 44 . Should there be more than three collimating segments, each upper collimating segment may be more flared than the one below it.
Last, it may also be appreciated from FIG. 2 that there is an inside surface 46 of the collimating assembly 34 . The inside surface 46 of the assembly 34 is understood to be non-specular in non-limiting embodiments. Examples of such non-specular surfaces are disclosed in the present assignee's U.S. Pat. No. 7,146,768 and USPPs 2006/0191214 and 2007/0266652, incorporated herein by reference. In brief, the non-specular inside surface can be established by a structured surface in the metal substrate, reflective film or adhesive on the film. It can be in the form of dimples, corrugated patterns or other shapes known to provide a controlled spread of light of, e.g., less than about ten degrees. Using a non-specular surface provides a controlled light spread as desired, e.g., a spread of light that is less than plus or minus five degrees from the central reflected ray of light.
The multi-stage collimator described above advantageously consumes less axial space than a single stage collimator yielding equivalent performance.
With greater specificity and with the understanding that the discussion below is not intended to limit the invention but rather provide background explanation, the following terms are used. Refer to FIG. 3 . “SALT” (in degrees) refers to the solar altitude, angle of the sun from the horizontal plane, and the angle of the sunlight reflecting down a parallel walled tube. “TT” (degrees) refers to the tube taper, angle from vertical and/or parallel, while “ALT” (in degrees) refers to the alignment angle of light after reflecting off of the tapered wall. This angle is in relation to a horizontal plane. Then:
TT=((ALT)−(SALT))/2 and ALT=(2)(TT)+(SALT)
Present principles can be used to provide a single reflection, variable tapered tube that is optimally designed to realign sunlight while minimizing reflective material and space of the collimator.
In example embodiments and now referring to FIG. 3 , dimensions of the first (top) segment may be determined using the following equations:
DIATOP(inches)=Diameter of tapered tube at the top or light entrance; DIATT(inches)=Diameter of tapered tube where light is reflected based on light entering the tapered tube from the top diameter at a specific SALT and light reflected at a specific ALT requirement; HTTT(inches)=Height of tapered tube at the related DIATT; then
DIATT=(2)((DIATOP)(tan SALT))/((1/tan TT)−(tan SALT))+(DIATOP)
HTTT=(DIATT-DIATOP)/(2 tan TT) where “TT” is the angle of tube taper relative to the vertical axis.
Each consecutive segment diameter and height can be determined from the previous segments values as follows:
N is new value, P is previous value and AP is ½ the increase in diameter from DIATOP to DIATTP. Thus using the example in the table below to determine HTTTN for the collimator @ a SALT of 35 degrees, AP would be (13.64−10.0)/2=1.82″.
HTTTN=((DIATOP+ AP )(tan SALTN)−(HTTTP)(tan SALTN)(tan TTN))/1−(tan SALTN)(tan TTN)
DIATTN=DIATTP+(2)(HTTTN−HTTTP)(tan TTN)
Preferably, light undergoes only one reflection in the variable tapered tube to provide the required alignment angle.
With the above in mind, for a variable tapered tube that provides an alignment angle (ALT, the axis of the light spread as shown) greater than or equal to 55 degrees with an input range of light (SALT) from 15 degrees up to 55 degrees, the following dimensions may be used. The below table is in increments of ten degrees/five segments of (SALT). For this example, the top of the tapered tube opening is assumed to be ten inches in diameter. An example multiple stage collimator is shown in FIG. 4 .
SALT
TT
Tube Dia.
Tube height
15°
20°
12.16″
2.96″
25
15
13.64
5.51
35
10
14.91
8.72
45
5
15.81
12.90
55
0
16.04
18.59
The multiple stage collimator results in smaller dimensions than were a single stage collimator to be used with a taper angle of eight degrees to accomplish the same requirement. Such a single stage collimator would be expected to be fully one third-longer in axial dimension and six percent greater in diameter than the multi-stage collimator of equivalent performance.
In addition to saving space, use of a non-specular inside surface with controlled light spread in the present collimator can reduce glare and non-uniform illumination associated with using a specularly reflective surface. A non-specular surface provides a controlled spread of light, less than approximately ten degrees, which eliminates the problems mentioned above, without unduly affecting the alignment angle since there is only one reflection.
It may now be appreciated that use of a multi-stage collimator changes the angle of low angle sunlight to a consistent high angle and, when a non-specular inside surface is used, with a minimum of glare. By maintaining relatively high angles to the diffuser/glazing independent of the solar altitude, consistent glazing efficiencies are maintained throughout the day. Furthermore, by establishing the downward angle of the sunlight and slightly spreading the light at the same time as described above, in some examples no diffuser need cover the open bottom end 38 of the collimator, simulating a recessed lighting fixture. Present principles also provide a consistent angular controlled light source for any light directing pendent or other optical element placed under the variable tapered tube.
A collimator assembly 100 may be provided as shown in FIG. 4 that has more than three stages and indeed may have a number of stages that approach the limit of infinity, i.e., each stage effectively has little or no thickness in the longitudinal dimension. Accordingly, the collimator 100 assumes a continuously curved shape in the longitudinal dimension as shown in FIG. 4 in which tangents 102 to the surface with respect to the longitudinal axis 104 of the collimator progressively define steeper angles from the collimator's light entry to the light exit. The equations above may be used at each axial location to establish the tangent at that location. The reflection angles and collimator dimensions shown in FIG. 4 are exemplary only and not limiting.
A collimator assembly 200 is shown in FIGS. 5-7 that has, from a round top opening 202 to a rectilinear bottom opening 204 , multiple collimator stages 206 , 208 , 210 , with the stages 206 - 210 being successively less flared than the next upper stage. Thus, the assembly 200 in FIGS. 5-7 is substantially identical to the collimators discussed above with the exception of the round to square configuration from top to bottom as shown. To achieve the round-to-square configuration, in which the top opening 202 may mate with the bottom of a cylindrical skylight tube while the bottom opening 204 may mate with a rectilinear diffuser or ceiling opening, the stages 206 - 210 transition progressively in the axial dimension from mostly round (the top stage 206 ) to predominantly rectilinear (bottom stage 210 ) as shown.
While the particular SKYLIGHT COLLIMATOR WITH MULTIPLE STAGES is herein shown and described in detail, it is to be understood that the subject matter which is encompassed by the present invention is limited only by the claims. | A non-specular skylight collimator has at least two axially successive collimator segments from top to bottom, with the segments becoming successively less flared from top to bottom. A skylight diffuser assembly typically covers the open end of the bottom segment. | 5 |
[0001] This application claims the benefit of U.S. Provisional Application No. 60/443,609, filed Jan. 30, 2003, entitled “Support for Selective Reduction Catalyst”, by Cutler et al.
BACKGROUND OF INVENTION
[0002] The present invention relates to a catalyst support for emission control technologies of nitrogen oxides (NOx) in diesel and gasoline direct injection (GDI) engines. In particular the invention relates to a ceramic catalyst support capable of achieving higher catalyst loadings without a pressure drop and/or mechanical strength penalty.
[0003] Diesel and GDI engines are becoming increasingly popular due to the promise of increased fuel efficiency. Similarly to conventional engines, the exhaust gas discharged from diesel and GDI engines needs to be purified of NOx. However, unlike conventional engines which employ three-way catalysts, the diesel and GDI engines cannot employ such catalysts because they produce exhaust gas with an excess amount of oxygen and require conditions where the air-fuel ratio is substantially stoichiometric. Technologies which address NOx reduction in the aforementioned type of engines, are selective catalytic reduction (SCR) and NOx adsorbers.
[0004] SCR has been successfully used for the past 20 years in stationary power plants to convert NOx from exhaust gas into nitrogen and water. The same technology now finds employment in mobile diesel engines as an exhaust gas aftertreatment system to help meet impending emission regulations (i.e., Euro IV (2005) and Euro V (2008) in Europe, and Lev 11 (2007) in the USA). In transferring SCR from stationary power plants to mobile diesel engines, however, several factors must be taken into consideration; these include engine exhaust temperature fluctuations, space velocity constraints (limited real estate under vehicle), urea storage and delivery system, sensors and detectors, long term on-vehicle durability and the like. Notwithstanding such obstacles, mobile SCR systems are currently being pursued in the industry.
[0005] The SCR system utilizes a reducing agent either dosed into the system or created in-situ, such ammonia or urea (preferred), to react with NOx on a suitable catalyst. Currently, there are three types of SCR catalysts; extruded, impregnated & wrapped and washcoated. Washcoated catalysts are the preferred industry choice. Typically, in such systems a catalyst is coated on an inert support substrate.
[0006] NOx adsorbers are similar in that they are made of a support having a catalyst washcoated thereon, and an additional component in the catalyst coating which stores the trapped NOx. The NOx is trapped and stored during lean operation phase of the engine operation and released during the rich phase.
[0007] In both technologies the catalyst support is most often formed of cordierite. Washcoated cordierite catalysts offer several advantages, including low cost, high cell density leading to high geometric surface areas, low coefficient of thermal expansion (CTE) and good thermal shock resistance. However, washcoating only provides a limited amount of catalyst per unit substrate volume as is directly related to the thickness of the coating. Increasing the coating layer is one way to increase catalyst loading, however, as a result the pressure drop across the structure increases, which in turn affects fuel efficiency and engine performance.
[0008] It would be considered an advancement in the art to obtain a support substrate for use in a SCR catalyst and being capable of attaining higher catalyst loadings without incurring a pressure drop penalty or sacrificing strength. The present invention provides such bodies.
SUMMARY OF INVENTION
[0009] In accordance with the present invention there is provided a novel support for NOx reduction based on washcoating technologies, such as SCR and NOx adsorbers. The support combines high porosity, with an interconnected pore structure, and a narrow pore size distribution, along with a low CTE. As a result the inventive structures allow for higher catalyst loadings than previously possible without a pressure drop penalty, or a loss in the mechanical strength.
[0010] Specifically, the inventive catalyst support comprises a honeycomb body composed of a porous ceramic material, and including a plurality of parallel cell channels traversing the body from a frontal inlet end to an outlet end thereof. The honeycomb body has a cell density of 100 cells/in 2 (15.5 cells/cm 2 ) to 900 cells/in 2 (141 cells/cm 2 ), preferably 400 cells/in 2 (62 cells/cm 2 ) to 600 cells/in 2 (94 cells/cm 2 ), and a wall thickness of 0.004 in. (0.10 mm) to 0.020 in. (0.50 mm).
[0011] The porous ceramic material is defined by a total porosity greater than 45 vol. %, preferably greater than 50 vol. %, and more preferably greater than 55 vol. %, and a network of interconnected pores with a narrow pore size distribution of pores having a median pore size greater than 5 micrometers but less than 30 micrometers, preferably less than 20 micrometers, and more preferably less than 15 micrometers. The support is further characterized by a low coefficient of thermal expansion (CTE) at 25-800° C., of less than 15×10 −7 /° C., preferably less than 10×10 −7 /° C., and more preferably less than 7×10 −7 /° C.
[0012] The porous ceramic material comprising the catalyst support honeycomb body is selected from the group consisting of titanates, silicates, aluminates, lithium aluminosilicates, carbides, nitrides, borides. In a preferred material the ceramic material is a silicate, more preferably a silicate ceramic predominately composed of a primarily crystalline phase comprising cordierite, and having a composition close to that of Mg 2 Al 4 Si 5 O 18 .
DETAILED DESCRIPTION OF INVENTION
[0013] The catalyst support in accordance with the present invention is a multicellular ceramic monolith, preferably comprising a honeycomb body having an inlet end and an outlet end, and a multiplicity of cells extending from the inlet end to the outlet end, the cells having porous walls. Suitable honeycomb structures have cellular densities from about 100 cells/in 2 (15.5 cells/cm 2 ) to about 900 cells/in 2 (141 cells/cm 2 ), preferably 400 cells/in 2 (62 cells/cm 2 ) to 600 cells/in 2 (94 cells/cm 2 ), and wall thickness of 0.004 in. (0.10 mm) to 0.020 in. (0.50 mm).
[0014] The catalyst support is further characterized by more open wall porosity for catalyst storage, as well as larger pores to improve catalyst accessibility during catalyst coating processes. Accordingly, a significantly higher catalyst loading can be attained than with commercially available cordierite substrates. Unlike conventional substrates which can only be coated on the walls due to low porosity and small pores, in the present invention the catalyst is loaded into the wall pores of the inventive supports. This not only provides for more catalyst per unit substrate volume, but also no pressure drop or mechanical strength penalty, and minimal impact on CTE in the resulting structure.
[0015] Accordingly, the total porosity is greater than 45 vol. %, preferably greater than 50 vol. %, and more preferably greater than 55 vol. %. The porosity is uniquely comprised of a network of interconnected pores with a narrow pore size distribution of pores having a median pore size greater than 5 micrometers but less than 30 micrometers, preferably less than 20 micrometers, and more preferably less than 15 micrometers. By narrow pore size distribution is meant that more than 85% of the total porosity has a median pore size of greater than 5 micrometers and less than 30 micrometers, preferably less than 20 micrometers, and more preferably less than 15 micrometers.
[0016] Good pore connectivity and narrow pore size distribution promote a low pressure drop regardless of the higher catalyst loadings. Also, a narrow pore size distribution is conducive to high mechanical strength. Strength is particularly important for structures with very thin webs (<0.008 in), and is inversely proportional to the radius of the largest pore, and therefore by modifying the large end of the pore size distribution the strength in the resulting product is greatly benefited.
[0017] Another advantage of the present invention is a low thermal expansion resulting in excellent thermal shock resistance (TSR). TSR is inversely proportional to the coefficient of thermal expansion (CTE). That is, honeycomb structures with low thermal expansion have good thermal shock resistance and can survive the wide temperature fluctuations that are encountered in application. Accordingly, the coated CTE from 22° to 800° C., as measured by dilatometry, is less than 15×10 −7 /° C., preferably less than 10×10 −7 /° C., and more preferably less than 7×10 −7 /° C.
[0018] The invention is especially suited for catalyst supports comprising ceramic materials such as titanates, silicates, aluminates, lithium aluminosilicates, carbides, nitrides, borides, as well as others. In particular, ceramic materials comprising silicon carbide, aluminum titanate, calcium aluminate, and the like. In a particularly preferred embodiment, the present invention is especially suitable for ceramic materials, such as those that yield cordierite, mullite, or mixtures of these on firing. Some examples of such mixtures are about 2-60% mullite, and about 30-96% cordierite, with allowance for other phases, typically up to about 10% by weight.
[0019] In order to obtain a cordierite body possessing the unique combination of properties described above it is necessary to utilize specific combinations of cordierite-forming raw materials in the batch mixture. Some batch mixture compositions that are especially suited to the practice of the present invention are those disclosed in co-pending, co-assigned U.S. patent application entitled “Magnesium Aluminum Silicate Structures for DPF Applications” by Beall et al., having serial No. 60/392,699, herein incorporated by referenced in its entirety. A particularly preferred batch composition consists essentially of 12 to 16% by weight magnesium oxide, 35 to 41% by weight alumina, and 43 to 53% by weight silica.
[0020] Other batch mixture compositions that are especially suited to the practice of the present invention are those disclosed in co-pending, co-assigned U.S. patent application entitled “Cordierite Ceramic Body and Method” by Gregory A. Merkel, having Ser. No. 10/354,326, herein incorporated by reference in its entirety. A particularly preferred batch composition consists essentially of 11 to 23% by weight silica, 28 to 40% by weight alumina, 39 to 42% by weight percent fine talc having a median particle diameter, as measured by laser diffraction, of less than 10 micrometers, preferably less than 7 micrometers, and more preferably less than 5 micrometers, and a B.E.T. specific surface area of greater than 5 m 2 /g, preferably greater than 8 m 2 /g. and 20 to 40 percent graphite as the pore former having a median particle diameter of between 15 and 50 micrometers, and optionally 8 to 17% by weight kaolin.
[0021] The batch composition could further include a pore former to better control the porosity and/or pore size, that is preferably a particulate material selected from the group consisting of graphite, cellulose, starch, synthetic polymers such as polyacrylates and polyethylenes, and combinations thereof. The weight percent of the pore former is computed as: 100×[weight of pore former/weight of cordierite-forming raw materials]. Preferably the pore former is added at 5 to 40 weight percent. Graphite and potato starch are preferred pore formers for purposes of the present invention. The median particle diameter of the pore former is at least 3 micrometers and not more than 200 micrometers, preferably at least 5 micrometers and not more than 1500 micrometers, and more preferably at least 10 micrometers and not more than 100 micrometers.
[0022] As it will be recognized by those skilled in the art, ceramic batches of the type described above are intimately blended with a vehicle and forming aids which impart plastic formability and green strength to the raw materials when they are shaped into a body. Forming is by any known method for shaping plastic mixtures, but preferably by extrusion which is well known in the art. Extrusion aids are used, most typically methyl cellulose which serves as a binder, and sodium stearate, which serves as a lubricant. The relative amounts of forming aids can vary depending on factors such as the nature and amounts of raw materials used, and the like. For example, the typical amounts of forming aids are about 2% to about 10% by weight of methyl cellulose, and preferably about 3% to about 6% by weight, and about 0.3% to about 2% by weight sodium stearate, and preferably about 0.6% by weight.
[0023] The aforementioned components are mixed together in dry form, and then with water as the vehicle. The amount of water can vary from one batch of materials to another and therefore is determined by pre-testing the particular batch for extrudability. The resulting plastic mixture is forced through a die to form a multicellular structure, preferably a honeycomb structure having a plurality of parallel cell channels traversing the body from a frontal inlet end to an outlet end thereof. The green honeycomb bodies are dried, and then fired at a sufficient temperature and for a sufficient time to form the final cordierite (Mg 2 Al 4 Si 5 O 18 ) product structure. Typically, firing is done by heating to a maximum temperature of about 1405° C. to 1430° C., over a time period of 50 to 300 hours, with a hold at top temperature of 5 to 25 hours. The resulting honeycomb structures are ready for coating with a catalyst and use in SCR systems.
[0024] To more fully illustrate the invention, the following non-limiting examples are presented below. All parts, portion and percentages are on a weight basis unless otherwise stated.
EXAMPLES
[0025] Batch mixtures, as listed in percent by weight, suitable for the formation of cordierite structures, are listed in TABLE II. TABLE I provides particle size information on the raw materials. Particle sizes were obtained via laser diffraction unless otherwise stated. Examples were prepared by mixing together 100 parts by weight of the dry ingredients (oxides plus pore formers) with about 4 to 6 parts by weight methyl cellulose and 1 part by weight sodium stearate. Example 4 additionally includes about 1 part by stearic acid, and 10 parts by weight polyalphyl olefin.
[0026] The dry mixtures were then plasticized with about 25 to 45 parts by weight deionized water and extruded into honeycomb having a nominal cell density of 200 cells/inch 2 and a wall thickness of 0.012 inches. The honeycombs were dried, and subsequently fired to a temperature of 1405 to 1415° C. (examples 1-3), 1425° C. (example 4), and 1430° C. (example 5), held at that temperature for 10 to 25 hours, and then cooled to room temperature.
[0027] Properties provided include the percent porosity, in volume percent, and median pore size, both as measured by mercury porosimetry, the mean or average coefficient of thermal expansion (CTE) as measured by dilatometry over a temperature of 25 to 800° C., and the modulus of rupture strength (MOR) in psi as measured by a four-point method on bars.
[0028] An examination of TABLE II reveals that the examples provided possess the claimed porosity of between about 49 and 61 vol. %, and median pore size of between about 7 and 14 micrometers. Furthermore the examples exhibit a low CTE of between about 4 and 13×10 −7 /° C.
[0029] It should be understood that while the present invention has been described in detail with respect to certain illustrative and specific embodiments thereof, it should not be considered limited to such, as numerous modifications are possible without departing from the broad spirit and scope of the present invention as defined by the appended claims.
TABLE I Raw Materials Raw Material Median Particle Diameter (μm) Talc 4.9 Magnesium Oxide 1.0* Alumina I 6.8 Alumina III 5.6-7.0* Alumina IV 1.8-3.5* Aluminum Hydroxide 5.0 Dispersable Boehmite — Silica I 23 Silica II 4.6 Graphite I (spherical) 29 Graphite II 36 Corn Starch 15
[0030] [0030] TABLE II Compositions and Properties Example Number 1 2 3 4 5 Talc 39.96 39.96 39.86 Alumina I 21.54 21.54 19.05 Alumina II Alumina III 28.9 35.0 Aluminum Hydroxide 16.35 16.35 14.01 Dispersable Boehmite 4.99 Magnesium Oxide 10.3 14.0 Silica I 22.15 22.15 22.09 Silica II 50.7 51.0 Graphite I 25.00 40.00 Graphite II 30.00 Corn Starch 10.0 % Porosity 54.7 61.3 54.3 52.9 49.0 Median Pore Size (μm) 12.1 13.8 10.4 7.3 8.6 CTE, 25-800° C. (10 −7 /° C.) 5.1 5.9 4.3 12.7 5.75 4-Point MOR (psi) — — — 2044 — | A catalyst support for use in technologies (i.e., SCR and NOx adsorbers) which address the reduction of NOx from exhaust emissions of diesel and GDI engines. The catalyst support has a honeycomb body composed of a porous ceramic material, and a plurality of parallel cell channels traversing the body from a frontal inlet end to an outlet end thereof. The porous ceramic material is defined by a total porosity greater than 45 vol. %, and a network of interconnected pores with a narrow pore size distribution of pores having a median pore size greater than 5 micrometers but less than 20 micrometers. The catalyst support is capable of attaining higher catalyst loadings without a pressure drop penalty. | 5 |
FEDERAL RESEARCH STATEMENT
The invention described herein was made by employees of the United States Government and may be manufactured and used by or for the Government of the United States of America for governmental purposes without the payment of any royalties thereon or therefore.
CROSS REFERENCE
This application is related to U.S. application Ser. No. 13/369,704 entitled “Adaptable Transponder for Multiple Telemetry Systems” and filed on Feb. 9, 2012, and U.S. application Ser. No. 13/424,754, entitled “System for Configuring Modular Telemetry Transponders” and filed on Mar. 20, 2012, which are hereby incorporated by reference in their entireties.
FIELD OF INVENTION
The present invention is a telemetry system, and more specifically is a rapidly deployed modular telemetry system which incorporates flexible design principles of Software Defined Radio (SDR) and Field Programmable Gate Array (FPGA) technology.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates an exemplary embodiment of components of a satellite telemetry system, wherein all system components have been prequalified for in flight use by NASA.
FIG. 2 illustrates an exemplary FPGA configuration to perform telemetry uplink and downlink functions to allow onboard flight computer to communicate with a ground control station.
TERMS OF ART
As used herein, the term “application specific integrated circuit” or “ASIC” means a computer chip or logic circuit manufactured to perform a specific function, usually involving a large number of gates.
As used herein, the term “ARM processor” means a 32-bit reduced instruction set computer (RISC) instruction set architecture (ISA) developed by ARM Holdings, a commercial processor, or any functional equivalent.
As used herein, the term “BCH error-checking protocol” means a CCSDS protocol that incorporates the BCH multilevel cyclic variable-length digital error-correcting code used to correct multiple random error patterns or any algorithmic and functional equivalent or derivative of this protocol.
As used herein, the term “convolutional code” refers to a type of error-correcting code used to achieve reliable data transfer in digital communication systems. This is a type of channel coding which adds patterns of redundancy to the data in order to improve the signal-to-noise ratio (SNR) for more accurate decoding at the receiving end.
As used herein, the term “CCSDS” means compliant with the standards of the Consultative Committee for Space Data Systems.
As used herein, the term “check module” refers to any hardware or software component which utilizes a watchdog, watchdog timer, heartbeat pulse or combinations thereof to create and maintain a semi-redundant and fault tolerant system between two components.
As used herein, the term “downlink component” refers to any components, including but not limited to filters, synchronizers, error-checking processing components, general packet processing components, or any other components that or facilitate the communication from flight computer (e.g., a satellite) to a ground computer.
As used herein, the term “Field-Programmable Gate Array” or “FPGA” means an integrated circuit that can be programmed after manufacturing to perform the functions of an ASIC.
As used herein, the term “First In, First Out” or “FIFO” refers to the principle organizing and manipulation of data relative to time and prioritization. This expression describes the principle of a queue-processing technique or servicing conflicting demands by ordering the process by handling first the data that arrives first, with data that comes next waiting until the processing the first is finished.
As used herein, the term “forward error correction” or “FEC” means a system of error control for data transmission wherein the sending system adds systematically-generated redundant data to its messages. This allows a receiver to detect and correct errors in the transmission without having to request the retransmission of data.
As used herein, the term “flight computer interface” means a component of a telemetry apparatus that allows that apparatus to communicate or be operatively coupled with the main computer system of a satellite, referred to as the flight computer.
As used herein, the term “Low Density Parity Check” or “LDPC” means a linear error correction code used for transmitting messages that can withstand noisy transmission signals.
As used herein, the term “microcontroller” means a controller on a single integrated circuit containing a processor core, memory, and programmable input/output peripherals.
As used herein, the term “multiplexer” means a telecommunications device that combines several input information signals into one output signal, which carries several communications channels.
As used herein, the term “PIC M32” means a 32-bit commercial microcontroller manufactured by Microchip Technology Inc. or any functionally equivalent device by any other vendor.
As used herein, the term “pseudo-randomization protocol” means a CCSDS protocol that synchronizes data by using a deterministic procedure that produces random numbers within definable limits or any algorithmic and functional equivalent or derivative of this protocol known in the art.
As used herein, the term “Reed-Solomon protocol” means a CCSDS protocol that incorporates the non-binary cyclic error-correcting codes, or any algorithmic and functional equivalent or derivative of this Reed-Solomon protocol known in the art. Reed-Solomon codes are one type of BCH codes.
As used herein, the term “software defined radio” or “SDR” means a radio communications system where components that have been typically implemented in hardware (such as mixers, filters, amplifiers, modulators/demodulators, and detectors) are instead implemented by means of software on an embedded computing device.
As used herein, the term “synchronous 422 interface” means a flight computer interface that complies with the RS-422 standard developed by the American National Standards Institute or any algorithmic and functional equivalent or derivative of this protocol.
As used herein, the term “transponder” means any automatic device that receives, amplifies, and retransmits a signal on a different frequency.
As used herein, the term “telemetry system” refers to technology used by a satellite to transmit data to a monitoring station.
As used herein, the term “turbo code” means a code in the class of high-performance forward error-correction codes used achieve reliable information transfer in the presence of data-corrupting noise.
As used herein, the term “universal asynchronous receiver/transmitter” or “UART” means an individual integrated circuit used for serial communications over the serial port of a computer.
As used herein, the term “uplink components” refers to filters, synchronizers, error-checking processing components, general packet processing components, or any processing components that can interface from a ground computer to a flight computer.
As used herein, the term “Viterbi algorithm” means the algorithm first conceived by Andrew Viterbi for decoding convolutional codes over digital communication links for encryption and auto-ranging.
BACKGROUND
Software Defined Radio (SDR) and Field Programmable Gate Array (FPGA) devices are technologies which allow enormous flexibility in the design of communications components and systems.
Despite the widespread availability of these technologies, they have not been systematically integrated into telemetry system design processes to increase efficiency and reduce cost associated with customizing telemetry systems.
For example, a transponder for a NASA communication system costs more than $500,000. There is currently a need to reconfigure countless hardware components for a specific telemetry application.
Software Defined Radio (SDR) is a term used to refer to technologies which minimizes the amount of analog and radio frequency components needed to convert radio frequencies into digital frequencies. The SDR concept and principles of design use a minimum amount of analog/Radio Frequency components to up/down-convert the RF signal to/from a digital format. Once analog signals are converted to digital signals, all other processing (filtering, modulation, demodulation, etc.) can be done in software rather than with hardware.
A field programmable gate array (FPGA) is an integrated circuit designed to be configured by a user after manufacturing and is a simplified and economical alternative to an application specific integrated circuit (ASIC). In theory, an FPGA can be used to implement any logical function that an ASIC can perform. For example, a user can embed various programming languages, processing functions and FEC error checking protocols into an FPGA.
Error checking protocols are critical to all telemetry systems. Error detection, correction and control enable reliable delivery of digital data over unreliable communication channels without requiring retransmission of data. Error detection techniques allow detecting such errors, while error correction enables reconstruction of the original data.
Error checking protocols are used for both uplink and downlink communications. FEC protocols, in a particular are used for controlling errors over unreliable communication channels.
There are several protocols for telemetry systems that comply with standards developed by the Consultative Committee for Space Data Systems (CCSDS), and which may be used in conjunction for specific telemetry applications. Examples of CCSDS protocols related to telemetry include Reed-Solomon (forward error correction), ASIC BCH (error detection), and Pseudo-Randomization (required for synchronization). These protocols are typically programmed onto microchips and embedded processors that are combined into telemetry systems. Each FEC or detection code may be considered an intellectual property (IP) block that can be added or removed from the design to support mission requirements using proven IP.
There is an unmet need for an optimized telemetry transponder device and system that utilizes the efficiencies and flexibility of SDR and FPGA technology to meet all of NASA's telemetry needs and minimize the cost of expensive reconfiguration.
There is a further unmet need for telemetry systems which can be modularly reconfigured with various CCSDS compliant error checking protocols to accommodate diverse telemetry systems without requiring a complete redesign of a transponder.
SUMMARY OF THE INVENTION
The present invention is a rapidly deployed modular telemetry system comprised of at least one flight computer, at least one microcontroller, at least one FPGA component, at least one error-checking encoder, and at least one flight computer interface. The FPGA is configured with CCSDS compliant software and operatively connected to the microcontroller. The error-checking encoder component is operatively connected with the FPGA to perform at least one error-checking protocol. The flight computer interface is operatively connected with the FPGA and flight computer. The system also includes a receiver deck for receiving signals, a transmitter deck and a power source.
DETAILED DESCRIPTION OF INVENTION
For the purpose of promoting an understanding of the present invention, references are made in the text to exemplary embodiments of satellite telemetry system, only some of which are described herein. It should be understood that no limitations on the scope of the invention are intended by describing these exemplary embodiments. One of ordinary skill in the art will readily appreciate that alternate but functionally equivalent components, materials, and placement may be used. The inclusion of additional elements may be deemed readily apparent and obvious to one of ordinary skill in the art. Specific elements disclosed herein are not to be interpreted as limiting, but rather as a basis for the claims and as a representative basis for teaching one of ordinary skill in the art to employ the present invention.
It should be understood that the drawings are not necessarily to scale; instead, emphasis has been placed upon illustrating the principles of the invention. In addition, in the embodiments depicted herein, reference numerals in the various drawings refer to identical or near identical structural elements.
Moreover, the terms “substantially” or “approximately” as used herein may be applied to modify any quantitative representation that could permissibly vary without resulting in a change in the basic function to which it is related.
FIG. 1 illustrates an exemplary embodiment of rapidly deployed modular telemetry (RDMT) system 100 . The embodiment shown is designed for use in small and micro-satellites. In the embodiment shown, flight computer 10 includes the Command and Data Handling (C&DH) system of the satellite. The C&DH system receives and executes commands; collects, stores, and transmits house-keeping data; and supports the onboard payloads. Flight computer 10 receives data and commands from, and sends data and commands to, processor deck 80 through flight computer interface 20 . RMDT system 100 further includes receiver deck 60 and transmitter deck 70 .
In the exemplary embodiment shown, processor deck 80 is capable of decoding uplink commands and encoding downlink data in a variety of formats depending on engineering and satellite mission requirements. In the exemplary embodiment shown, processor deck 80 comprises flight computer interface 20 , microcontroller 30 , field-programmable gate array (FPGA) 40 , check module 45 , and encoder 50 .
As illustrated in FIG. 1 , flight computer interface 20 is a balanced, serial interface for the transmission of data and commands. Flight computer interface 20 transfers data and commands from flight computer 10 to FPGA 40 and microcontroller 30 , and it then transfers data back to flight computer 10 . In further exemplary embodiments, flight computer interface 20 may be a synchronous 422 interface or a universal asynchronous receiver/transmitter (UART).
In the exemplary embodiment shown, microcontroller 30 is the internal watchdog for processor deck 80 . In these exemplary embodiments, microcontroller 30 is a PIC M32.
In the exemplary embodiment shown in FIG. 1 , FPGA 40 performs decoding and synchronizing functions. In the exemplary embodiment shown, FPGA 40 is an integrated circuit that is operatively connected to flight computer interface 20 , microcontroller 30 , and encoder 50 . FPGA 40 is easily altered via software to perform various functions and to connect with different types of computer hardware.
FPGA 40 is configured with software enabling it to perform various CCSDS protocols, including but not limited to a BCH error-checking protocol and a pseudo-randomization protocol. In addition, FPGA 40 may be modified to include other modules configured with software to perform other CCSDS protocols, depending on the needs of the particular satellite and its mission, such as Turbo codes, convolutional code, Viterbi, encryption, auto-ranging, low density parity check (LDPC), other versions of the BCH error-correcting protocol and variations of FEC codes whether known or unknown. In various other embodiments, FPGA 40 may be a 32 bit ARM processor. In these embodiments, FPGA 40 could include support of other satellite communication systems such as television, music, etc.
In the exemplary embodiment shown, processor deck 80 contains check module 45 operatively connected between microcontroller 30 and FPGA 40 . Check module 45 uses multiple levels of watchdogs and heartbeat pulses to create a semi-redundant and fault tolerant system between microcontroller 30 and FPGA 40 . While RMDT system 100 may omit check module 45 , check module 45 significantly increases reliability of satellite system 100 by giving it the ability to monitor, detect and correct incorrect operation of any component within the SDR, for example, radiation exposure that causes unintentional operation of the SDR. Additionally, check module 45 allows offloading of flight computer 10 , and specifically the C&DH system, from tasks associated with telemetry encoding/decoding and data formatting in relation to ground interface activities. Therefore, this allows the C&DH system to send most of the data to the satellite telemetry system 100 , and allows the system to conduct the CCSDS protocol framing and decoding/encoding implementing in FPGA 40 and encoder 50 .
In the exemplary embodiment shown in FIG. 1 , encoder 50 is an application specific integrated circuit (ASIC) configured with Reed-Solomon forward error correction. It detects and corrects multiple random symbol errors to allow for the transmittal of data without potentially corrupting errors. Encoder 50 then transfers data to transmitter deck 70 for transmission to receiving station 12 . However, in further exemplary embodiments, the functions of encoder 50 are incorporated into FPGA 40 rather than contained in a separate ASIC. Incorporating these functions onto an FPGA greatly increases the flexibility of the operations and is limited only by the internal space of the device and the imagination of the design engineer(s). In the present embodiment, processor deck 80 , transmitter deck 70 , and receiver deck 60 are powered by a power deck operating at 200 mW of power.
FIG. 2 is an exemplary embodiment of FPGA 40 , which performs uplink function 200 and downlink function 210 . In the embodiment shown, the portion of FPGA 40 that handles incoming transmissions from receiver deck 60 (shown in FIG. 1 ) comprises bit sync 110 , randomizer 120 , BCH encoder 130 , BCH processor 140 , first in, first out (FIFO) control processor 150 , and FIFO computer chip 160 .
In the embodiment shown, bit sync 110 synchronizes the clock of the incoming data stream clock to the internal clock of randomizer 120 . BCH encoder 130 then uses internal commands to encode incoming data streams to match the parameters set by programmers of FPGA 40 . In the embodiment shown, BCH processor 140 ensures that incoming data has been corrected and matches the internal commands of BCH encoder 130 .
In the exemplary embodiment shown in FIG. 2 , FIFO control processor 150 controls the activity of FIFO computer 160 and allows for the turning off of the first in, first out capabilities. FIFO control processor 150 can fine-tune the capabilities of FIFO computer chip 160 . In the embodiment shown, FIFO computer chip 160 handles all incoming data on a first come, first serve basis, taking care of whatever information is transmitted first, causing the rest of the information to wait for processing.
In the embodiment shown, the portion of FPGA 40 that handles outgoing transmissions sent to transmitter deck 70 (shown in FIG. 1 ) is comprised of attached sync marker generator 170 , Reed-Solomon ASIC control 180 , pseudo random generator 190 , and multiplexer 195 . Reed-Solomon ASIC Control 180 performs forward error correction that detects and corrects multiple random symbol errors. In the embodiment shown, pseudo random generator 190 uses a deterministic procedure to produce numbers that are random, but only within the consistent programming that has been provided. Attached sync marker generator 170 is necessary for the synchronization of the Reed-Solomon ASIC control 180 , enabling a proper transmission of data for downlink function 210 . In the embodiment shown, ASIC control 180 then consolidates the frequencies of the transmissions into one complex and coherent signal, which is then sent to transmitter deck 70 (shown in FIG. 1 ). | The present invention is a telemetry system, and more specifically is a rapidly deployed modular telemetry apparatus which utilizes of SDR technology and the FPGA programming capability to reduce the number of hardware components and programming required to deploy a telemetry system. | 7 |
CROSS REFERENCE TO RELATED APPLICATIONS
This application is a continuation-in-part of patent application Ser. No. 09/286,650, filed Apr. 6, 1999, entitled “Method and Apparatus for Determining Position in Pipe”, now U.S. Pat. No. 6,333,699, which claims the benefit of U.S. Provisional Application No. 60/098,284, filed on Aug. 28, 1998, now abandoned.
This application is related to the following copending patent applications: U.S. patent application Ser. No. 09/656,720, filed on Sep. 7, 2000 and entitled “Method and System for Performing a Casing Conveyed Perforating Process and Other Operations in Wells”; U.S. patent application Ser. No. 09/843,998, filed on Apr. 27, 2001 and entitled “Process and Assembly for Identifying and Tracking Assets”; and U.S. patent application Ser. No. 10/032,114, filed on Dec. 21, 2001 and entitled “Method and Apparatus for Determining Position in a Pipe”.
FIELD OF THE INVENTION
This invention relates to generally to wells used in the production of fluids such as oil and gas. More specifically, this invention relates to a method and system for performing various operations and for improving production in wells.
BACKGROUND OF THE INVENTION
Different operations are performed during the drilling and completion of a subterranean well, and also during the production of fluids from subterranean formations via the completed well. For example, different downhole operations are typically performed at some depth within the well, but are controlled at the surface.
A perforating process is one type of downhole operation that is used to perforate a well casing. A conventional perforating process is performed by placing a perforating tool (i.e., perforating gun) in a well casing, along a section of the casing proximate to a geological formation of interest. The perforating tool carries shaped charges that are detonated using a signal transmitted from the surface to the charges. Detonation of the charges creates openings in the casing and concrete around the casing, which are then used to establish fluid communication between the geological formation, and the inside diameter of the casing.
Another example of a downhole operation is the setting of packers within the well casing to isolate a particular section of the well or a particular geological formation. In this case, a packer can be placed within the well casing at a desired depth, and then set by a setting tool actuated from the surface. Other exemplary downhole operations include the placement of logging tools at a particular geological formation or depth within the well casing, and the placement of bridge plugs, casing patches, tubulars, and associated tools in the well casing.
One critical aspect of any downhole operation involves ascertaining the depth in the well where the operation is to be performed. The depth is typically ascertained using well logs. A conventional well log includes continuous readings from a logging instrument, and an axis which represents the well depths at which the readings were obtained. The instrument readings measure rock characteristics such as natural gamma ray radiation, electrical resistivity, density and acoustic properties. Using these rock characteristics geological formations of interest within the well, such as oil and gas bearing formations, can be identified. The well is initially logged “open hole” which becomes the bench mark for all future logs. After the well is cased, a cased hole log is then prepared and correlated, or “tied in”, to the open hole log.
Using the logs and a positioning mechanism, such as a wire line or coiled tubing, coupled to an odometer, a tool can be placed at a desired depth within the well, and then actuated as required to perform the downhole operation. One problem with conventional logging and positioning techniques is that it is difficult to accurately identify the depth of the tool, and to correlate the depth to the open hole logs.
FIG. 1 illustrates a prior art perforating process being performed in an oil and gas well 10 . The well 10 includes a well bore 12 , and a casing 14 within the well bore 12 surrounded by concrete 16 . The well 10 extends from an earthen surface 18 through geological formations within the earth, which are represented as Zones A, B and C. The casing 14 is formed by tubular elements, such as pipe or tubing sections, connected to one another by collars 20 . In this example the tubular elements that form the casing 14 are about 40 feet long so that the casing collars 20 are forty feet apart. However, tubular elements with shorter lengths (e.g., twenty feet) can be interspersed with the forty feet lengths to aid in depth determinations. Thus in FIG. 1 two of the casing collars 20 are only twenty feet apart.
For performing the perforating operation a perforating tool 22 has been lowered into the casing 14 on a wire line 24 . A mast 26 and pulleys 28 support the wire line 24 , and a wire line unit 30 controls the wire line 24 . The wire line unit 30 includes a drive mechanism 32 that lowers the wire line 24 and the tool 22 into the well 10 , and raises the wire line 24 and the tool 22 out of the well 10 at the completion of the process. The wire line unit 30 also includes an odometer 34 that measures the unwound length of the wire line 24 as it is lowered into the well 10 , and equates this measurement to the depth of the tool 22 within the well.
During formation of the well 10 an open hole log 36 was prepared. The open hole log 36 includes various instrument readings, such as gamma ray readings 38 and spontaneous potential (SP) readings 40 which are plotted as a function of depth in feet. For simplicity only a portion of the open hole log 36 , from about 7000 feet to about 7220 feet, is illustrated. However, in actual practice the entire well 10 from the surface 18 to the bottom of the well 10 may be logged. The open hole log 36 permits skilled artisans to ascertain the oil and gas containing formations within the well 10 and the most productive intervals of those formations. For example, based on the gamma ray readings 38 and the SP readings 40 it is determined that Zone A may contain oil and gas reserves. It is thus desired to perforate the casing 14 along a section thereof proximate to Zone A.
In addition to the open hole log 36 , following casing of the well 10 , cased hole gamma ray readings 44 are made, and a casing collar log 42 can be prepared. The casing collar log 42 is also referred to as a PDC log (perforating depth control log). The casing collar log 42 can be used to identify the section of the casing 14 proximate to Zone A where the perforations are to be made.
Using techniques and equipment that are known in the art, the casing collar log 42 can be accurately correlated, or “tied in”, to the open hole log 36 . However, using conventional positioning mechanisms, such as the wire line unit 30 , it may be difficult to accurately place the perforating tool 22 at the required depth within the well. For example, factors such as stretching, elongation from thermal effects, sinusoidal and helical buckling, and deformation of the wire line 24 can affect the odometer readings, and the accuracy of the odometer readings relative to the open hole odometer readings.
Thus, as shown in FIG. 1 , the odometer readings which indicate the depth of the perforating tool 22 , may not equate to the actual depths, as reflected in the open hole log 36 and the casing collar log 42 . In this example, the odometer readings differ from the depths identified in the open hole log 36 and the casing collar log 42 by about 40 feet. With this situation, when the perforating tool 22 is fired, the section of casing 20 proximate to Zone A may be only partially perforated, or not perforated at all.
Because of these tool positioning inaccuracies, various correlative joint logging and wire logging techniques have been developed in the art. For example, one prior art technique uses electronic joint sensors, and electrically conductive wire line, to determine joint-to-joint lengths, and to correlate the odometer readings of the wire line to the casing collar log. Although these correlative joint logging and wire line logging techniques are accurate, they are expensive and time consuming. In particular, additional crews and surface equipment are required, and additional wire line footage charges are incurred.
In addition to tool positioning inaccuracies, computational errors also introduce inaccuracies in depth computations. For example, a tool operator can make computational errors by thinking one number (e.g., 7100), while the true number may be different (e.g., 7010). Also, the tool operator may position the tool by compensating a desired amount in the uphole direction, when in reality the downhole direction should have been used. These computational errors are compounded by fatigue, the weather, and communication problems at the well site.
It would be desirable to obtain accurate depth readings for downhole tools without the necessity for complicated and expensive correlative joint logging and wire logging techniques. In addition, it would be desirable to control down hole operations and processes without having to rely on inaccurate depth readings contaminated by computational errors. The present invention is directed to an improved method and system for performing operations and processes in wells, in which the depths of down hole tools are accurately ascertained and used to control the operations and processes.
Another limitation of conventional downhole operations that are dependent on depth measurements, is that downhole tools must first be positioned in the well, and then actuated from the surface. This requires additional time and effort from well crews. In addition, surface actuation introduces additional equipment and variables to the operations. It would be advantageous to be able to control downhole operations without the requirement of surface actuation of the downhole tools. With the present invention actuation of downhole tools can be performed in the well at the required depth.
SUMMARY OF THE INVENTION
In accordance with the present invention a method and a system for performing various operations in wells, and for improving production in wells, are provided. Exemplary operations that can be performed using the method include perforating processes, packer setting processes, bridge plug setting processes, logging processes, inspection processes, chemical treating processes, casing patch processes, jet cutting processes and cleaning processes. Each of these processes, when performed in a well according to the method, improves the well and improves production from the well.
In an illustrative embodiment the method is used to perform a perforating process in an oil or gas production well. The well includes a well bore, and a well casing, extending from an earthen or subsea surface into various geological zones within the earth. The well casing includes lengths of pipe or tubing joined together by casing collars.
The method includes the initial step of providing identification devices at spaced intervals along the length of the well casing. The identification devices can comprise active or passive radio identification devices installed in each casing collar of the well casing. Each radio identification device is uniquely identified, and its depth, or location, within the well is accurately ascertained by correlation to well logs. Similarly, each casing collar is uniquely identified by the radio identification device contained therein, and a record of the well including the depth of each casing collar and identification device is established.
The method also includes the step of providing a reader device, and a transport mechanism for moving the reader device through the well casing proximate to the identification devices. In the illustrative embodiment the reader device comprises a radio frequency transmitter and receiver configured to provide transmission signals for reception by the identification devices. The identification devices are configured to receive the transmission signals, and to transmit response signals back to the reader device. The transport mechanism for the reader device can comprise a wire line, tubulars, coil tubing, a robotic mechanism, a fluid transport mechanism such as a pump or a blower, a free fall arrangement, or a controlled fall arrangement such as a parachute.
In addition to transmitting and receiving signals from the identification devices, the reader device is also configured to transmit control signals for controlling a process tool, as a function of the response signals from the identification devices. For example, the reader device can control a perforating tool configured to perforate the well casing. Specifically, the reader device and the perforating tool can be transported together through the well casing past the identification devices. In addition, the reader device can be programmed to transmit the control signal to detonate the perforating tool, upon reception of a response signal from an identification device located at a predetermined depth or location within the well. Stated differently, the reader device can be programmed to control the perforating tool responsive to locating a specific identification device.
As other examples, the reader device can be configured to control setting tools for packers, bridge plugs or casing patches, to control instrument readings from logging tools, and to control jet cutters and similar tools. With the method of the invention the true depth of the process tool can be ascertained in real time by the reader device using response signals from the identification devices. Accordingly, there is no need to ascertain the depth of the tool using an odometer, and expensive wire logging techniques. In addition, operator computational errors are reduced because true depth readings can be provided without the requirement of additional computations. Further, for some processes, there is no need to transmit signals to the surface, as the reader device can be programmed to control the process in situ within the well.
However, it is to be understood that the method of the invention can also be practiced by transmission of the control signals from the reader device to a controller or computer at the surface, and control of the process tool by the controller or computer. In addition, control of the process tool can be performed dynamically as the process tool moves through the well with the reader device, or statically by stopping the process tool at a required depth. Further, the method of the invention can be used to control a multi stage process, or to control a tool configured to perform multiple processes. For example, a combination packer setting and perforating tool can be configured to perform packer setting and perforating processes, as a function of true depth readings obtained using the method of the invention.
In the illustrative embodiment the system includes the identification devices installed in casing collars at spaced intervals along the well casing. The identification devices include a programmable element, such as a transceiver chip for receiving and storing identification information, such as casing collar and depth designations. Each identification device can be configured as a passive device, an active device having an antenna, or a passive device which can be placed in an active state by transmission of signals through well fluids.
The system also includes the reader device and the process tool configured for transport through the well casing. In addition to the transmitter and receiver, the reader device includes one or more programmable memory devices, such as semiconductor chips configured to receive and store information. The reader device also includes a power source such as a power line to the surface, or a battery. In addition, the reader device includes a telemetry circuit for transmitting the control signals, which can be used to control the process tool, and to provide depth and other information to operators and equipment at the surface. The system can also include a computer configured to receive and process the control signals, and to provide and store information in visual or other form for well operators and equipment. Further, the system can include a controller configured to process the control signals for controlling the process tool and various process equipment. The controller can be located at the surface, or on the process tool, to provide a self contained system. Also, the system can be transported to a well site in the form of a kit, and then assembled at the well site.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic diagram of a prior art downhole operation being performed using well logs and odometer readings from a tool positioning mechanism;
FIG. 2 is a flow diagram illustrating steps in the method of the invention for controlling a perforating process in a well;
FIGS. 3A and 3B are schematic cross sectional views illustrating a system constructed in accordance with the invention for performing the perforating process;
FIG. 3C is an enlarged portion of FIG. 3B , taken along section line 3 C, illustrating a perforating tool of the system;
FIG. 3D is an enlarged portion of FIG. 3A , taken along section line 3 D, illustrating a reader device and an identification device of the system;
FIG. 3E is an enlarged cross sectional view taken along section line 3 E of FIG. 3D illustrating a portion of the reader device;
FIG. 3F is a side elevation view of an alternate embodiment active reader device and threaded mounting device;
FIG. 4A is an electrical schematic for the system;
FIG. 4B is a view of a computer screen for a computer of the system;
FIGS. 5A and 5B are schematic views illustrating exemplary spacer elements for spacing the reader device of the system from the perforating tool of the system;
FIGS. 6A-6D are schematic cross sectional views illustrating various alternate embodiment transport mechanisms for the system;
FIGS. 7A and 7B are schematic cross sectional views illustrating an alternate embodiment system constructed in accordance with the invention for performing a packer setting process in a well;
FIG. 7C is an enlarged portion of FIG. 7A taken along section line 7 C illustrating a threaded connection of a tubing string of the alternate embodiment system; and
FIGS. 8A-8C are schematic cross sectional views illustrating an alternate embodiment multi stage method and system of the invention for performing a packer setting and a perforating processes in combination.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 2 , broad steps in a method for controlling an operation or process in a subterranean well in accordance with the invention are illustrated. The method, broadly stated, includes the steps of:
A. Providing a process tool.
B. Providing a reader device in signal communication with the process tool.
C. Providing a transport mechanism for the process tool and the reader device.
D. Providing spaced identification devices in a well casing readable by the reader device.
E. Uniquely identifying each identification device and determining its depth, or location, in the well using well logs.
F. Programming the reader device to transmit a control signal to the process tool upon reception of a response signal from a selected identification device.
G. Transporting the process tool and the reader device through the well casing.
H. Reading the identification devices using the reader device.
I. Transmitting the control signal to the process tool upon reception of the signal from the selected identification device to actuate the process tool at a selected depth.
Referring to FIGS. 3A-3D , a system 50 constructed in accordance with the invention is illustrated. The system 50 is installed in a subterranean well 52 , such as an oil and gas production well. In this embodiment the system 50 is configured to perform a perforating process in the well 52 . The perforating process performed in accordance with the invention provides an improved well 52 , and improves production from the well 52 .
The well 52 includes a well bore 54 , and a well casing 56 within the well bore 54 surrounded by concrete 56 . The well 52 extends from an earthen surface 60 through geological formations within the earth, which are represented as Zones E, F and G. The earthen surface 60 can be the ground, or alternately a structure, such as an oil platform located above water. In the illustrative embodiment, the well 52 extends generally vertically from the surface 60 through Zones E, F, and G. However, it is to be understood that the method can also be practiced on inclined wells, and on horizontal wells.
The well casing 56 comprises a plurality of tubular elements 62 , such as lengths of metal pipe or tubing, connected to one another by collars 64 . The casing 56 includes an inside diameter adapted to transmit fluids into, or out of, the well 52 , and an outside diameter surrounded by the concrete 58 . The collars 64 can comprise couplings having female threads adapted for mating engagement with male threads on the tubular elements 62 . Alternately, the collars 64 can comprise weldable couplings adapted for welding to the tubular elements 62 .
Also in the illustrative embodiment the casing 56 is illustrated as having the same outside diameter and inside diameter throughout its length. However, it is to be understood that the casing 56 can vary in size at different depths in the well 52 , as would occur by assembling tubulars with different diameters. For example, the casing 56 can comprise a telescoping structure in which the size thereof decreases with increasing depth.
Based on an open hole well log ( 36 - FIG. 1 ), or other information, it is determined that Zone F of the well 52 may contain oil and gas. It is thus desired to perforate the casing 56 proximate to Zone F to establish fluid communication between Zone F, and the inside diameter of the well casing 56 .
For performing the perforating process, the system 50 includes a perforating tool 68 , and a reader device 70 in signal communication with the perforating tool 68 . The system 50 also includes a plurality of identification devices 72 ( FIG. 3D ) attached to the collars 64 on the casing 56 , and readable by the reader device 70 . In addition, the system 50 includes a transport mechanism 66 W for transporting the perforating tool 68 and the reader device 70 through the well casing 56 to Zone F. If desired, the system 50 can be transported to the well 52 as a kit, and then assembled at the well 52 .
As shown in FIG. 3C , the perforating tool 68 includes a detonator 74 (illustrated schematically) and a detonator cord 76 in signal communication with the detonator 74 . The detonator 74 can comprise a commercially available impact or electrical detonator configured for actuation by a signal from the reader device 70 . Similarly, the detonator cord 76 can comprise a commercially available component. The detonator 74 and the detonator cord 76 are configured to generate and apply a threshold detonating energy to initiate a detonation sequence of the perforating tool 68 . In the illustrative embodiment, the detonator 74 is located on, or within, the perforating tool 68 .
As shown in FIG. 3C , the perforating tool 68 also includes one or more charge carriers 78 each of which comprises a plurality of charge assemblies 80 . The charge carriers 78 and charge assemblies 80 can be similar to, or constructed from, commercially available perforating guns. Upon detonation, each charge assembly 80 is adapted to blast an opening 82 through the casing 56 and the concrete 58 , and into the rock or other material that forms Zone F.
As shown in FIG. 3D , each collar 64 includes an identification device 72 . Each identification device 72 can be attached to a resilient o-ring 86 placed in a groove 84 within each collar 64 .
In the illustrative embodiment, the identification devices 72 comprise passive radio identification devices (PRIDs). PRIDs are commercially available and are widely used in applications such as to identify merchandise in retail stores, and books in libraries. The PRIDs include a circuit which is configured to resonate upon reception of radio frequency energy from a radio transmission of appropriate frequency and strength. Passive PRIDs do not require a power source, as the energy received from the transmission signal provides the power for the PRIDs to transmit a reply signal during reception of the transmission signal.
The identification device 72 includes an integrated circuit chip, such as a transceiver chip, having memory storage capabilities. The integrated circuit chip can be configured to receive RF signals and to encode and store data based on the signals. During a data encoding operation each identification device 72 can be uniquely identified such that each collar 64 is also uniquely identified. This identification information is indicated by the C 1 -C 8 designations in FIGS. 3A and 3B . In addition, the depth of each collar 64 can be ascertained using well logs, as previously explained and shown in FIG. 1 . The depth information can then be correlated to the identification information encoded into the identification device 72 . A record can thus be established identifying each collar 64 and its true depth in the well 52 .
Alternately, as shown in FIG. 3F , identification device 72 A can be in the form of an active device having a separate power source such as a battery. In addition, the identification device 72 A can include an antenna 89 for transmitting signals. Alternately, an identification device (not shown) can be configured to transmit signals through a well fluid or other transmission medium within the well 52 . Such an identification device is further described in previously cited parent application Ser. No. 09/286,650, which is incorporated herein by reference.
As also shown in FIG. 3F , the identification device 72 A can be contained in a threaded mounting device 87 . The threaded mounting device 87 can comprise a rigid, non-conductive material such as a plastic. The threaded mounting device 87 is configured to be screwed into the middle portions of the casing collar 64 ( FIG. 3D ), and to be retained between adjacent tubular elements of the casing 56 . The threaded mounting device 87 includes a circumferential groove 91 for the antenna 89 , and a recess 93 for the identification device 72 A. If desired, the antenna 89 and the identification device 72 A can be retained in the groove 91 and the recess 93 using an adhesive or a suitable fastener.
Referring to FIG. 3E , the reader device 70 is shown in greater detail. The reader device 70 is configured to transmit RF transmission signals at a selected frequency to the identification devices 72 , and to receive RF response signals from the identification devices 72 . As such, the reader device 70 includes a base member 77 having a transmitter 73 configured to transmit transmission signals of a first frequency to the identification devices 72 . The reader device 70 includes a receiver 71 on the base member 77 configured to receive signals of a second frequency from the identification devices 72 .
Preferably, the transmitter 73 is configured to provide relatively weak transmission signals such that only an identification device 72 within a close proximity (e.g., one foot) of the reader device 70 receives the transmission signals. Alternately, the antenna of the reader device 70 can be configured to provide highly directional transmission signals such that the transmission signals radiate essentially horizontally from the reader device 70 . Accordingly, the transmission signals from the reader device 70 are only received by a single identification device 72 as the reader devices passes in close proximity to the single identification device 72 .
In addition to the transmitter 73 and the receiver 71 , the reader device 70 includes a cover 79 made of an electrically non-conductive material, such as plastic or fiberglass. The reader device 70 also includes o-rings 75 on the base member 77 for sealing the cover 79 , and a cap member 81 attached to the base member 77 which secures the cover 79 on the base member 77 . In addition, the reader device 70 includes spacer elements 83 formed of an electrically non-conductive material such as ferrite, ceramic or plastic, which separate the transmitter 73 and the receiver 71 from the base member 77 . In the illustrative embodiment, the base member 77 is generally cylindrical in shape, and the spacer elements 83 comprise donuts with a half moon or contoured cross section.
Referring to FIG. 4A , an electrical schematic for the system 50 is illustrated. As illustrated schematically, each identification device 72 includes a memory device 110 , in the form of a programmable integrated circuit chip, such as a transceiver chip, configured to receive and store identification information. As previously explained, the identification information can uniquely identify each casing collar 64 with an alpha numerical, numerical or other designator. In addition, using previously prepared well logs, the depth of each uniquely identified casing collar 64 can be ascertained.
As also shown in FIG. 4A , the reader device 70 includes the transmitter 73 for transmitting transmission signals to the identification devices 72 , and the receiver 71 for receiving the response signals from the identification devices 72 . The reader device 70 can be powered by a suitable power source, such as a battery, or a power supply at the surface. In addition, the reader device 70 includes a memory device 112 , such as one or more integrated circuit chips, configured to receive and store programming information. The reader device 70 also includes a telemetry circuit 114 configured to transmit control signals in digital or other form, through software 116 to a controller 118 , or alternately to a computer 122 .
As is apparent the software 116 can be included in the controller 118 , or in the computer 122 . In addition, the computer 122 can comprise a portable device such as a lap top which can be pre-programmed and transported to the well site. Also, as will be further explained, the computer 122 can include a visual display for displaying information received from the reader device 70 . The controller 118 , or the computer 122 , interface with tool control circuitry 120 , which is configured to control the perforating tool 68 as required.
In the illustrative embodiment, the tool control circuitry 120 is in signal communication with the detonator 74 ( FIG. 3C ) of the perforating tool 68 . The tool control circuitry 120 can be located on the perforating tool 68 , on the reader device 70 , or at the surface. The reader device 70 is programmed to transmit control signals to the tool control circuitry 120 , as a function of response signals received from the identification devices 72 . For example, in the perforating process illustrated in FIGS. 3A and 3B , coupling C 4 is located proximate to the upper level, or entry point into Zone F. Since it is desired to actuate the perforating tool 68 while it is in Zone F, the reader device 70 can be programmed to transmit actuation control signals through the tool control circuitry 120 to the detonator 74 ( FIG. 3C ), when it passes coupling C 4 and receives response signals from the identification device 72 contained in coupling C 4 . Because coupling C 4 is uniquely identified by the identification device 72 contained therein, and the depth of coupling C 4 has been previously identified using well logs, the perforating process can be initiated in real time, as the perforating tool 68 passes coupling C 4 and enters the section of the well casing 56 proximate to Zone F.
However, in order to insure that the detonation sequence is initiated at the right time additional factors must be considered. For example, the perforating tool 68 and reader device 70 can be transported through the well casing 56 with a certain velocity (V). In addition, the reader device 70 requires a certain time period (T 1 ) to transmit transmission signals to the identification device 72 in coupling C 4 , and to receive response signals from the identification device 72 in coupling C 4 . In addition, a certain time period (T 2 ) is required for transmitting signals to the tool control circuitry 120 and to the detonator 74 ( FIG. 3C ). Further, the charge assemblies 80 require a certain time period (T 3 ) before detonation, explosion and perforation of the casing 56 occur. All of these factors can be considered in determining which identification device 72 in which casing 64 will be used to make the reader device 70 transmit actuation control signals through the tool control circuitry 120 to the detonator 74 ( FIG. 3C ).
In order to provide proper timing for the detonation sequence, the velocity (V) of the perforating tool 68 and the reader device 70 can be selected as required. In addition, as shown in FIGS. 5A and 5B , a spacer element 88 can be used to space the perforating tool 68 from the reader device 70 by a predetermined distance (D). As shown in FIG. 5A , the perforating tool 68 can be above the reader device 70 (i.e., closer to the surface 60 ), or alternately as shown in FIG. 5B can be below the reader device 70 (i.e., farther from the surface 60 ).
As an alternative to a dynamic detonation sequence, the perforating tool 68 can be stopped when the required depth is reached, and a static detonation sequence performed. For example, the reader device 70 can be programmed to send a signal for stopping the perforating tool 68 when it reaches coupling C 6 . In this case, the signal from the reader device 70 can be used to control the wire line unit 92 and stop the wire line 90 . The detonation and explosive sequence can then be initiated by signals from the tool control circuit 120 , with the perforating tool 68 in a static condition at the required depth.
As shown in FIG. 4B , signals from the reader device 70 can be used to generate a visual display 124 , such as a computer screen on the computer 122 , which is viewable by an operator at the surface. The visual display 124 is titled “True Depth Systems” and includes a power switch for enabling power to the reader device 70 and other system components. The visual display 124 also includes a “Depth Meter” that indicates the depth of the reader device 70 (or the perforating tool 68 ) within the well 52 . The visual display 124 also includes “Alarm Indicators” including a “Well Alarm Top” indicator, a “Well Alarm Bottom” indicator, and an “Explosive Device” indicator. The “Alarm Indicators” are similar to stop lights with green, yellow and red lights to indicate varying conditions.
The visual display 124 also includes “Power Indicators” including a “True Depth Reader” power indicator, a “True Depth Encoder” power indicator, and a “System Monitor” power indicator. In addition, the visual display 124 includes various “Digital Indicators”. For example, a “Line Speed” digital indicator indicates the speed at which the reader device 70 , and the perforating tool 68 , are being transported through the well casing 56 . An “Encoder Depth” digital indicator indicates the depth of each identification device 72 as the reader device 70 passes by the identification devices 72 . A “True Depth” indicator indicates the actual depth of the reader device 70 in real time as it is transported through the well casing 56 .
The visual display 124 also includes a “TDS ID” indicator that indicates an ID number for each identification device 72 . In addition, the visual display 124 includes a “TDS Description” indicator that further describes each identification device 72 (e.g., location in a specific component or zone). The visual display 124 also includes a “Time” indicator that can be used as a time drive (forward or backward) for demonstration or review purposes. Finally, the visual display 124 includes an “API Log” which indicates log information, such as gamma ray or SPE readings, from the previously described well logs, correlated to the “Digital Indicators” for depth.
Referring again to FIGS. 3A and 3B , in the embodiment illustrated therein, the transport mechanism 66 W includes a wire line 90 operable by a wire line unit 92 , substantially as previously explained and shown in FIG. 1 . The wire line 90 can comprise a slick line, an electric line, a braided line, or coil tubing. If the controller 118 , or the computer 122 , is located at the surface 60 , the wire line 90 can be used to establish signal communication between the reader device 70 and the controller 118 or the computer 122 .
Referring to FIGS. 6A-6D , alternate embodiment transport mechanisms for transporting the perforating tool 68 and the reader device 70 through the casing 56 are shown. In FIG. 6A , a transport mechanism 66 P comprises a pump for pumping a conveyance fluid through the inside diameter of the casing 56 . The pumped conveyance fluid then transports the perforating tool 68 and the reader device 70 through the casing 56 . In FIG. 6B , a transport mechanism 66 R comprises one or more robotic devices attached to the perforating tool 68 and the reader device 70 , and configured to transport the perforating tool 68 and the reader device 70 through the casing 56 . In FIG. 6C , a transport mechanism 66 G comprises gravity (G) such that the perforating tool 68 and the reader device 70 free fall through the casing 56 . The free fall can be through a well fluid within the casing 56 , or through air in the casing 56 . In FIG. 6D , a transport mechanism 66 PA includes a parachute which controls the rate of descent of the perforating tool 68 and the reader device 70 in the casing 56 . Again, the parachute can operate in a well fluid, or in air contained in the casing 56 .
Referring to FIGS. 7A-7C , an alternate embodiment system 50 A constructed in accordance with the invention is illustrated. The system 50 A is installed in a subterranean well 52 A, such as an oil and gas production well. In this embodiment the system 50 A is configured to perform a packer setting process in the well 52 A.
The well 52 A includes a well bore 54 A, and a well casing 56 A within the well bore 54 A surrounded by concrete 58 A. The well casing 56 A comprises a plurality of tubular elements 62 A, such as lengths of metal pipe or tubing, connected to one another by collars 64 A. The well 52 A extends from an earthen surface 60 A through geological formations within the earth, which are represented as Zones H and I.
For performing the packer setting process, the system 50 A includes a packer setting tool 68 A, an inflation device 98 A for the packer setting tool 68 A, and a reader device 70 A in signal communication with the packer setting tool 68 A. In this embodiment, the inflation device 98 A is located on the surface 60 A such that a wire, or other signal transmission medium must be provided between the packer setting tool 68 A and the inflation device 98 A. The packer setting tool 68 A can include an inflatable packer element designed for inflation by the inflation device 98 A and configured to sealingly engage the inside diameter of the casing 56 A. In FIG. 7B , the inflatable packer element of the packer setting tool 68 A has been inflated to seal the inside diameter of the casing 56 A proximate to Zone I.
The system 50 A also includes a plurality of identification devices 72 ( FIG. 3D ) attached to the collars 64 A on the casing 56 A, and readable by the reader device 70 A. In addition, the system 50 A includes a transport mechanism 66 A for transporting the packer setting tool 68 A and the reader device 70 A through the well casing 56 A to Zone I. In this embodiment, the transport mechanism 66 A comprises a tubing string formed by tubular elements 102 A. As shown in FIG. 7C , each tubular element 102 A includes a male tool joint 94 A on one end, and a female tool joint 96 A on an opposing end. This permits the tubular elements 102 A to be attached to one another to form the transport mechanism 66 A. In addition, the packer setting tool 68 A can include a central mandrel in fluid communication with the inside diameter of the transport mechanism 66 A.
The reader device 70 A is programmed to transmit a control signal to the inflation device 98 A upon actuation by a selected identification device 72 ( FIG. 3D ). For example, in the packer setting process illustrated in FIGS. 7A and 7B , coupling C 4 A is located proximate to the upper level, or entry point into Zone I. Since it is desired to inflate the inflatable packer element of the packer setting tool 68 A while it is proximate to Zone I, the reader device 70 A can be programmed to transmit the control signal to the inflation device 68 A when it reaches coupling C 4 A. In this embodiment a spacer element 88 A separates the packer setting tool 68 A and the reader device 70 A. In addition, the packer setting tool 68 A is located downhole relative to the reader device 70 A.
In order to insure that the packer setting sequence is initiated at the right time additional factors must be considered as previously explained. These factors can include the velocity (V) of the packer setting tool 68 A and the reader device 70 A, and the time required to inflate the inflatable packer element of the packer setting tool 68 A. Alternately, the packer setting tool 68 A can be stopped at a particular coupling (e.g., coupling C 5 A) and then inflated as required. In this case the reader device 70 A can be programmed to transmit the control signals to the visual display 124 ( FIG. 4B ) on the surface 60 A when the packer tool 68 A passes a coupling 64 A at the required depth. The operator can then control the inflation device 98 A to initiate inflation of the packer setting tool 68 A. Alternately the inflation sequence can be initiated automatically by the tool control circuit 120 ( FIG. 4A ).
In each of the described processes the method of the invention provides an improved well. For example, in the perforating process of FIGS. 3A and 3B , the well 52 can be perforated in the selected zone, or in a selected interval of the selected zone. Production from the well 52 is thus optimized and the well 52 is able to produce more fluids, particularly oil and gas.
Referring to FIGS. 8A-8C , a multi stage operation performed in accordance with the method of the invention is illustrated. Initially, as shown in FIG. 8A , a combination tool 130 is provided. The combination tool 134 includes a packer setting tool 132 and a perforating tool 134 , which function substantially as previously described for the packer setting tool 68 A ( FIG. 7B ), and the perforating tool 68 ( FIG. 3A ) previously described. In addition, the combination tool 134 includes the reader device 70 and the casing 56 includes identification devices 72 ( FIG. 3D ) substantially as previously described. As also shown in FIG. 8A , the combination tool 130 is transported through the casing 56 using the gravity transport mechanism 66 G. Alternately, any of the other previously described transport mechanisms can be employed.
Next, as shown in FIG. 8B , the packer setting tool 132 is actuated such that an inflatable packer element of the tool 132 seals the casing 56 at a desired depth. In this embodiment the packer setting tool 132 is a self contained unit, with an integral inflation source. As with the previously described embodiments, the reader device 70 provides control signals for controlling the packer setting tool 132 , and the packer setting process. For example, the inflatable packer element of the packer setting tool 132 can be inflated when the reader device 70 passes a selected coupling 64 , and receives a response signal from the identification device 72 contained within the selected coupling 64 . As also shown in FIG. 8B , the perforating tool 134 separates from the packer setting tool 132 and continues to free fall through the casing 56 .
Next, as shown in FIG. 8C , the perforating tool 132 is controlled such that detonation and explosive sequences are initiated substantially as previously described. Again the reader device 70 provides control signals, for controlling the perforating tool 132 to initiate the detonation and explosive sequences at the proper depth. As indicated by the dashed arrows in FIG. 8C explosion of the charge assemblies 80 ( FIG. 3C ) of the perforating tool 134 forms openings in the casing 58 and the concrete 58 .
Thus the invention provides a method and a system for performing various operations or processes in wells and for improving production from the wells. While the invention has been described with reference to certain preferred embodiments, as will be apparent to those skilled in the art, certain changes and modifications can be made without departing from the scope of the invention as defined by the following claims. | A method for performing operations and for improving production in a well includes the steps of: providing radio identification devices at known locations in the well, and providing a reader device configured to read the identification devices, and to control the operations responsive to signals from the identification devices. The method also includes the steps of providing a process tool, and transporting the process tool and the reader device through the well. The reader device is programmed to control the process tool upon reception of a response signal from a selected identification device. The method can be used to perform perforating processes, packer setting processes, bridge plug setting processes, logging processes, inspection processes, chemical treating processes, and cleaning processes. In addition, the method can be performed dynamically by controlling the tool as it moves through the well, or statically by stopping the tool at a particular location within the well. A system for performing the method includes the identification devices, the reader device, the process tool, and a computer or controller. In addition the identification devices can be placed in casing collars of the well and can be configured as passive devices or as active devices. | 4 |
The United States Government has rights in this invention as claimed pursuant to contract number DE-AC01-78ET29313 between the United States Department of Energy and the General Electric Company (41 CFR §9-9.109).
This application is a division of application Ser. No. 972,239 filed Dec. 22, 1978, which is now U.S. Pat. No. 4,341,845.
The invention herein is related to the invention disclosed and claimed in copending application Ser. No. 249,033, filed Mar. 30, 1981, in the names of the same inventive entity as the instant application, assigned to the same assignee as the instant application, and entitled "Method of Making Patterned Helical Metallic Ribbon for Continuous Edge Winding Applications" which is now U.S. Pat. No. 4,343,347; said Ser. No. 249,033 application is a divisional application of Ser. No. 972,240, filed Dec. 22, 1978, which, in turn, is now U.S. Pat. No. 4,281,706.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to patterned metallic ribbons in helical form for continuous edge winding applications.
2. Description of the Prior Art
The fabrication of glassy alloy magnetic ribbon for use in electric motor applications is commonly believed to involve conventional punching operations performed on sheets or strips of the ribbon. However, a low filling or packing factor will result from conventional or prior art laminations of known glassy alloys because of the greater number of punchings required when compared with the number of punchings required when using prior art materials for laminations. This is because of the inherent limit on thickness in melt-quenched glassy alloy specimens. The overall effect is to increase the size and cost of the finished electric motor, thereby negating the savings offered by use of the glassy alloy material. A prior art method of making glassy alloy ribbon is to extrude the alloy in molten form through an appropriate orifice in a crucible and to subsequently impinge the melt jet onto the circumferential surface of a rapidly rotating substrate wheel. The melt jet axis is typically made to lie parallel to the plane of the substrate wheel. The ribbon so formed has the shape of conventional tape or ribbon and can be wound upon a spool.
It would be desirable to manufacture a motor stator comprising two concentric pieces of material. A center piece would be prefabricated with teeth and windings. The outer piece would be prefabricated or built in situ from an edge-wound strip in the form of a large helix,
Therefore, it is an object of this invention to provide patterned metallic ribbon in a continuous helical form.
Another object of this invention is to provide a new and improved patterned edge-wound glassy alloy magnetic ribbon in a helical form.
A further object of this invention is to provide patterned edge-wound metallic or glassy alloy magnetic ribbon in a nested helical form.
A still further object of this invention is to provide edge-wound metallic or glassy alloy magnetic ribbon with prefabricated cutouts therein for making, as an example, a motor stator.
Other objects of this invention will, in part, be obvious and will, in part, appear hereinafter.
BRIEF DESCRIPTION OF THE INVENTION
In accordance with the teachings of this invention, there is provided a continuous length of patterned edge-wound metallic ribbon having a helical shape, a substantially uniform cross-section and an axis normal to the plane of the helix. The ribbon has an inner peripheral edge and an outer peripheral edge as well as a pair of substantially parallel, opposed major surfaces. The composition of the ribbon may be that of a glassy alloy system which may be successfully produced by rapid quenching from the melt. Typical examples of such systems are Fe-B, Fe-B-C, Fe-B-Si, Fe-Ni-B, Cu-Zr and the like.
The ribbon is formed in situ with predetermined geometrically shaped cutouts in the inner and/or outer edges and/or between the edges of the ribbon. Additionally, the ribbon may be formed in such a manner whereby the helical coil is nested in such a fashion that the helix axis is not parallel to the local normal to the ribbon surface. This cast ribbon is suitable, for example, for use in making appropriately designed electrical devices.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic view illustrating fabrication of edge-wound metallic ribbon in a helical form.
FIG. 1a is a top planar view of the schematic of FIG. 1 showing the azimuthal orientation of the melt flow axis in relation of the area of stream impingement on the moving substrate surface 22.
FIG. 2 is a partial cross-section schematic view of fabricating a nested edge-wound metallic ribbon in a helical form.
FIG. 3 is a partial cross-section side elevation view of a nested edge-wound metallic ribbon.
FIG. 4 is a partial cross-section schematic view of fabricating a nested edge-wound metallic ribbon in a helical form.
FIG. 5 is a partial cross-section side elevation view of a nested edge-wound metallic ribbon.
FIGS. 6, 7 and 8 are schematic views of fabricating an edge-wound metallic ribbon with a continuous pattern of predetermined periodic geometry in either one or both of the inner or the outer peripheral edges of the ribbon.
FIG. 9 is a schematic of a portion of ribbon illustrating a continuous geometric pattern within the ribbon.
DESCRIPTION OF THE INVENTION
Referring now to FIG. 1, there is shown a method of making edge-wound metallic ribbon 10. Within the limits of the present invention, a ribbon is a thin body whose transverse dimensions are very much smaller than its length. The ribbon 10 is formed by impinging a melt stream or jet 12 onto a moving substrate surface 13 of a substrate wheel 14, rotating about axis 20, by extrusion of the molten alloy through an appropriate orifice 16 of a crucible 18. The axis 15 of the melt stream or jet 12 is made to lie in a plane 26 defined by the tangent to the rotation of the substrate wheel 14 at the point of melt stream or jet axis 15 intersection 24 and by the normal to the local substrate surface 22 at the same point 24. Upon impingement of the melt stream or jet 12 onto the portion 22 of the moving substrate surface 13 of the wheel 14, the melt is chilled into the shape of the ribbon 10 which assumes an inplane curvature defined by the motion of the wheel at the area of impingement 24. The width of the ribbon formed at the melt stream or jet impingement area 24 determines the radius of the inner and outer peripheral edge Ri and Ro, respectively, of the edge-wound helical metallic ribbon 10.
The melt stream or jet axis 15 in the plane described may intersect the portion 22 of the moving substrate surface 13 at an angle α typically between 30° and 90°, with the range 40°≦α≦70° preferred for optimized ribbon geometric uniformity. The structure of the resulting metallic ribbon may be crystalline or glassy. Glassy metallic ribbon may be made from a glassy alloy system obtainable by rapid quenching from the melt. Typical examples of glossy alloy systems are Fe-B, Fe-B-C, Fe-B-Si, Fe-Ni-B, Cu-Zr and the like.
It has been empirically found that the edge-wound ribbon most readily forms within certain limits of melt stream or jet velocity and substrate surface velocity. The preferred melt stream or jet velocity should range from about 1 m/s to about 10 m/s. The substrate surface speed preferably ranges from about 12 m/s to about 50 m/s. Precautions must be taken to assure intimate contact between the substrate surface and the cooling ribbon for a sufficient length of time in order to form a suitable helix. One particular method is to roughen the surface of the substrate wheel and thereby prolong ribbon dwell time on the surface of the wheel. Another method is to employ a gas or mechanical type of "hold-down" device which is well known to those skilled in the art.
The ribbon as formed has a substantially uniform cross-section when compared with helical products fabricated by mechanical means of deformation such, for example, as by cambered rolling. The latter products typically have a tapered cross-section wherein the thickness of the ribbon is uniformly reduced towards the outer peripheral edge across the width of the ribbon.
With reference to FIGS. 1 and 1a, the possible orientations of the crucible axis with respect to the moving substrate surface may be defined by an inverted cone with apex at the point of stream axis impingement. This cone is defined by the inclination and azimuthal angles α and γ, respectively. Using the projection as an arbitrary reference marker, the azimuthal angle may have values of 0≦|γ|≦180°. "Backstreaming" occurs when |γ|>90°, thereby resulting in ribbon 10 formed in the direction of substrate motion and in droplets or a continuous stream formed against the general direction of substrate motion, sometimes resulting in a continuous fiber.
When the melt stream or jet 12 is made to impinge onto a beveled surface 50, that is, a portion of the substrate surface 13 which is modified by shaping it to be integral with and inclined to the remaining portion of the surface 13 of the rotating substrate wheel 14, an edge-wound helical metallic ribbon results and has a nesting angle somewhat less than that of the bevel inclination on the rotating substrate wheel 14. The surface 50 intersects the substrate surface 13 and forms the included obtuse angle β therewith. For example, with reference to FIGS. 2 and 3, the melt jet 12 from crucible 18 is made to impinge upon the beveled surface 50 of the wheel 14 in plane 26 previously described.
The melt stream or jet 12, which is directed onto the moving substrate surface 50, has an axis 15 lying in plane 26 and inclined at 30°≦α≦90° with the surface 50. The plane 26 is defined by the tangent to the rotation of the substrate wheel 14 at the point of melt stream or jet axis 15 intersection 24 and by the normal to the local substrate surface 50 at the same point 24. The range 40°≦α≦90° is preferred for optimized ribbon geometry.
A nested glassy alloy ribbon 54 which is produced has parallel surfaces 56 and 58 inclined away from the central axis 20 of the helical coil 20.
Alternately, as shown in FIGS. 4 and 5, the melt stream or jet 12 from crucible 18 is made to impinge on a beveled surface 60 formed in the outer portion 62 of the substrate surface 13 of the wheel 14. The surface 60 intersects an extension of the surface 13 of the wheel 14 and forms an included acute angle β therewith. The melt stream or jet 12, which is directed onto the moving substrate surface 60, has an axis 15 lying in plane 26 and inclined at 30°≦α≦90° with the surface 60. The plane 26 is defined by the tangent to the rotation of the substrate wheel 14 at the point of melt stream or jet axis 15 intersection 24 and by the normal to the local substrate surface 60 at the same point 24. The range 40°≦α≦70° is preferred for optimized ribbon geometry. The nested metallic ribbon 64 which is produced has substantially parallel surfaces 66 and 68 which are inclined toward the central axis 20 of the helical coil.
Referring to FIG. 6, the portion 22 of the moving substrate surface 13 on the rotating substrate wheel 14 may be modified in order to form a metallic ribbon 70 with predetermined cutout regions therein. The substrate surface portion 22 is modified by suitable means to contain barrier lines. For example, such lines may be introduced by scribing with a sharp-edged tool or by a silk screening ink application to produce a plurality of lines 72 which define the geometric configuration of the cutout to be made in the inner peripheral portion of the ribbon 70. The lines 72 provide a differential cooling rate between the molten metal cast on the lines 72 and the metal cast on the substrate surface portion 22. The lines 72 made either by the removal of material from the substrate surface portion 22 or by the application of ink provide a barrier which prevents the cast metal from cooling rapidly in the vicinity thereof. Therefore, the alloy cast as the result of the contact of the melt and the moving substrate surface portion 22 produces the metallic ribbon. Centrifugal force causes the ribbon 70 to be cast from the wheel after an adequate dwell time required to define the helical shape and causes the portion of the ribbon 70 enclosed by scribe marks to break or flake away and produce individual amorphous flakes or platelets 74. The ribbon 70 is suitable for many types of electromagnetic devices such as, for example, the rotor and stator portions of an electric motor, and applications requiring a pre-defined air gap such as in a ballast or in a linear reactor.
With reference to FIG. 7, there is shown another alternate embodiment of the ribbon 10. In this instance, lines 80 are made on the substrate surface portion 22 of the wheel 14 to form metallic ribbon 82 suitable for use in making the rotor portion of an electric motor. Again, metallic flakes 84 are a by-product. The cutouts are made in the outer peripheral portion of the ribbon 82.
The glassy alloy ribbons 70 and 82 may be employed in AC motors as stated heretofore. The ribbon 70 may be utilized in an AC motor stator for a squirrel cage induction or synchronous motor. The ribbon 82 is suitable for the direct casting of one or more components of an AC motor for squirrel cage induction, synchronous with or without amortisseur winding, or hysteresis motors as well as DC or universal motor parts.
Alternately, the barrier imposed by the scribe lines 72 and 80 may be obtained by employing a low thermal conducting, a non-thermal conducting, or a non-wetting medium to delineate the pattern of the flakes 74 and 84.
The flakes or platelets 74 and 84 may be employed in making composites or encapsulated shaped articles made from the flakes.
Referring now to FIG. 8, there is shown a ribbon 90 which embodies cutouts in both the inner and outer peripheral edges of ribbon 90. The ribbon 90 is manufactured in a process which embodies a process very similar to that required for producing ribbons 70 and 82. Metallic flakes are a by-product of the process.
The following Examples are illustrative of the teachings of this invention:
EXAMPLE I
The substrate was provided by the face of a 7.5 cm diameter OFHC copper wheel as shown in FIG. 1 finished with 400 grit emery paper and rotating at 8500 rpm. Angles α and γ were set at 50° and 0°, respectively. The angle β was 180°. The Fe 40 Ni 40 B 20 molten alloy jet was at 1200° C. and was formed by extrusion under 60 kPa Ar driving pressure through a 500 μm hole in a clear fused quartz crucible. The point of melt jet impingement was at a radius of 3 cm from the axis of the rotating wheel. The resultant product was a glassy alloy helix with average diameter 6 cm, ribbon width 0.9 mm, and ribbon thickness 38 μm, as measured by a micrometer.
EXAMPLE II
The substrate was provided by the face of a 7.5 cm diameter OFHC copper wheel as shown in FIG. 1 finished with 400 grit emery paper and rotating at a speed resulting in 35 m/s substrate surface speed at point of impingement. Angles α and γ were set at 70° and 0°, respectively. The angle β was 150°. The Fe 40 Ni 40 B 20 jet was formed by pressurization with 60 kPa Ar and extrusion of the melt through a 500 μm round orifice at 1200° C. The resulting helical glassy alloy ribbon sample has an average diameter equal to that of the wheel at the point of melt jet impingement. The nesting angle of the helix was some 10°-15° less than β.
Although the invention has been described relative to the employment of a free jet stream impinging upon the moving substrate surface to form a dynamic melt puddle from which ribbon is drawn, the apparatus of M. C. Narasimhan, appropriately modified, may be employed as well. The apparatus and process of using it is taught in Belgian Pat. No. 859,694 issued Jan. 2, 1978. In the apparatus of M. C. Narasimham, the molten alloy jet stream is kept confined to within a full breadth of the slit used in casting.
The invention has been described with the possible embodiment of a continuous pattern of geometric cut-outs in either or both of the peripheral portions of the ribbon. However, a continuous pattern of a specific geometrical configuration may also be provided within the ribbon itself in order to meet motor performance standards. With reference to FIG. 9, there is shown a portion 100 of a ribbon 104 having walls 102 defining a cut-out in the ribbon which is part of a continuous pattern. The ribbon 104 is manufactured in the same manner as the previous ribbons and employing the same barrier line technique to obtain the continuous pattern. The cut-outs may be of any planar geometrical configuration and are determined by the required motor performance for which the ribbon is employed. | Metallic ribbon having cutout patterns therein is provided in continuous helical form. The cutout patterns may be situated to intersect either or both of the ribbon edges or may be situated entirely within the ribbon. The helical ribbon with the cutout patterns may additionally have a nesting, or self-stacking, feature. | 8 |
TECHNICAL FIELD
[0001] The present invention relates to a suspension for a clamping jaw, in particular to a sealing jaw used in a sealing unit for forming and sealing an open end of a tubular packaging container.
BACKGROUND
[0002] Within the field of packaging of pourable products, and in particular of pourable foods, there are various kinds of packaging containers used. The packaging containers vary in package shape, packaging material, etc. resulting in variation in the method used for filling of the packaging container and sealing of the packaging container. The present invention may preferably be used for a packaging container made from a packaging laminate comprising a core layer and several surrounding barrier layers.
[0003] When sealing an end of a tubular packaging container use is often made of sealing jaws, clamping and heating the end of the packaging container in order to seal one end thereof. The basic technique is well-known and will not be discussed in any more detail here. For the purposes of the present invention, however it should be mentioned that “tubular” includes packages having a cross section other than circular, such as quadratic, rectangular, hexagonal, oval, etc, i.e. a packaging container being formed by bonding two opposite edges thereof to form a sleeve.
[0004] The sealing of an end of a packaging container is a complex procedure. The end should be sealed, formed and folded according to a preset pattern, and fixed to the desired shape (usually flat in the case of the bottom of a container). The different operations are not necessarily performed in the order stated above; when sealing the final open end of a container, the sealing should preferably be performed late, since a surplus of air will be caught inside the container if sealed too early. This poses no problem when the first end of the container is sealed, formed and folded.
[0005] The stated operations are not necessarily performed by the same tool, either. Generally, the sealing and initial forming and folding are performed by one tool, and the final folding and fixing is accomplished by another tool, or arrangement of tools.
[0006] The tool for sealing and initial forming and folding may comprise two opposing sealing jaws, clamping the open end of the tubular packaging container and providing energy for the accomplishment of sealing. On their way from an open position to a clamping position the two opposing sealing jaws may follow a path of movement such that they initiate the forming and folding, and after clamping and sealing the packaging container, they may continue their movement to continue the forming and folding. Even if the path as such may be simple enough, the mechanics needed in order to make the sealing jaws follow such path will be more complex, in particular since factors such as reliability, repeatability, and durability are important and since price is always an issue. Examples of prior art solutions may be found in WO2004054790, by the present applicant, and US2008/0276576 also by the present applicant. Further, there is great effort put into the accomplishment of adequate sealing force at the time of clamping the packaging material between the sealing jaws. The present invention aims at providing a sealing jaw suspension which among other things facilitates the accomplishment of such adequate sealing force/clamping force.
SUMMARY
[0007] For achieving the above purposes a suspension according to the present invention may be defined as a sealing unit having a suspension configured to suspend a sealing jaw in a socket, the suspension comprising a first spring arrangement and a second spring arrangement for selectively biasing the sealing jaw in a sealing direction, i.e. in the direction of an opposing sealing jaw,
[0008] wherein in that the first spring arrangement has a state in which it is rigidly attached to the socket and a state in which it is movably attached to the socket.
[0009] This may also be worded as the sealing unit comprising a sealing jaw suspended in a socket via a suspension comprising a first spring arrangement and a second spring arrangement for biasing the sealing jaw in a sealing direction, wherein the suspension has
a first state in which the first spring arrangement is rigidly attached to the socket and operable to apply a biasing force onto the sealing jaw in the sealing direction while the second spring arrangement is prevented from applying a biasing force onto the sealing jaw, and a second state in which the first spring arrangement is movably arranged to the socket and the second spring arrangement is arranged to apply a biasing force onto the sealing jaw, also in the sealing direction.
[0012] The ability to engage and disengage the first spring arrangement enables isolation of the second spring arrangement during calibration of the sealing jaws, i.e. in the procedure during which the distance between opposing sealing jaws is set. This distance, the spring constants and the thickness of the packaging material are parameters that determine the force applied onto the packaging material during forming and sealing (the sealing pressure).
[0013] In one or more embodiments the second spring arrangement is configured to selectively apply a biasing force onto the sealing jaw, which makes it possible to activate the action of the second spring arrangement during calibration only. In this way the sealing pressure will be perfectly predictable.
[0014] The first spring arrangement of the suspension may comprise a first housing in which a first spring is arranged, the housing having an open end in the direction of the sealing jaw. The use of a housing enables simple confinement of the first spring and makes it readily attachable to a socket or shoe. In one or several embodiments the second spring arrangement may be configured to act directly onto the sealing jaw, and in other embodiments it may be configured to act on the housing of the first spring arrangement and thus indirectly onto the sealing jaw. The latter embodiment vouches for a space efficient and slender construction, while the former is a more straightforward construction in which the function of the first and the second spring arrangement is separated.
[0015] In order to increase the performance of the suspension a resilient buffer may be arranged between the first spring and the sealing jaw, the resilient buffer having a through hole in the biasing direction. The resilient buffer, embodiments of which will be described in the detailed description, will make the suspension less susceptible for damage since it may absorb unexpected behaviour of the sealing jaw.
[0016] The housing of the first spring arrangement may be arranged in a matching opening of the socket/shoe, and in other embodiments a housing of the second spring arrangement may be arranged in a matching opening of the shoe/socket too, which makes is ease to accomplish engagement/disengagement. The show/socket may comprise two halves such that clamping of the first spring arrangement in its opening is readily accomplished, as will be clarified in the detailed description.
[0017] In any embodiment of the present invention an effective spring constant for the first spring arrangement may exceeds an effective spring constant for the second spring arrangement.
[0018] In general terms, and describing common features of various embodiments of the invention, a method for calibrating the distance between opposing sealing jaws then may comprise the following steps, which do not necessarily have to be conducted in the stated order:
Bringing the opposing sealing jaws to a fully closed position, Disengaging the first spring arrangement such that the sealing jaws are biased towards each other by means of a force provided by a second spring arrangement only, Engaging the first spring arrangement.
[0022] The disengagement/engagement of the first spring arrangement may preferably be effected by disengaging/engaging its coupling to the socket.
[0023] This method may also comprise the steps of engaging and disengaging the second spring arrangement, wherein the step of disengaging the second spring arrangement is effected after the step of engaging the first spring arrangement. “Engaging” the second spring arrangement implies that the second spring arrangement effectively acts on the first sealing jaw to force the sealing jaws towards each other and “disengaging” implies that it does not. These additional steps may be conducted in a situation where the second spring arrangement should be prevented from interacting during the actual working cycle of the forming/sealing unit utilizing the floating dolly.
[0024] The method may also comprise, with or without the above mentioned additional steps, the step of arranging a shim element between the sealing jaws. The shim element may comprise a piece of sheet material with the desired thickness such as a piece of sheet metal or a piece of folded or non-folded packaging material. The desired thickness may preferably be smaller than the thickness of the material being arranged between the sealing jaws during actual operation.
[0025] The floating dolly system may be utilized on the form and sealing unit according to any embodiment previously described, yet it may also be used as standalone construction which may be applied to a sealing and/or forming unit utilizing sealing jaws in general.
[0026] Although the present invention has been described above with reference to specific embodiments, it is not intended to be limited to the specific form set forth herein. Rather, the invention is limited only by the accompanying claims and, other embodiments than the specific above are equally possible within the scope of these appended claims.
[0027] In the claims, the term “comprises/comprising” does not exclude the presence of other elements or steps. Furthermore, although individually listed, a plurality of means, elements or method steps may be implemented by e.g. a single unit or processor. Additionally, although individual features may be included in different claims, these may possibly advantageously be combined, and the inclusion in different claims does not imply that a combination of features is not feasible and/or advantageous. In addition, singular references do not exclude a plurality. The terms “a”, “an”, “first”, “second” etc do not preclude a plurality. Reference signs in the claims are provided merely as a clarifying example and shall not be construed as limiting the scope of the claims in any way.
BRIEF DESCRIPTION OF THE DRAWINGS
[0028] FIG. 1 is a perspective view of a form and sealing unit comprising a suspension according to a first embodiment of the present invention.
[0029] FIG. 2 is a detailed view in perspective of the form and sealing unit of FIG. 1 .
[0030] FIGS. 3 and 4 are sectional views of a sealing-jaw suspension according to a first embodiment.
[0031] FIG. 5 is a perspective view of a form and sealing unit comprising a suspension according to a second embodiment of the present invention.
[0032] FIG. 6 is a sectional view of a sealing-jaw suspension according to the second embodiment.
DETAILED DESCRIPTION
[0033] In order to put the present invention into context reference is first made to FIG. 1 , illustrating a form and sealing unit 100 having a suspension arrangement according to a first embodiment of the present invention. Starting from the top, the function of the form and sealing unit 100 is to move the sealing jaws 102 , 104 between an open and a closed position. The open position allows for a new package container to be inserted between the sealing jaws and the closed position allows for one end of a package container to be closed and sealed. The purpose and function of the sealing jaws will not be discussed in detail here, since the purpose is obvious and the basic function may be considered well known for the skilled person. The path chosen by the sealing jaws on their way from the open to the closed position will affect their interaction with the package container, and the path is a parameter to account for. This will be discussed later on in the detailed description.
[0034] Moving on, each sealing jaw 102 , 104 is attached to a proximal end of a corresponding tong 106 , 108 . At least one of the sealing jaws 104 is movably attached to the corresponding tong 108 , such that the distance between the sealing jaws 102 , 104 may be varied. The main purpose for wanting to vary the distance between sealing jaws is to account for specific thickness of the packaging material by adjusting the clearance between the sealing jaws. The opposing, distal end of each tong 106 , 108 is coupled to a first pivot axis 110 , which in the present embodiment is a common pivot axis for both tongs 106 , 108 .
[0035] Details of the sealing jaw 104 are more readily appreciated studying FIG. 2 .
[0036] In a position between the sealing jaws 102 , 104 and the first pivot axis 110 links 112 , 114 (partly obscured in FIG. 1 ) extend from the tongs 106 , 108 to a common second pivot axis 116 (not shown in FIG. 1 ). The links 112 , 114 are allowed to pivot at both their attachment points, and in the present embodiment each tong is associated with two links. It is readily understood that by altering the relative distance between the first and the second pivot axis, the inclination of each link will vary, and by that the distance between the sealing jaws 102 , 104 . The device is preferably tuned such that the position in which the links are directed 180° degrees relative to each other is included in an operational cycle, corresponding to the position in which the sealing jaws are fully closed (or at least cannot be brought any closer to each other).
[0037] A socket 118 acts as the framework for the unit 100 , and components being rigidly connected to the socket will form a part of the framework. It should be obvious for the skilled person reading this description that all forces generated by the system will be absorbed inside the system too, since the socket 118 will act as a rigid anchor. If the system operates in such a way that inertial forces become an issue it will have to be balanced properly. What has been described above is located on one side of the socket 118 . The other side of the socket 118 comprises the drive section, details of which is not relevant for the present invention.
[0038] Returning to the sealing jaws 102 , 104 and in particular their suspension the reader may benefit from knowing that in the present embodiment the tongs 106 , 108 are essentially identical and two tongs are used for each sealing jaw. One of the sealing jaws 102 comprises an inductor, which is used to heat the packaging material clamped between the first sealing jaw 102 and the second sealing jaw 104 during operation. The second sealing jaw 104 acts as an anvil for the inductor. Generally, energy has to be transferred from the sealing unit to the packaging material in order to generate heat and accomplish sealing, yet in some instances the application of a clamping force suffices. A cable or busbar 142 is used to transfer power to the inductor used for heating. In situations where heating is desired, inductive heating is one of several alternatives, and thus the present invention should not be construed as limited to this specific embodiment. The second sealing jaw 104 is attached to the corresponding tong 108 in such a way that the distance between the sealing jaws may be varied. In this way the arrangement may be adapted to various thicknesses of the packaging material in a simple and straightforward manner.
[0039] After loosening bolts 144 of a two part holder (or socket) 160 , cylinders 146 may be slid back and forth, which effectively will alter the distance between the sealing jaws in their closed position. The cylinders 146 have a slightly more complex construction than what is obvious from FIG. 1 . They offer a resilient suspension for the sealing jaw 104 , and an internal variable spring arrangement (inside each cylinder 146 , and referred to as first spring arrangement in the appended claims) enables a variable sealing force to be applied to a packaging material clamped between the sealing jaws. The suspension also comprises further spring arrangement 151 (called second spring arrangement in the appended claims to distinguish from the first spring arrangement) arranged to push the sealing jaw 104 away from the holder. The further spring arrangement is a separate element, and a spring 149 provides the biasing force of the further spring arrangement 151 . This differs from the second embodiment, yet to be described, where the “further spring arrangement” 249 is arranged in the same element as the first spring arrangement and refers directly to the actual spring (pair of springs providing the biasing force. The force applied by the spring arrangement 151 may be varied and set to about half the desired sealing force, and the spring arrangement 151 are particularly useful when calibrating the sealing jaws, and the whole arrangement, the procedure which will be described in the following paragraph. It should be noted that only one bolt 144 , cylinder 146 and further spring arrangement 151 has been given a reference numeral in FIG. 1 , yet this is only to increase the readability of FIG. 1 and should not be used as an indication for the actual number of components. From FIG. 1 it is possible to deduce that there are four bolts 144 , four cylinders 146 and two spring arrangements 151 in the arrangement of the present embodiment. The skilled person realizes that it is the desired function of the components that is the issue rather than the type or number of the actual components. The effect of the further spring arrangement 151 is controlled by operation of the screw 148 , which will be described in more detail in relation to FIGS. 3 and 4 .
[0040] The calibration of the above system is particularly simple, and it does not have to be performed in the order to be stated below even if it may be the most straightforward manner. The user simply transfers the sealing jaws to their fully closed position having the desired amount of packaging material clamped between the sealing jaws, preferably being less than the amount of packaging material located there during actual operation of the system. The arrangement may then be locked in this position, e.g. by physical locking of the cam wheel. After loosening the bolts 144 the sealing jaw 104 will be biased towards the sealing jaw 102 with about half the desired sealing force, provided by the further spring arrangement 151 ( 149 ), clamping the packaging material therebetween. At this point the bolts 144 are tightened again, and the arrangement has been calibrated. In some embodiments the biasing force of the spring arrangement 151 is not desired during operation, in which case they are only activated during calibration of the sealing jaws. The sealing arrangement comprises a number of joints, and each joint will result in some amount of play which will affect the tolerances. The force generated by the spring arrangement during calibration will effectively force the total play in the system towards one extreme, and in this way the tolerances of the arrangement when packaging material is clamped between the sealing jaws are minimized.
[0041] Rubber bushings may be arranged between the sealing jaw 104 and the cylinders 146 as part of the suspension. The rubber bushings may easily be designed by a suitable choice of shape and material such that they will not affect the sealing force, at least not to a significant degree, while still acting as a protective safety measure for the arrangement. If there is a jam in the sealing unit a possible effect may be that the amount of packaging material between the sealing jaws is doubled or more. The packaging material may also be shifted towards one end of the sealing jaws, causing an uneven load. Such unwanted displacement of the sealing jaws may result in failure of the sealing jaws, their suspension and undesired forces may be transferred through the arrangement and cause failure of the whole arrangement. The rubber bushings will absorb the forces and displacement within foreseeable limits, which will spare integrity of the arrangement.
[0042] The first embodiment is further illustrated in the detailed views of FIGS. 3 and 4 . FIG. 3 illustrates a section of the further spring arrangement 151 and FIG. 4 illustrates a section of the cylinder 146 . There, an element providing the effect of the main spring (used during operation of the device) is located in the cylinders 146 , which may have a construction being basically identical to the one that will be described in relation to the second embodiment, but for a disc-spring means present in the second embodiment. The action of the disc spring is however instead provided by an additional, separate spring housing, i.e. the “further spring arrangement” 151 , the function of which in the present embodiment is provided by coils springs 149 . The disc spring in the embodiment of FIGS. 5 and 6 and the coil spring 149 have that in common that they are configured to try to bias the jaw 104 / 204 beyond the position in which it abuts its opposing jaw 102 / 202 when the cylinder 146 /spring housing 246 is released from its shoe or socket 160 / 260 , such that an actual biasing force will be applied. The further spring arrangement 151 may be provided with a disc springs instead of the coil spring 149 , yet any other suitable biasing arrangements may be applied. In this first embodiment the coil spring 149 is arranged in an opening of the socket 160 , one end of the spring abutting the bottom of the opening (remote to the sealing jaw). The other end of the coil spring s arranged in an abutment element (see the element at reference numeral 149 ), which in turn is connectable to a screw 148 . The screw threadingly engages the abutment element and extends concentrically with the coil spring 149 and through a hole in the bottom of the opening to the remote end of the socket 160 , where the screw head is located. By operating the screw 148 the coil spring may be compressed (and pulled out of contact with the sealing jaw) or released (such that it applies a biasing force onto the sealing jaw).
[0043] In the embodiment of FIGS. 3 and 4 (and 1 and 2 ) a method of calibrating the sealing jaws by means of the suspension may comprise the steps of
Loosen screw 144 , which will allow the main spring cylinder 146 to slide in its socket. Set cam in sealing position with a shim or one layer of carton between sealing jaw and the dolly. Loosen screw 148 which will allow the further spring arrangement 151 ( 149 ) to bias the sealing jaw in a closing direction with a force determined by the properties of the coils spring 149 . Tighten screw 144 , such as to lock the main spring cylinder 146 in its socket. Tighten screw 148 , which will retract the further spring arrangement 151 ( 149 ) such that its biasing effect is discontinued.
[0049] In use it is common to utilize the forming and sealing unit to operate at two or more packaging containers simultaneously. In such a case the sealing jaw 104 may be divided cross its longitudinal direction such that it comprises two or more segments. This may be utilized in such a way that each packaging container being formed and sealed using the inventive system will be handled by an individual segment. In this way one segment will not be affected if there is an anomaly at the other segment. Examples of anomalies include the absence of a packaging container, an unexpected thickness of the material, etc. The effect on the inventive suspension is that two or more duplicate suspension arrangements have to be used, preferably two per segment of the sealing jaw. In an alternative embodiment two main springs are used for each segment, yet only one further spring arrangement according to any previous or subsequent description. The most common arrangement is however that the two types of biasing arrangements come in pairs.
[0050] A second embodiment of the present invention is illustrated in FIGS. 5 and 6 , and the drawing of FIG. 5 is collected from a copending application with application number SE1000902-5, in which details of that particular system is disclosed and to which reference is made for better understanding. Details directly related to the present embodiment are described below. Suspension carries a sealing jaw 204 in the distal end, which connects to a spring housing 246 via a rubber bushing 252 and a jaw piston 254 , running through the rubber bushing 252 , proximally of the sealing jaw 204 . The spring housing 246 encloses a main spring 247 , which is stressed inside the spring housing, by a distal plate 256 and a proximal plug 258 . Proximally, the spring housing 246 is attached to a driven arm 208 by a shoe 260 . In between the spring housing 246 and the arm 208 , i.e. in between the plug 258 and the arm 208 , held by the shoe 260 , a disc spring 249 is located. Thus, the disc spring 249 is positioned proximally of the plug 258 and distally of the arm 208 . By tightening/loosening the shoe 260 , by tightening/loosening the screw 244 , the disc spring 249 will be able to bias the spring housing 246 in a sealing direction (to the left as illustrated in FIG. 6 ). The rubber bushing is in the illustrated embodiments comprised of rubber vulcanized between two metal cylinders, which may be seen in FIG. 6 .
[0051] Thus, when the shoe 260 is in a relaxed position the disc spring 249 is in a released state, and the spring housing 246 is displaceable proximodistally within the shoe 260 . Simultaneously, the main spring 247 is prestressed within the spring housing 246 , in between the plate 256 and the plug 258 . In this position, a shim or a layer of carton may be put in between the sealing jaw 204 and a corresponding sealing jaw.
[0052] The sealing jaws are then brought into contact in a clamping position. In this position, the main spring 247 is not affected to the extent that it will be compressed, while the spring housing 246 will be in correct sealing position with respect to the sealing jaw 204 . The disc spring 249 is now compressed, and the shoe 260 is fixed with relation to the spring housing 246 by for example tightening a screw member 244 . In this step the first spring arrangement, the main spring 244 , is engaged while the second spring arrangement, the disc spring 249 is disengaged since the housing will be positionally locked in relation to the socket 260 . In the particular embodiment of FIG. 6 the spring force provided by the disc spring 249 is lower than the spring force provided by the main spring 247 explaining why the main spring is not affected. This is true as long as the stroke of the housing 246 remains within the active stroke of the disc spring 249 . As soon as the disc spring 249 is fully compressed or if the housing 246 is engaged with—i.e. locked in positional relationship with—the shoe 260 any further compression will activate the main spring 247 . This relationship does not have to be true for the first embodiment, yet in most cases, however, it is preferred that the relationship that the effective spring constant of the first spring exceeds the spring constant of the second spring still prevails.
[0053] When sealing two layers of carton, during use, the spring housing 246 will be fixedly arranged in the shoe, and the disc spring 249 is not affected. Thus, instead the main spring 247 will be stressed when the jaw piston 254 , running through the rubber bushing 252 , pushes on the plate 256 . In this state, a washer 250 will be released, which washer was clamped in between the spring housing 246 and the plate 256 . In this way, by pushing the washer 250 , the user may control if the main spring 247 has been affected, and thus if correct sealing position has been obtained. If the main spring 247 is compressed ever so slightly, it will disengage from the washer 250 , whereby a handle portion of the washer 250 extending out from the spring housing 246 will become loose to the touch. So, if the washer 250 is loosely arranged the main spring 247 has been compressed, which in turn means that the correct sealing force is applied. Even if the washer 250 provides a convenient control parameter it should not be considered an essential feature of the present invention.
[0054] The spring force provided by the disc spring 249 may be balanced to provide about half the force needed during clamping.
[0055] There are numerous applications for the present embodiment, one being for the system disclosed in the copending application with application number SE1000902-5, where it may be used to suspend the sealing jaw 102 (reference numeral as used in FIGS. 1 and 2 of the cited application), | A sealing jaw assembly for a sealing unit, and in particular an arrangement for suspending a sealing jaw in a socket is disclosed. The arrangement is based on a first and a second spring arrangement wherein the action of the first spring arrangement onto the sealing jaw may be activated and deactivated. | 1 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates generally to audio signal recognition and classification and more specifically, to automated classification of an audio or audio/video signal with respect to the degree of musical content therein.
2. Description of the Related Art
Automated indexing and filtering of audio/video data is an important element of the construction of systems which electronically store and distribute such data. Examples of such storage and distribution systems include on-demand movie and music services, electronic news monitoring and excerpting, multi-media services, and archiving audio/video data, etcetera. The efficiency of indexing and filtering systems depends on accurate recognition of input data signals. For the sake of understanding, "indexing" refers to the determination of the location of features or events with respect to some coordinate system, such as frame number or elapsed time. Moreover, "filtering" is considered to be the real-time detection of features or events with the purpose of triggering other actions, such as adjusting sound volume or switching data sources.
Machine detection of music in audio tracks is currently a formidable problem for automatic audio/video indexing or filtering systems. Automated indexing and filtering processes are essential because manually processing very large amounts of data, especially in short periods of time, is extremely labor-intensive and because automation offers a consistency of performance generally not attainable by human operators.
Additionally, typical multi-media indexing and filtering applications, such as those mentioned above, are faced with the need to receive properly classified audio/video data from diverse sources. These sources vary widely in the format and quality of the input data. Current detection systems and methods cannot handle such variety in signal quality and format for a number of reasons. For example, such systems rely on separation and processing of high frequency components, which is not possible when sampling rates are low. Moreover, some systems rely on specific characteristics of pure audio signals, such as zero-crossings or peak run lengths, which cannot be reliably measured when the signal to be recognized is mixed with other signals.
There is also a need for the ability to identify an entire class of signals by its general characteristics, as opposed to recognition of a single, particular audio signal instance, such as the recognition of a particular recording of a popular song. Methods of the latter type cannot be used to solve the more general problem except in cases where the definition of a signal class is through the simple enumeration of previously recorded signals. There is a need for a system and method which can recognize the membership of a signal in a general class, even if that signal has not been previously encountered.
To date, most systems and methods in the area of music detection have been solely concerned with the problem of distinguishing between music and speech. This problem has different requirements than that of a general music detector, since, for music-or-speech classification, there is no need to distinguish music from non-music, non-speech sounds. Systems for music-or-speech classification make use of differences exhibited by these two types of signals in their signal power distribution with respect to frequency and/or time. The signal power of speech is concentrated in a narrower frequency band than that of music, and there are differences in power distribution within a signal with respect to time due to phrasing differences between speech and music.
Such power distribution differences are inadequate for a general music detector. For such a detector, it is necessary that musical signals be distinguished from a wide variety of other signals, not just from speech signals. There exist many types of non-musical audio signals which have patterns of power distribution with respect to frequency and/or time which are more similar to music that to speech. Thus a general music detector employing the current systems and methods results in many false positives when applied to signals which have a significant proportion of non-speech, non-music content.
One example of such a music-or-speech system is that discussed in U.S. Pat. No. 5,298,674 to Yun, entitled "APPARATUS FOR DISCRIMINATING AN AUDIO SIGNAL AS AN ORDINARY VOCAL SOUND OR MUSICAL SOUND". Yun's system is a hardware implementation of four separate music/speech classifiers, with the final music-or-speech classification resulting from a majority vote of the separate classifiers. One classifier addresses stereophonic signals by determining whether the left and right channel signals are nearly the same; if so, then the signal is classified as speech, otherwise as music. A second classifier determines whether the signal power in the speech frequency band (400-1600 Hz) is significantly higher than that in the music frequency band (below 200 Hz and above 3200 Hz); if so, the signal is classified as speech, otherwise as music. A third classifier ascertains whether there is low power intermittence in the speech frequency band; if so, the signal is classified as speech, otherwise as music. A last classifier determines whether there is high peak frequency variation in the music band; if so, the signal is classified as music, otherwise as speech.
The measurement of power levels in specific frequency bands is required for the Yun system, which makes it sensitive to aliasing and signal contamination. Further, signal properties such as power band differences, intermittence, and peak frequency variation are specific to the music-or-speech classification problem. This is inappropriate for the applications noted above.
Another music-or-speech system is that found in U.S. Pat. No. 4,541,110 issued to Hopf et al., entitled "CIRCUIT FOR AUTOMATIC SELECTION BETWEEN SPEECH AND MUSIC SOUND SIGNALS". In this system the signal is subdivided into two band limited signals, one covering the 0-3000 Hz band, and the other 6000-10,000 Hz band, corresponding to the voiced and voiceless components of speech, respectively. Null transitions are counted for both signals. Patterns of null transitions, both with respect to time, and with respect to the two frequency bands, lead to a classification as either speech or music. Long, uninterrupted sequences of null transitions which occur either in both frequency bands simultaneously, or in the lower band only, are classified as music. Patterns of null transitions which are interrupted by many short pauses (caused by pauses between syllables, words, etc.) and which occur in one or the other band, but not in both simultaneously (due to the alternation of voiced and voiceless speech sounds), are classified as speech.
This Hopf et al. method requires measurement of power levels in the particular given frequency bands. However, the 6000-10,000 Hz band is either missing or aliased when the sampling rate is 8000 Hz, which is the typical sampling rate for many types of digitized audio tracks. This method is therefore inapplicable to such audio or audio/video material. Additionally, the measurement of null transitions is easily corrupted by the presence of background noise or the mixture of other sounds. The Hopf et al. criteria for classification do not account for the possible presence of non-speech, non-music sounds. Thus, the effectiveness of systems such as that of Hopf et al. is reduced if the particular frequency range required is truncated by filtering, aliased to a different frequency range, or contaminated by aliased frequencies.
A further music-or-speech detection system is that disclosed in U.S. Pat. No. 4,441,203 to Fleming, entitled "MUSIC SPEECH FILTER". According to the Fleming system, components of the signal below 800 Hz are filtered out, thereby removing most speech components, and leaving the remaining signal composed largely of music components which may (or may not) be present. The total power level of the filtered signal is measured, and when above a pre-set threshold, the signal is classified as music.
The Fleming method depends on the absence of non-speech, non-music sounds, since there are many such sounds which have their power band in the 800 Hz and above band, which are erroneously detected as music. Moreover, at the more typical sampling rates (e.g., 8000 Hz) the Fleming method can be defeated by voiceless speech sounds aliased into the 800 Hz and above band. The method also misses musical sounds deleted by an anti-aliasing filter.
A system for detecting music is discussed in the doctoral thesis of Michael Hawley of the Massachusetts Institute of Technology, entitled "Structure out of Sound". The thesis contains descriptions of several sound processing algorithms which Hawley developed, one of which detects music. The Hawley music detector operates by taking advantage of the tendency of a typical musical tone to maintain a fairly constant power spectrum over its duration. This tendency causes the spectral image of musical sound to exhibit "streaks" in the time dimension, resulting from power spectrum peaks being sustained over time. A spectral image shows signal power, with respect to frequency and time, as a grey level image with log power level normalized to the pixel value range of 0 (low power) to 255 (high power). Hawley's detector automatically measures the location and duration of such streaks by finding "peak runs". A peak is a local maximum, with respect to frequency, of the power spectrum sampled at a given time. The spectral image is constructed by moving a Fast Fourier Transform ("FFT") window along the signal by regular increments. At each window position, a single power spectrum is taken. Each of these spectra forms a single vertical "slice" of a spectral image. Thus, a "peak run" is a sequence of peaks which occur at the same frequency over successive spectrum samples.
The Hawley music detector tracks the average peak run length of a sound signal over time. If the average run length goes above a threshold, the sound is judged to be musical. Hawley reports a distinct valley in the histogram of average peak run lengths over various types of sound signals. The value at which this valley occurs is used as a run length threshold which works well in separating music from other sounds.
However, the Hawley music detector exhibits some noticeable shortcomings. For example, it tends to be triggered by non-musical signals whose power spectra also exhibit time-extended frequency peaks, such as door bells or car horns. Further, and more important, the detector was found to be "brittle", that is, overly sensitive to any conditions which varied from the ideal, such as noise or errors of measurement. The concept "peak run", while simple and intuitive for humans to perceive, turns out to be difficult to implement as a mechanical pattern recognizer. Small run gaps or frequency fluctuations easily cause the detector to underestimate average run length and miss music segments. Noise, which can cause spectral image areas containing large numbers of scattered frequency peaks, triggers the detection of spurious runs, especially if the pattern recognizer is constructed to tolerate run gaps. Thus, while seeking to automate indexing of audio/video material from sources whose quality widely varies, the brittleness of the Hawley system and method presented a formidable problem.
SUMMARY OF THE INVENTION
In view of the above problems associated with the related art, it is an object of the present invention to provide a system and method for classification of an audio or audio/video signal on the basis of its musical content.
It is another object of the present invention to provide a system and method for classification of an audio or audio/video signal which degrades smoothly in proportion to any non-musical component of a mixed signal and which is tolerant of signals with multiple component signals or noise. Such system and method have a variety of parameters which can be adjusted so as to cause the system and method to accept a controlled level of non-musical signal mixed in with a musical signal while still classifying the mixed signal as music.
It is a further object of the present invention to provide a system and method for indexing or filtering data on the basis of audio features directly processed. It should be understood that such data may be multi-media data.
It is a still further object of the present invention to provide a system and method for classification of an audio or audio/video signal which is not affected by any anti-aliasing filtering which does not destroy the audible characteristics of the signal.
It is yet another object of the present invention to provide a system and method for classification of an audio or audio/video signal which is tolerant of a variety of data formats and encodings, including those with relatively low sampling rates and, hence, low bandwidth.
It is another object of the present invention to provide a system and method for indexing or filtering data on the basis of non-audio features which are processed by means of their correlation with audio features.
The present invention achieves these and other objects by providing an automated system and method for classifying audio or audio/video signals as music or non-music. A spectrum module receives at least one digitized audio signal from a source and generates representations of the power distribution of the audio signal with respect to frequency and time. A first moment module calculates, for each time instant, a first moment of the represented distribution with respect to frequency and in turn generates a representation of a time series of first moment values.
A degree of variation module in turn calculates a measure of degree of variation with respect to time of the values of the first moment time series and produces a representation of the first moment time series variation measuring values. Lastly, a module classifies the representation by detecting patterns of low variation, which correspond to the presence of musical content in the original digitized audio signal, and patterns of high variation, which correspond to the absence of musical content in the original digitized audio signal.
The system and method of the present invention provides improvement over existing systems and methods by using fundamental characteristics of music embodied as components of a digital audio or digital audio/video signal which distinguish musical signals from a large number of non-musical signals other than speech. As a result, the system and method of the present invention provides more accurate identification (or classification) resulting in more efficient and effective indexing and filtering applications for diverse multimedia material.
The system and method of the present invention is better able to process digitally sampled material than existing systems. This is particularly important because multimedia audio data is normally stored in a digital format (such as mu-law encoding), which requires sampling. For example, mu-law encoding at a sampling rate of 8000 Hz is typical. This sampling rate results in a Nyquist frequency of 4000 Hz. All frequency components above the Nyquist frequency are usually filtered out prior to sampling to avoid aliasing. Because the present invention measures the degree of variation of the first moment of the power distribution with respect to frequency in a way not significantly affected by aliasing, it is also not effected by any anti-aliasing filtering which does not destroy the audible characteristics of the signal. This is a significant improvement over existing systems which, as noted above, depend on the identification of signal strengths in a particular frequency range. This also results in the effectiveness of the present invention remaining acceptable if that frequency range is truncated by filtering, or is aliased partially or wholly to a different frequency range, which is an improvement over the existing art.
Another improvement achieved by the present invention over existing systems and methods derives from the statistical nature of the power distribution variation measurement which is used by the present invention. This measurement is based on the first moment of the power distribution. The first moment statistic degrades smoothly in proportion to any non-musical component of a mixed signal. Moreover, the parameters of the present invention can be adjusted to predetermined settings so as to cause the system and method of the present invention to accept a controlled level of non-musical signal mixed in with a musical signal while still classifying the mixed signal as music. As discussed earlier, the methods employed by existing systems tend to be sensitive to signal contamination ("brittle") and fail more rapidly in the face of such contamination.
These and other features and advantages of the invention will be apparent to those skilled in the art from the following detailed description of preferred embodiments, taken together with the accompanying drawings, in which:
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1a-g are simplified waveform graphs illustrating behavior of typical audio or audio/video signals as they are processed according to the method of the present invention, specifically:
FIG. 1a is a graph of the behavior of an example music first moment;
FIG. 1b is a graph of the behavior of an example of non-music first moment;
FIG. 1c is a graph of the behavior of a first derivative of an example music first moment;
FIG. 1d is a graph of the behavior of a first derivative of an example non-music first moment;
FIG. 1e is a graph illustrating a refinement of the behavior of an example music first moment;
FIG. 1f is a graph of the first derivative of the example music first moment of FIG. 1e;
FIG. 1g is a graph of the second derivative of the example music first moment of FIG. 1e;
FIG. 2 is a block diagram of an automated music detection system for classifying a signal as music or non-music according to an embodiment of the present invention;
FIG. 3 is a flow chart of the method of the voting module of the present invention;
FIG. 4 is an idealized graph of a typical second derivative histogram illustrating overlap of music and non-music portions;
FIG. 5 is a flowchart of a method for classifying a signal as music or non-music according to a preferred embodiment of the present invention; and
FIG. 6 is a block diagram illustrating the relationship the system of the present invention has with respect to various applications.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
Musical sound is composed of a succession of notes or chords, each of which are sounded for an interval of time. While the notes of a musical performance overlap in time in various ways, the performance can be divided into segments whose boundaries are the points in time at which a new note or notes begins to be played, or at which one or more notes stops being played. During such a segment, the sound signal consists of a harmonic combination of discrete overtones, contributed by one or more notes, whose relative frequency distribution remains nearly constant over the segment. The length of these segments is in general sufficient for the character of the sound to be apprehended by a human listener, typically on the order of a tenth of a second or more.
In contrast to musical sound, most other sounds have power spectra whose distribution varies more continuously and on a shorter time scale than that of music. This reflects an essential difference between musical and non-musical sound which gives music its expressive power. Melody and harmony are conveyed through the perception of musical tones. Perception of tone requires that a spectral distribution of power be maintained for an interval of time sufficient for human apprehension.
The music detector of the present invention preferably uses the same characteristic of musical sound exploited by the Hawley detector discussed earlier, namely, piecewise constancy of the power spectrum over time. The improvement is in the method used to measure this characteristic. The system and method of the present invention measures variation in the spectral power distribution by tracking its first moment.
Given the characteristics of music described above, the first moment of the example musical sound ideally exhibits behavior such as that shown in FIG. 1a. At any given moment during musical performance, a set of zero or more musical tones is being played simultaneously. Their power spectra sum to produce the total power spectrum of the sound. This tone set continues to play for a period of time, during which the power spectrum, and hence the first moment, remains constant. Eventually, either at least one of the tones ceases playing, or at least one tone begins playing. At that point, the power spectrum suddenly shifts to reflect the new tone set. Thus the example first moment exhibits the piecewise constant behavior of FIG. 1a.
On the other hand, most non-musical sounds have a more constantly varying spectral distribution, and hence a constantly varying first moment, as illustrated with the example waveform in FIG. 1b. Such behavior has been confirmed through observation of many types of nonmusical sound, and is especially true of speech.
Taking the first derivative with respect to time of the functions in FIGS. 1a-b, yields those shown in FIGS. 1c-d, respectively. The first derivative of the first moment is almost always zero for music, with spikes occurring where the first moment suddenly shifts due to changes in the set of tones being played. For non-music, the first derivative is usually non-zero, so that, on average, the absolute value of the first derivative of the first moment is much smaller for music than for non-music.
Experimentation has shown, however, that the distinction between musical and non-musical sound is not quite so dramatic as might be expected from examination of FIGS. 1c-d. There are a number of reasons for this, including the simplifications built into the described musical performance model. As a result, the following refinement of the performance model has proven to result in better music detector performance. Instead of considering tone set transitions as occurring instantaneously, transitions are preferably assumed to be extended in time, with a gradual shift in first moment values, as shown in FIG. 1e. Extended transition events cause the first derivative of the first moment (seen in FIG. 1f) to have non-zero values for much longer periods of time. Under this model, the first derivative of the first moment of music much more closely resembles that of non-music. However, using the second derivative results in the spiked behavior shown in FIG. 1g, which is similar to that of the first derivative in the previous performance model. Experiments show that using the second derivative of the first moment in fact improves the ability to separate music from non-music, and is therefore more accurate.
FIG. 2 depicts a block diagram illustrating automated music classification system 200 for classifying an audio or audio/video signal as music or non-music. System 200 consists of a series of software modules 210-280 running as communicating processes preferably on a single general purpose central processor connected to an input unit capable of reading a digital audio signal source. It should be understood that such processes may also be implemented on more than one processor, in which subsets of the modules run as communicating processes on multiple processors thereby implementing a data pipeline, with modules communicating in the order illustrated in FIG. 2, and with inter-processor communication requirements as described by the input/output specifications of the components given below. It should also be appreciated that the particular abstract data structures and numerical quantities employed in the discussion herein can be represented in various ways, are a matter of design choice, and should in no way be used to limit the scope of the present invention.
As an overview, the present invention operates on sampled power spectra of the sound signal. Power spectra are obtained using a Hartley transform employing a Hamming window function. Most tests used a window size of 256 samples. Operating on signals sampled at 8000 Hz (8-bit mu-law encoded), a window size of 256 gives a 128 sample single-sided power spectrum ranging from 0 Hz to a maximum unaliased frequency of 4000 Hz. Thus the spectrum is sampled with a frequency resolution of 4000 Hz/128 or 31.25 Hz.
The sampled power spectra are processed as shown in FIG. 2, and discussed in more detail later. Power spectra are calculated regularly at every 128 input audio samples, or in other words every 0.016 seconds with the sampling rate of 8000 Hz. The spectrum analyzer writes out one block of 128 values for each power spectrum. For each of these, a "noise floor" is taken in which spectral power values below the floor value are forced to zero. The first central moment is then taken, giving the "center of mass" of the power spectrum distribution with respect to frequency.
The sequence of first moment values, one per block, is processed by taking the absolute value of the second derivative, and then smoothed using a moving average. A threshold is used to produce a first music detector output.
Considering FIG. 2 in more detail, system 200 of the present invention receives and processes a digital audio signal. It should be understood that an analog audio signal can also be processed by the system and method of the present invention if it is first digitized. Such digitization can be accomplished using well-known methods. The present invention is not dependent on any particular sampling rate or quantization level for its proper operation. It should also be understood that digital audio signals which are encoded using non-linear coding schemes can be processed by the present invention by first converting them to linear coding using well-known methods. One of ordinary skill in the art will also appreciate that it is possible to employ system 200 to index an audio/video signal by using it to process an audio track which has been separated from such a signal and then re-combining the indexing information derived by system 200 from the processed audio track with the combined audio/video signal.
Window module 210 extracts sample vectors, I i = S i ,1, . . . , S i ,L ! from the input data stream, forms the vector product of each sample vector with a sampled windowing function W= W 1 , . . . , W L !, and writes the resulting vectors V i = W 1 S i ,1, . . . , W L S i ,L ! to output. Input sample vectors consist of a sequence of consecutive input samples, whose length L is a parameter of the module. In the current embodiment, L is preferably a power of 2, due to the requirements of the spectrum module (see below). Sample vectors are extracted at regular intervals whose length is specified by the parameter D, which is the number of samples separating the first sample of a sample vector from the first sample of the previous sample vector. The size of D determines the number of power spectra which are calculated per unit of time. This means that smaller values of D result in a more detailed tracking of variations in the power spectra, with a correspondingly greater processing burden, per unit of time. D preferably remains fixed during a given signal processing task.
The vector W i , . . . , W L ! consists of values sampled from standard windowing function for spectrum analysis. The use of such functions in spectrum analysis is well known. In the current embodiment, the samples are taken from a Hamming windowing function, although other windowing functions could be used instead.
Thus, the input to window module 210 is . . . , I t , I t+1 , I t+2 , . . . , and the parameters for window module 210 are W, L, and D, where:
I i is a linearly coded sample of the input audio signal taken at time i.
L is the "window length", i.e., the number of consecutive samples placed in each output window vector.
D is the "window delta", i.e., the number of samples by which the first sample of an input sample vector is offset from the first sample of the previous sample vector.
W is a vector W 1 , . . . , W L ! of samples from the windowing function.
The implementation of the window module is based on a circular list buffer. The buffer holds L samples at a time, and is initialized by reading into it the first L samples of the input signal. The module then enters a loop in which (1) the samples in the buffer are used to form the next vector V i , which is written out, and then (2) the buffer is updated with new samples from the input stream. These two steps are repeated until the entire input signal is processed. As a result of this processing, window module 210 outputs . . . , V t , V t+1 , V t+2 , . . . .
In step (1), samples from the buffer are multiplied with the window function sample vector. A pointer is kept which indicates the oldest element in the buffer, and this is used to read the samples from the buffer in order from oldest to newest. The product W 1 S i ,1, . . . , W L S i ,L ! is formed in a separate buffer and then written.
The manner in which the buffer is updated in step (2) depends on the relationship between L and D. If D<L, then for each loop the oldest L-D samples in the buffer are overwritten by new input samples, using the oldest sample pointer, which is then updated. If D≧L then the entire buffer is filled with new samples for every loop iteration.
Spectrum module 220 receives the output from window module 210 and applies the parameter L, which is the "window length", i.e., the number of consecutive samples placed in each output vector of module 210. Spectrum module 220 implements a method of discrete spectral analysis; any one of a variety of well-known discrete spectral analysis methods (e.g., fast Fourier transforms and Hartley transforms) can be used. Module 220 operates on the output vectors from window module 210 to produce a sampled power spectrum which approximates the instantaneous spectral power distribution of the input data segment by preferably treating the segment as one period of an infinitely extended periodic function and performing Fourier analysis on that function, the input data having generally been multiplied by a windowing function which attenuates the samples near either end of the data segment in order to reduce the effects of high-frequency components resulting from discontinuities created by extending the data segment to an unbounded periodic function.
The preferred embodiment of the present invention makes use of the Hartley transform, which is performed for each input vector V i , where V i is the ith output vector produced by the window function. The Hartley transform requires that L, the length of the input vector, be a power of 2. The output vectors P i which are produced are also of length L. Each P i is a vector P i ,1, . . . , P i ,L ! of spectral power values at frequencies 1, . . . , L for the signal segment contained in the ith input sample vector. The elements of P i represent power levels sampled at discrete frequencies nQ/L Hz for n=1, . . . , L, where Q is the Nyquist frequency. Since spectrum module 220 is concerned with variation in power distribution and not absolute power levels, no normalization of the sampled power values is performed.
The function of floor module 230 is to amplify variations in the power spectrum distribution input received from spectrum module 220. This is accomplished by setting all power levels below a "floor value", F, to zero, which increases the difference between the highest and lowest power levels occurring in a power distribution, thereby emphasizing the effects of shifting peak frequencies on the first moment. The value of F is a parameter whose optimal setting varies with the type of audio material being processed, and is preferably determined empirically.
Floor module 230 uses a buffer to hold the vector P i , which is composed of the spectral power values produced by spectrum module 220. After each vector is read, each vector element is compared to F, and set to zero if it is less than F. The vector P* i is then written directly from the modified buffer, and the next input vector read. P* i is a vector P* i ,1, . . . , P* i ,L ! of values defined as follows: ##EQU1## where F is the "floor value".
First moment module 240 calculates the first moment with respect to frequency of the modified power distribution vector P* i output from floor module 230. The calculation is performed by reading the input vector into a buffer, calculating the total spectral power T, and then the first moment m i , according to the formulas given below. Both calculations are implemented as simple iterative arithmetic loops operating on P* i , where:
P* i is the ith output vector P* i ,1, . . . , P* i ,L ! of the floor function.
m i is the first moment of the vector P* i ,1, . . . , P* i ,L !, that is: ##EQU2## and where ##EQU3##
Degree of variation module 250 calculates the measure with respect to time of the degree of variation of the values output by first moment module 240. The measure calculated is preferably the absolute second difference with respect to time of the sequence of values output by first moment module 240. The calculation is performed using a circular list which buffers three (3) consecutive first moment values. Each time a new first moment value is read, the oldest currently buffered value is replaced by the new value, and the second difference is calculated according to the formula:
di=∥m.sub.i -m.sub.i+1 |-|m.sub.i+1 -m.sub.i+2 ∥
where:
m i is the ith first moment output from the first moment function.
d i is the absolute second difference of the first moment output.
The purpose of degree of variation module 250 is to derive a measure of the degree of variation of the first moment time series. As a review, FIG. 1e illustrates the general form of typical first moment behavior over time for musical sound, based on the model of musical performance discussed above and on empirical observation. Taking the second derivative of this function, which is preferred, results in a graph such as illustrated in FIG. 1g. It can thus be seen that the second derivative of the first moment of musical sound tends to remain close to zero. This contrasts with the second derivative of the first moment for typical non-musical sound, which has no such tendency. Thus the average level of the absolute value of the second derivative correlates negatively with the presence of a musical component of the input sound signal.
Moving average module 260 implements an order M moving average of the second difference values output by degree of variation module 250. The purpose of module 260 is to counteract the high frequency amplification effect of degree of variation module 250. The output of moving average module 260 provides the trend of the second difference of the first moment over a history of M first moment measurements. The optimal value of the parameter M varies with the type of input audio material and must be determined empirically. Module 260 is preferably implemented using a circular list buffer of size M. Each input value read replaces the oldest buffered value. The output value is calculated by a simple arithmetic loop operating on the buffered values according to the formula: ##EQU4## where:
d i is the ith absolute second difference output by the second difference function.
M is the moving average window length.
a i is the moving average of the second differences
Threshold module 270 performs a thresholding operation on the moving average of the second difference of the first moment output . . . , a t , a t+1 , a t+2 , . . . , received from moving average module 260. This provides a preliminary classification as to music content of the input sample segment from which the input second difference value was derived. The optimal threshold value T varies with the type of input audio data and must be determined empirically. Threshold module 270 is implemented as a one sample buffer. The current buffer value is compared with T, and a Boolean value of 1 is written if the value is greater than or equal to T, or a 0 is written if it is less. The output of threshold module 270 is . . . , b t , b t+1 , b t+2 , . . . and is calculated by the formula: ##EQU5## where:
a i is the ith moving average output by the moving average function.
b i is the thresholded ith moving average value.
The system and method of the present invention is able to detect the presence of musical components mixed with other types of sound when the musical component contains a significant portion of the signal power. This is due to the fact that the average degree of variation in the first moment is increased by the presence of non-musical components in proportion to the contribution of those components to the signal power. Thus setting the threshold properly allows mixed signals to be detected as having significantly less variation than purely non-musical signals.
Threshold module 270 makes a music/non-music classification decision for every spectrum sample, in other words for the present example, once every 0.016 seconds. This is a much smaller time scale than that of human perception, which requires a sound segment on the order of at least a second to make such a judgment. The purpose of voting module 280 is to make evaluations on a more human time scale, filtering out fluctuations of threshold module 270 output which happen at a time scale far below that of human perception, but recognizing longer lasting shifts in output values which indicate perceptually significant changes in the input signal.
Voting module 280 adjusts the preliminary music classification values . . . , b t , b t+1 , b t+2 , . . . output by threshold module 270 to take into account the context of each value, where b i is the ith value output by the thresholding function. For example, at a sampling rate of 8000 Hz and a window length L of 256 samples, each value output by the threshold module represents a classification of 0.016 seconds of the audio signal. A single threshold module output of "0" (music) in the context of several hundred "1" (non-music) output values is therefore likely to be a spurious classification. Voting module 280 measures the statistics of the preliminary classification provided by threshold module over longer segments of the input signal and use this measurement to form a final classification. Voting module 280 outputs . . . , c t , c t+1 , c t+2 , . . . , where c i is the ith state value.
Voting module 280 maintains a state value, which is either 0 or 1. It outputs its current state value each time it receives a raw threshold value from threshold module 270. A 1 output indicates categorization as music. The state value is determined by the history of inputs from threshold module 270, as follows.
Variables are defined and initialized as follows when system 200 is started: state, initialized to 0; min -- thresh and max -- thresh, initialized to any values so that min -- thresh is less than or equal to max -- thresh; vote, initialized to 0; vote -- thresh, initialized to min -- thresh.
For each threshold value, T, received from threshold module 270, if T does not equal state, then vote is incremented by 1. In effect, threshold module 270 has voted for voting module 280 to change state. If T=state, then vote is decremented, but vote is not allowed to become less than zero.
For every N first level inputs received which do not cause a change of state, the value of vote -- thresh is incremented by one, until it reaches the value max -- thresh, after which it remains constant until the next change of state. N is a parameter of the algorithm.
If vote ever reaches vote -- thresh, then state is flipped to its other value, vote -- thresh is reset to min -- thresh, vote is reset to zero, and processing continues.
The general effect of the above is to give the variable state "inertia" which is overcome only by a significant imbalance in threshold module 270 votes. The longer state remains unchanged, the higher the inertia, up to the limit determined by max -- thresh. As a result there is a tendency to ignore short segments of music within longer segments of non-music, and vice versa. The setting of max -- thresh determines the longest segment which will be ignored through this mechanism.
Voting module 280 may be better understood by reviewing FIG. 3, which illustrates a flow chart of the voting method according to a preferred embodiment of the present invention. At each moment of time, the voting module state reflects its current "judgment" of the input signal as to musical content, either "0" (music) or "1" (non-music). The values received from the threshold module each count as V incr "votes" to either remain in the current state or switch to the opposite state. For example, if the voting module is in state "0", each "1" received from the threshold module is V incr votes to switch state to "1", and each "0" is V incr votes to remain in state "0".
For each time step, the voting module compares the vote counts for switching states and for staying in the current state. If the vote to switch exceeds the vote to stay by a least vote -- thresh, then the voting module switches state and resets its vote counts to zero.
The variable vote -- thresh increases its value by 1 for each time step, from a starting value of V min up to a maximum of V max . Thus, the longer the voting module remains in the same state, the more difficult it is, up to a limit, to cause it to switch to the other state. The value of vote -- thresh is reset to V min on every change of state.
The overall effect of voting module 280 is to classify the signal in terms of its behavior over periods of time which are more on the scale of human perception, i.e., for periods of seconds rather than hundredths of a second. The parameters V min , V max , and V incr can be set according to the type of input signals expected. For example, higher values of V min and V max cause the voting module to react only to relatively long term changes in the statistics of the threshold module output, which would be appropriate for input material in which only longer segments of music are of interest.
The settable parameters of the present invention include:
1) Hartley transform window size.
2) Hartley transform window type. Rectangular, Hamming, and Blackman windows are currently implemented.
3) Hartley transform window delta. The number of audio samples that the Hartley transform window is advanced between successive spectra.
4) Frequency window high and low values. The spectrum analyzer can be set to produce data for only a limited frequency band.
5) The noise floor level
6) Moving average window length. The number of past values used in calculating the moving average.
7) Detector threshold. The threshold value of the averaged second derivative which separates music (below threshold) from non-music (above threshold).
The best values for these parameters were determined through experimentation. The performance of the first level processor showed little sensitivity to parameters 1, 2, and 3. Setting parameter 4 to a low frequency band (for example, 0-500 Hz) showed better performance results than using the full available spectrum. Performance was not sensitive to the exact value of parameter 5, but there was a range of values which produced improved performance over those outside of that range. The values in this range put roughly 10% to 20% of the spectrum power values below the noise floor. Parameter 6 showed similar behavior, in that there was a range of values which gave better results, but performance was not sensitive to the precise value.
The best value for parameter 7, the detector threshold, varied depending on the other parameter settings. Generally, the histograms of the second derivative values for music and non-music had similar shapes and degrees of overlap over a wide range of parameter settings. The detector threshold was always set in the obvious way to maximize separation, but under no parameter settings was complete separation possible--there was always some degree of overlap between the histograms for music and non-music (see FIG. 4).
A preferred method embodiment of the present invention is illustrated in the flow chart seen in FIG. 5. After receiving a digital audio signal input, a discrete power spectrum is calculated (Block 510) for successive segments of the input signal by means of a suitable frequency analysis method, such as the Hartley transform referred to above. This produces a sequence of vectors, ordered by time, each vector describing the power versus frequency function for one segment of the input signal. The variations of the power spectrum is preferably amplified (Block 520) before continuing with the process.
Next, the first moment of spectral power with respect to frequency is calculated (Block 530) for each of the vectors. This results in a sequence of values which describes the variation of the first moment with respect to time. This sequence is then subjected to a measure of the degree of variation (Block 540), such as the second order differential described above.
At Block 550, a moving average is preferably implemented on the degree of variation values generated at Block 540. The degree of variation in the first moment over time is then subjected to thresholding (Block 560), with a lower degree of variation correlating with the presence of a musical component in that part of the input audio signal. The output of the thresholding process is preferably a sequence of Boolean values which indicate whether each successive signal segment exceeds the threshold.
Lastly, the Boolean value sequence produced by thresholding is subjected to a pattern recognizer in which the pattern of Boolean values is examined to produce the final evaluation of the musical content of each signal segment. The purpose of the recognizer is to use the contextual information provided by an entire sequence of threshold evaluations to adjust the individual threshold evaluation of the sequence. In this manner, prior knowledge as to the likely pattern of occurrence of musical and non-musical content can be employed in forming a sequence of adjusted Boolean values which are the final indicators of the classification of the signal with respect to the musical content of the signal segments.
Since the invention operates on the degree of variation of the first moment of the power distribution with respect to frequency, its operation is not affected by the sampling rate of the input audio signal or the frequency resolution of the derived power spectra. The method of the invention is also effective in cases where the range of measurable frequencies is restricted to a narrow band which does not include all frequencies of musical sound, as long as it includes a band which contains a significant portion of the power of both the musical sounds and the non-musical sounds of the signal. Moreover, the present invention is not defeated by aliasing of the signal frequencies being measured, because variations in power distribution in frequencies above the Nyquist frequency show up as variations folded into the measured frequencies.
FIG. 6 is a block diagram illustrating the relationship system 200 has with respect to application 620. Specifically, a source of digitized audio signal(s) 610 feeds input signals to system 200 to be classified. System 200 provides a continuous stream of decisions (music or non-music) to application 620. Application 620 can be a filtering application, an indexing application, a management application for, say, multimedia data, etcetera. It will be apparent to those of ordinary skill in the art that system 200 can be implemented in hardware or as a software digital signal processing ("DSP") system depending upon the particular use envisioned.
It should be understood by those skilled in the art that the present description is provided only by way of illustrative example and should in no manner be construed to limit the invention as described herein. Numerous modifications and alternate embodiments of the invention will occur to those skilled in the art. Accordingly, it is intended that the invention be limited only in terms of the following claims: | An automated system and method for classifying audio or audio/video signals as music or non-music is provided. A spectrum module receives at least one digitized audio signal from a source and generates representations of the power distribution of the audio signal with respect to frequency and time. A first moment module calculates, for each time instant, a first moment of the distribution representation with respect to frequency and in turn generates a representation of a time series of first moment values.
A degree of variation module in turn calculates a measure of degree of variation with respect to time of the values of the time series and produces a representation of the first moment time series variation measuring values. Lastly, a module classifies the representation by detecting patterns of low variation, which correspond to the presence of musical content in the original digitized audio signal, and patterns of high variation, which correspond to the absence of musical content in the original digitized audio signal. | 6 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] Not applicable.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not applicable.
TECHNICAL FIELD
[0003] The present invention generally relates to automated sewing machinery. More particularly, the invention relates to an automated flanging machine for sewing a flange onto a work panel having a consistent corner radius and a straight edge.
BACKGROUND OF THE INVENTION
[0004] The sewing of large panels of material often involves manual manipulation by an operator. For example, when sewing a flange onto bedding panels having a predetermined size and straight edges, a high level of skill and attention is required by the operator during sewing and manipulation of the panel along each side. To reduce the amount of operator attention required during sewing, some panels are sewn using automated methods.
[0005] One problem with automated sewing machinery is ensuring that panels may be automatically sewn with a consistent corner radius and straight edges. For example, some automated sewing machines follow the cut edge of a work panel, and therefore do not automatically produce straight sewn edges when the sides of a panel are not cut along a straight line. Further, if the automatic turning of a work panel is not accurate, the finished work panel may be sewn with varying corner angles, creating a trapezoid-shaped panel. In addition to straight edges and consistent corner turns, it is also important that a panel may be manipulated and turned during sewing with minimal operator intervention.
[0006] Accordingly, a need exists for an automated flanging system that automatically sews a flange onto panels having a consistent corner radius and straight edges, with minimal operator intervention, which addresses the foregoing and other problems.
BRIEF SUMMARY OF THE INVENTION
[0007] The present invention generally relates to an automated flanging machine that requires minimal operator intervention and sews work panels having a consistent corner radius and straight edges. Throughout the remainder of this application, reference will be made to a “work panel.” It should be understood that the invention contemplates sewing flanges onto all types of panels made of a variety of materials, both bedding and otherwise, and that the invention is not limited to the specific component being operated on. The automated flanging machine has a table with a table surface that supports a work panel during sewing. In one embodiment, an operator loads a work panel on the table surface and enters identifying information associated with the work panel into an operator interface associated with the machine.
[0008] The table includes a sewing head mounted directly adjacent to the table for performing a sewing operation on the work panel. The operator may actuate a foot pedal that lifts the presser foot of the sewing head while the work panel is loaded onto the machine. After positioning of the work panel onto the table, the machine then automatically sews a flange onto the straight edges of the work panel, creating straight sewn sides and corners with a consistently-sewn radius. In some embodiments, the machine may be used to sew the straight edges and consistent corners of the work panel, without attaching a flange to the bottom of the work panel.
[0009] To selectively turn the work panel on the table surface, the automated flanging machine utilizes a turning arm mounted adjacent to the table. In embodiments, the turning arm is engaged against a work panel during turning of the work panel (and sewing of the corner radius), and is not in contact with the work panel during sewing of the sides of the work panel. In further embodiments, a corner pivot mechanism is engaged against the corner of the work panel during turning of the work panel on the table surface. Additionally, the corner pivot mechanism maintains a consistent corner radius while the corner is sewn by the machine.
[0010] A rear conveyor, having a conveyor belt and a conveyor pressure skid, is mounted adjacent to the table. The conveyor belt advances the work panel along the table surface. In embodiments, the conveyor pressure skid is engaged against the work panel during sewing of the straight sides of the work panel, and is not in contact with the work panel while the work panel is being turned (and the corners are being sewn). A material guide and encoding arm is utilized to measure the progression of the work panel as it is sewn by the sewing head. In embodiments, the material guide and encoding arm is engaged against the edge of the work panel during sewing of the straight edges of the work panel, and is not in contact with the work panel during turning of the work panel. The machine also includes a flange knife assembly that cuts the flange once sewing of the work panel is completed.
[0011] Additional objects, advantages, and novel features of the invention will be set forth in part in the description which follows, and in part will become apparent to those skilled in the art upon examination of the following, or may be learned by practice of the invention.
BRIEF DESCRIPTION OF SEVERAL VIEWS OF THE DRAWING
[0012] The present invention is described in detail below with reference to the attached drawing figures, wherein:
[0013] FIG. 1 is a perspective view of one embodiment of the automated flanging machine;
[0014] FIGS. 2-14 are perspective views of the machine of FIG. 1 , with a work panel loaded onto the table surface;
[0015] FIG. 15 is an enlarged, perspective view of the rear conveyor of the machine of FIG. 1 ;
[0016] FIG. 16 is an enlarged, perspective view of the sewing area of the machine of FIG. 1 ; and
[0017] FIG. 17 is an enlarged, perspective view of the material guide and encoding arm of the machine of FIG. 1 .
DETAILED DESCRIPTION OF THE INVENTION
[0018] An embodiment of an automated flanging machine 10 is seen in FIGS. 1-17 . Referring first to FIG. 1 , automated flanging machine 10 includes a table surface 12 , a sewing head 14 , a turning arm 16 , a rear conveyor 18 , a conveyor belt 20 , a conveyor pressure skid 22 , a corner pivot mechanism 24 , a material guide and encoding arm 26 , a flange knife assembly 28 , a trailing edge sensor 30 , and an operator interface 64 . In some embodiments, the height of the machine 10 may be adjusted by an operator of the machine 10 , such that the table surface 12 reaches the operator's optimal standing working height. Further, although not depicted in FIG. 1 , the sewing head 14 may be associated with a foot pedal that the operator may use to raise and/or lower a presser foot of the sewing head 14 .
[0019] The rear conveyor 18 includes the conveyor belt 20 and the conveyor pressure skid 22 , which will be discussed later with reference to FIG. 15 . The rear conveyor 18 selectively moves a work panel on the table surface 12 , such as work panel 32 depicted in FIG. 2 . As such, the conveyor belt 20 and conveyor pressure skid 22 are engaged against the work panel 32 during sewing of a straight side of the work panel 32 , and are disengaged from the work panel 32 during turning of the work panel 32 (and sewing of the corner radius). In embodiments, the conveyor belt 20 of the rear conveyor 18 moves in the same direction and at the same rate as the sewing head 14 , in order to advance a work panel along the table surface 12 at a consistent speed.
[0020] As will be discussed in more detail with reference to FIG. 17 , the material guide and encoding arm 26 follows the edge of a work panel 32 as it is sewn by the machine 10 , and moved along the table surface 12 . In following the edge of the work panel 32 , the material guide and encoding arm 26 measures the distance sewn along the straight edges of the work panel 32 , which allows the machine 10 to determine when the work panel 32 is ready to be turned.
[0021] The turning arm 16 is capable of selectively engaging against a work panel 32 . During turning and sewing of the corner radius of the work panel 32 , the turning arm 16 is engaged against the work panel 32 , and is not in contact with the work panel during sewing along the straight sides of the work panel 32 . Similarly, the corner pivot mechanism 24 is engaged against the corner of a work panel during turning (and sewing of the corner radius), and is not in contact with the work panel during sewing (along the straight sides of the work panel 32 ) by the sewing head 14 .
[0022] As shown in FIG. 2 , a work panel 32 may be loaded on to the table surface 12 of the machine 10 for automatic sewing of a flange by the sewing head 14 . The work panel 32 has a first side 36 , a second side 38 , a third side 40 , and a fourth side 42 . In embodiments, the machine 10 is used to sew together two or more layers of material making the work panel 32 , or “close” the material of a work panel 32 together. For example, when the operator loads the work panel 32 onto the machine 10 , the edges may be “open” (i.e. not sewn together). In some embodiments, the work panel 32 is constructed of a bottom sheet of fabric, several middle layers of various types of foam and fiber fill, and top sheet of fabric. Prior to loading the work panel 32 onto the machine 10 , these layers of materials may be quilted on a quilting machine, with the work panel 32 being cut on its edges to the rough size of the finished work panel 32 . The machine 10 may then used to both close the edges of the work panel 32 and, at the same time, attach a flange to the bottom side of the work panel 32 . In further embodiments, the machine 10 is only used to close the edges of the work panel 32 , and does not attach a flange to the closed edge of the work panel 32 . In both embodiments (either closing the edges of the work panel 32 and attaching a flange, or simply closing the edges of the work panel 32 without attaching a flange), the machine 10 is used to produce a finished work panel 32 with sewn straight edges and corners sewn with a consistent corner radius, while measuring the work panel 32 in length and width. As such, sewing a work panel 32 with straight edges and consistent corners while measuring length and width produces a work panel 32 that is finished to the required dimensions.
[0023] Having loaded the work panel 32 onto the table surface 12 , an operator may enter identifying information related to the work panel 32 into the operator interface 64 . For example, the operator may select a pre-loaded SKU number (a “stock-keeping unit” number) from the operator interface 64 . Alternatively, the operator may input a new SKU number into the operator interface 64 , which identifies the work panel 32 . Such identifying information input by the operator may include the total size of the work panel 32 , the length of the straight sides of the work panel 32 , the corner radius to be sewn on the corners of the work panel 32 , and the like.
[0024] When preparing the work panel 32 for sewing by the machine 10 , the operator may actuate a foot pedal to raise and/or lower the presser foot 34 of the sewing head 14 . In doing so, a flange will be fed through the flange knife assembly 28 and underneath the presser foot 34 of the sewing head 14 . In embodiments, the presser foot 34 may be raised to varying heights to allow an operator to load various thicknesses of work panels 32 onto the machine 10 .
[0025] In one embodiment, the presser foot 34 may be raised up to 1.5 inches from the table surface 12 to allow for loading of a heavier-weighted work panel 32 . In preparing the work panel 32 for sewing by the machine 10 , in some embodiments, the operator uses a laser line generator to project a laser line onto the work panel 32 so that the operator can align the work panel 32 on the table surface 12 of the machine 10 . For example, the operator may align certain features within the quilted pattern of the work panel 32 with the laser line, thus allowing the work panel 32 to be cut and sewn in along a line that is parallel to the features of the work panel 32 .
[0026] Having confirmed that the work panel 32 is loaded correctly onto the table surface 12 of the machine 10 , the operator may engage the rear conveyor 18 by selection of an option from the operator interface 64 . In doing so, the conveyor belt 20 will engage against the bottom surface of the work panel 32 , and the conveyor pressure skid 22 will engage against the top surface of the work panel 32 , thereby securing the work panel 32 for movement. In embodiments, the conveyor belt 20 and conveyor pressure skid 22 secure the work panel 32 with minimal pressure between the two parts of the rear conveyor 18 . A foot pedal associated with the sewing head 14 may then be released and the presser foot 34 of the sewing head 14 may engage against the work panel 32 for the machine 10 to begin automatically sewing a flange around the perimeter of the work panel 32 .
[0027] As previously discussed, the conveyor belt 20 and the presser foot 34 of the sewing head 14 move at a consistent pace to advance the work panel 32 during sewing. During sewing, the material guide and encoding arm 26 may then engage against the rear edge of the work panel 32 . In embodiments, the material guide and encoding arm 26 clamps the edge of the work panel 32 , such as clamping the fourth side 42 of the work panel 32 depicted in FIG. 2 . In doing so, the material guide and encoding arm 26 follows the edge of the work panel 32 while the first side 36 of the work panel 32 is sewn by the sewing head 14 . In embodiments, a linear encoder in the material guide and encoding arm 26 is used to measure the distance sewn by the sewing head 14 along the straight sides of the work panel 32 .
[0028] Turning next to FIG. 3 , as the trailing edge of the first side 36 of the work panel 32 approaches the sewing head 14 , the trailing edge sensor 30 detects that the machine 10 has completed sewing at least a portion of the first side 36 of the work panel 32 . Having sensed the trailing edge of the first side 36 , the trailing edge sensor 30 indicates to the machine 30 that the work panel 32 is ready to be turned, and the corner radius is ready to be sewn. As shown in FIG. 3 , in order to turn the work panel 32 , the turning arm 16 and the corner pivot mechanism 24 engage against the work panel 32 . Engaging the corner pivot mechanism 24 against the work panel 32 provides a pivot point around which the machine 10 can sew a consistent corner radius. For example, when turning the work panel 32 from sewing the first side 36 to sewing the second side 38 , the corner pivot mechanism 24 maintains a constant distance between the sewing head 14 and the edge of the work panel 32 , thus ensuring that the machine 10 sews a consistent corner radius with the sewing head 14 .
[0029] Also depicted in FIG. 3 , the cylinders of the turning arm 16 actuate and engage the work panel 32 to turn the work panel 32 to a position that is 90 degrees relative to the initial position of the work panel 32 . For example, the turning arm 16 turns the work panel 32 from sewing along the first side 36 to sewing along the second side 38 . Once the turning arm 16 and the corner pivot mechanism 24 are engaged with the work panel 32 , the material guide and encoding arm 26 and rear conveyor 18 disengage from the work panel 32 so that the turning arm can reposition the work panel 32 .
[0030] Referring next to FIG. 4 , with the material guide and encoding arm 26 disengaged from against the work panel 32 , the turning arm 16 rotates the work panel 32 to a position 90 degrees relative to the original line sewn along the first side 36 , while continuing to sew the corner radius of the work panel 32 with the sewing head 14 . During turning, the sewing head 14 sews a consistent corner radius between two sides of the work panel 32 , such as the corner radius between the first side 36 and the second side 38 . As such, the corner pivot mechanism 24 maintains a constant distance between the edge of the work panel 32 and the sewing head 14 , which creates a consistently-sewn corner radius on the work panel 32 .
[0031] As shown in FIG. 5 , the corner between the first side 36 and the second side 38 has been sewn. Prior to beginning sewing the second side 38 , the rear conveyor 18 engages against the work panel 32 . Further, the material guide and encoding arm 26 moves forward into contact with the work panel 32 and clamps the work panel 32 at the rear edge of the sewing head 14 . Additionally, the cylinders of the turning arm 16 disengage and the turning arm 16 rotates back to its original position while the corner pivot mechanism also disengages from the surface of the work panel 32 , as shown in FIG. 6 . As further depicted in FIG. 6 , the clamp of the material guide and encoding arm 26 is engaged against the first side 36 of the work panel 32 , as the machine 10 prepares to sew the second side 38 of the work panel 32 . The point at which the material guide and encoding arm 26 clamps the work panel 32 is a known distance from the needles of the sewing head 14 because the sewing head 14 has just completed sewing the corner radius between the first side 36 and the second side 38 .
[0032] As the machine 10 begins sewing the second side 38 of the work panel 32 , the material guide and encoding arm 26 begins measuring the distance that is sewn using a linear encoder, as shown in FIG. 7 . When the distance sewn along the second side 38 , added to the known distance where the work panel 32 is clamped by the material guide and encoding arm 26 , equals the programmed length of the work panel minus the corner radius, the corner pivot mechanism 24 and the turning arm 16 engage to contact the work panel 32 . For example, for a programmed work panel 32 having a total length of 20 inches and a corner radius sewn between the first side 36 and the second side 38 of 3 inches, the corner pivot mechanism 24 and the turning arm 16 will engage when the distance sewn along the second side 38 (as measured by the linear encoder of the material guide and encoding arm 26 ) added to the known distance where the work panel is clamped by the material guide and encoding arm, is equal to 17 inches.
[0033] As shown in FIG. 8 , the known distance (the point at which the material guide and encoding arm 26 is clamped to the work panel 32 ) added to the distance measured by the material guide and encoding arm 26 during sewing of the second side 38 of the work panel 32 , equals the programmed length of the work panel 32 minus the corner radius. As such, the work panel 32 is ready to be turned for sewing of the corner between the second side 38 and the third side 40 , as well as the sewing of the third side 40 . As shown in FIG. 9 , the clamp of the material guide and encoding arm 26 is disengaged from the edge of the work panel 32 and the corner pivot mechanism 24 and turning arm 16 engages against the work panel 32 . The rear conveyor 18 is also disengaged from the work panel 32 during turning. The turning of the work panel around the corner between the second side 38 and the third side 40 is depicted in FIG. 9 . As such, the same corner radius sewn between the first and second sides 36 and 38 is sewn between the second and third sides 38 and 40 .
[0034] In FIG. 10 , having completed sewing the second corner of the work panel 32 , the machine 10 is prepared to sew the third side 40 of the work panel 32 . As previously discussed, in preparation for sewing the third side 40 , the clamp of the material guide and encoding arm 26 , the conveyor pressure skid 22 , and conveyor belt 20 , are engaged against the work panel 32 . Further, the turning arm 16 and corner pivot mechanism 24 are disengaged from the work panel 32 . The third side 40 and the corner between the third side 40 and the fourth side 42 are sewn similarly to the second side 38 (and the corner between the second side 38 and the third side 40 ) discussed above.
[0035] Referring next to FIG. 11 , the machine 10 has completed sewing the fourth side 42 . As discussed above, the sewing head 14 is determined to have completed sewing the fourth side 42 when the known distance (where the fourth side 42 is clamped by the material guide and encoding arm 26 ) added to the measured distance sewn (as measured by the material guide and encoding arm 26 during sewing of the fourth side 42 ) equals the programmed length (a pre-determined number programmed into the operator interface 64 ) minus the corner radius (the corner radius sewn at each corner when turning the work panel 90 degrees relative from one side of the work panel to the next).
[0036] As shown in FIG. 12 , the corner radius between the fourth side 42 and the first side 36 is sewn while the work panel 32 is turned. As previously discussed, the material guide and encoding arm 26 and the rear conveyor 18 are disengaged during turning and sewing of the corner, while the corner pivot mechanism 24 and the turning arm 16 are engaged against the work panel 32 . In FIG. 13 , having turned the work panel 32 so that the first side 36 is again aligned with the sewing head 14 , the operator sews at least a portion of the first side 36 , to the point where sewing began along the first side 36 . As the end sewing line sewn by the sewing head 14 approaches the beginning sewing line sewn by the sewing head 14 , the operator actuates the flange knife assembly 28 by selecting an option from the operator interface 64 , as shown in FIG. 14 . The flange knife assembly 28 actuates to cut off the flange, and the finished work panel 32 may be sewn off. As previously discussed, in some embodiments, the machine 10 sews the straight edges and consistent corners of the work panel 32 without attaching a flange to the bottom side of the work panel 32 .
[0037] Turning next to FIG. 15 , an enlarged view 44 of the rear conveyor 18 is shown. As depicted in the cut-away portion of the table surface 12 , the rear conveyor 18 includes a conveyor belt 20 which engages against the bottom surface of a work panel 32 . Further, the conveyor pressure skid 22 may be lowered into contact with a work panel 32 . As previously discussed, engaging both the conveyor belt 20 and the conveyor pressure skid 22 of the rear conveyor 18 enables the work panel 32 to be advanced during sewing by the machine 10 . In some embodiments, because of the pressure applied by the components of the rear conveyor 18 , the work panel 32 is fed at a consistent rate through the machine 10 , and the sides of the work panel 32 are sewn in a straight line by the sewing head 14 .
[0038] With reference to FIG. 16 , an enlarged view of the sewing area 46 is shown. The sewing area 46 includes the sewing head 14 and the presser foot 34 , which are used to sew the straight edges of the work panel 32 . Also viewed in the enlarged sewing area 46 are the corner pivot mechanism 24 , the pivot cylinder 48 , the trailing edge sensor 30 , the trailing edge reflector 50 , and the flange knife assembly 28 . In embodiments, the pivot cylinder 48 actuates the pivot mechanism 24 so that the pivot mechanism 24 is engaged against the work panel 32 during turning. The trailing edge sensor 30 , together with the trailing edge reflector 50 , detects the trailing edge of the work panel 32 during sewing, as discussed above with reference to sewing the initial portion of the first side 36 . In embodiments, the trailing edge sensor 30 is used to detect when the sewing head 14 has completed sewing at least a portion of the first side 36 , and also to determine when the machine 10 is ready to turn the work panel 32 for sewing the corner radius between the first side 36 and the second side 38 . When sewing subsequent sides of the work panel 32 , such as the second side 38 , third side 40 , and fourth side 42 , the material guide and encoding arm 26 is used to determine when to turn the work panel 32 and sew the corner radius, as opposed to using the trailing edge sensor 30 .
[0039] Turning last to FIG. 17 , the material guide and encoding arm 26 is shown in an enlarged view. The material guide and encoding arm 26 includes a clamp 52 , a linear guide 54 , a gear rack 56 , a constant force spring 58 , an encoder 60 , and a magnetic strip 62 . As previously discussed, the clamp 52 of the material guide and encoding arm 26 is able to engage against the edge of the work panel 32 to measure the progression of the work panel 32 as a straight side is sewn by the sewing head 14 . Such measurement is conducted using the encoder 60 , which may be a linear encoder or another form of measuring device. The constant force spring 58 allows the material guide and encoding arm 26 to follow the edge of the work panel 32 as it is advanced by the sewing head 14 and sewn by the machine 10 . As will be understood, in following the edge of the work panel 32 , the material guide and encoding arm 26 does not apply pulling force to the work panel 32 . Instead, the material guide and encoding arm 26 measures the progression of the work panel 32 as it is advanced by the sewing head 14 and the rear conveyor 18 .
[0040] From the foregoing, it will be seen that this invention is one well adapted to attain all the ends and objects hereinabove set forth together with other advantages, which are obvious and which are inherent to the structure.
[0041] It will be understood that certain features and subcombinations are of utility and may be employed without reference to other features and subcombinations. This is contemplated by and is within the scope of the claims.
[0042] Since many possible embodiments may be made of the invention without departing from the scope thereof, it is to be understood that all matter herein set forth or shown in the accompanying drawings is to be interpreted as illustrative and not in a limiting sense. | An automated flanging machine is provided. More specifically, a machine for automatically sewing a flange onto a work panel having a consistent corner radius and a straight edge is provided. The machine has a table adapted to support a work panel, a sewing head mounted directly adjacent to the table for performing a sewing operation on the work panel, a turning arm mounted adjacent to the table, and a rear conveyor for selectively moving the work panel on the table. The table may include a corner pivot mechanism for stabilizing the panel while the turning arm turns the panel 90 degree relative to an initial position, and for maintaining a consistent corner radius for sewing. The machine may also include a rear material guide and encoding arm for measuring the progression of the work panel as it is sewn along a side by the sewing head. | 3 |
FIELD OF THE INVENTION
[0001] The present invention relates to the business methods and, in particular, to methods of conducting the business of an association of sports fans.
BACKGROUND OF THE INVENTION
[0002] Competitive sports are big business and also the largest entertainment pastime in the world from grade school to pro. Today, sporting events can be heard on radio, viewed in person or on television at almost any time of any day. The prime driver behind the explosion in the business of sports has been the willingness of sports fans to watch sports and to spend their money on the sports that they love.
[0003] Exponential growth in spectator sports in recent years can be credited to the unlimited access and participation allowed the spectator through multi-media. Sports fans tend to be passionate about the sports that they follow, and sports talk radio has also become an extremely popular forum for sports fans to express their opinions about issues relating to their sports. Similarly, many web sites have proliferated that are dedicated to providing sports fans with sources of information and further outlets for them to express their opinions. Unfortunately, despite the many outlets for fans to obtain information and express their views, this information is not compiled in any user-specific manner and fans' views are now fragmented and are not brought together in any meaningful way. Further, these views are now expressed after the sporting event concludes, and no mechanism now exists for sports fans to express their views in a manner that allows them to effect change in the outcome of a live sporting event, or even have their opinion heard in real time; let alone as a registered group creating opinions from the masses that really object to a bad decision. We believe that is a disservice to the fans and the sports industry insofar as there is a vast group unheard from whose voice, when heard, could effect the direction of a given sports industry
[0004] Associations, such as trade associations, typically represent the interests of their members and conduct activities such as lobbying, standards setting, and education to its members. Associations exist in a large number of industries and endeavors. For example, the American Association of Retired People (AARP) represents the interests of members over the age of 55, while the American Bar Association represents the interests of its attorney members. In the field of sports, associations such as the Major League Baseball Players Association, the NFL Players Association, and others, represent the interests of professional sports players. Similarly, associations exist on the amateur level in groups such as the AAU, United States track and field Association, the United States golf Association, and others are involved in sports specific activities of interest to their members. Each of these associations caters specifically to participants in the sporting activities and not to those people who are fans of these sports. Further, no single association involves itself in a wide variety of sports.
[0005] Some current sports associations include charitable foundations aimed at promoting their particular sports. These foundations are typically run by staff and boards of directors, who review funding requests and award grants based upon the result of their review. Such foundations may also have relationships with providers of new and/or used sporting goods, who can provide free or discounted sporting goods to worthy groups. However, there currently is no way for members of an association to directly determine who receives grants. Further, there is no way for groups needing donations of new and/or used sporting goods to interact directly with other groups, and providers, who may be able to help them.
[0006] Finally, despite the great many sources of information on professional and college level sports, there is currently no central source of information relating to youth sports leagues. Thus, friends and family members who live a great distance away, or service men and women stationed overseas, have no way to keep track of their own “Future All Stars”, other than through direct contact with the participants.
[0007] Therefore, there is a need for an association of sports fans that caters to fans of a broad range of sports, that brings together the views of the fans of the sports in a single location that can be used by officials, players, and the management of sports teams, allows fans to have a voice in deciding issues relating to their sport both after the games are played and during the games themselves, that provides grants to youth and high school athletic programs in which members directly determine who receives grants, that provides a means for groups needing donations of new and/or used sporting goods to interact directly with other groups, and providers, who may be able to help them, and that provides a central source of information relating to youth sports leagues.
SUMMARY OF THE INVENTION
[0008] The present invention is directed to methods of conducting the business of an association of sports fans. One group of embodiments of the method involves the use of direct member voting to control actions that are taken by the association and by third parties. In their most basic form, these methods include the steps of registering a plurality of sports fans to serve as members and providing the members with access to a members website. The step of providing members with access to a members website includes the steps of creating a voting web page comprising at least one question for members to vote upon and transmitting the voting web page to members. Once the members transmit their votes, the method includes receiving votes cast by the members, generating results based upon the receiving step, transmitting a web page that includes the results, and taking a predetermined action based upon the results.
[0009] In preferred embodiments of the methods that include member voting, the registering step includes the steps of requesting that members identify at least one of a sport and a sport league that is of interest to the members, requesting that members provide demographic information, and storing results of each of the requesting steps in a member database. It is preferred that the demographic information include age, median family income, address, educational background, participation background for sports identified to be of interest, and/or team loyalty information. In some such embodiments, the information received by the members is used to impact the results of the vote. In these embodiments, the method also includes the step of linking votes received from members in the receiving step to demographic information of the members and weighting the votes cast by the members based upon the information provided by the members in the receiving step.
[0010] In preferred embodiments of the methods that include member voting, the association performs the steps of negotiating with a third party to agree to take a predetermined action based upon the results of the member vote. In these embodiments, the step of taking a predetermined action based upon the results includes instructing the third party to take the predetermined action. In some embodiments, the negotiating step includes negotiating with the third party to agree to allow the result to effect a decision made in a live sporting event, which may including decisions relating to replay decisions and/or penalty decisions. In other embodiments, the negotiating step includes negotiating with the third party to agree to allow the result to effect a disciplinary decision, a personnel decision, and/or a rulemaking decision.
[0011] Some embodiments of the methods that include member voting include the step of sending a wireless text message to members including at least one question for members to vote upon; and receiving text message votes cast by said members.
[0012] In some embodiments of the methods that include member voting, the registering step includes the step of requesting that the members designate a fund in which a donation is to be credited and the method includes the further step of crediting an amount of the donation to the fund. In some such embodiments, the step of requesting that a member designate fund includes requesting that a member designate a fund corresponding to at least one specific criterion, including a sport, a level of competition, a geographic area, and/or an athletic program. In some such embodiments, the step of posting questions for members to vote upon includes posting questions relating to the acceptance of grant proposals and the step of taking a predetermined action based upon the results includes donating at least of portion of the amount credited to the fund based upon the results.
[0013] Another group of embodiments of the method do not require member voting, but rather relate to the provision of member specific information to members based upon the information that the members provide. In their most basic form, these methods include the steps of registering a plurality of sports fans as members. The registering step includes requesting that members identify all sports that are of interest to the members, requesting that members identify all sports leagues that are of interest to the members, requesting that members provide demographic information, receiving results of the requesting steps transmitted by the members, and storing results of each of the requesting steps in a member database. The method also includes the step of providing the members with access to a website, which includes the sub-steps of accessing results of each of the requesting steps stored in the database, compiling member specific information based upon the results, creating a member specific web page comprising the compiled member specific information, and transmitting the member specific website for viewing by the member.
[0014] In some such embodiments, the method includes the steps of receiving youth sports league information from the members, creating at least one youth sports league web page containing the youth sports league information, and creating a member specific web page that includes at least one link to at least one youth sports league web page. In such embodiments, it is preferred that the method include the steps of receiving access information from the members and limiting transmission of at least one youth sports web page based upon the access information received from the members.
[0015] In some embodiments of the method, the registering step also includes the step of requesting that the members designate a fund in which a donation is to be credited and the method includes the further steps of crediting an amount of the donation to the fund based upon the result of the receiving step, creating a fund web page that includes a description of the fund and a total amount credited to the fund, and creating a member specific web page that includes at least one link to the fund web page.
[0016] Some embodiments of the method include the step of receiving grant requests, creating a grant request web page that includes the grant requests, and creating a member specific web page that includes at least one link to the grant request web page.
[0017] In some embodiments of the method the website is not member specific, but rather includes information relating to at least two different professional, collegiate, and high school sports, and includes member provided information relating to youth sports. In such embodiments, the method includes the steps of registering a plurality of members, wherein said members are sports fans and providing the members with access to a website. The providing step includes the steps of compiling information relating to at least two different professional, collegiate, and high school sports; creating web pages that include the compiled information, receiving youth sports league information from the members; creating at least one youth sports league web page containing the youth sports league information; and creating a member web page containing links to said youth sports league web page and web pages that include the compiled information relating to at least two different professional, collegiate, and high school sports, and transmitting the member web page for viewing by said member.
[0018] In some such embodiments, the members providing youth sports information may restrict access to the information. In these embodiments, the method includes the steps of receiving access information from the members and limiting transmission of at least one youth sports web page based upon the access information received from the members.
[0019] In other embodiments, the website includes grant request pages and/or donation offer pages. In these embodiments, the method includes the steps of receiving grant requests and/or donation offers, creating a grant request and/or donation offer web page, and creating a member web page with links to these pages.
[0020] Therefore, it is an aspect of the invention to provide a method of conducting the business of an association of sports fans in which the association serves fans of a broad range of sports.
[0021] It is a further aspect of the invention to provide a method of conducting the business of an association of sports fans that brings together the views of the fans of the sports in a single location that can be used by officials, players, and the management of sports teams.
[0022] It is a further aspect of the invention to provide a method of conducting the business of an association of sports fans that allows fans to have a voice in deciding issues relating to their sport.
[0023] It is a further aspect of the invention to provide a method of conducting the business of an association of sports fans that utilizes a website that provides targeted information based upon the member's particular demographic information.
[0024] It is a further aspect of the invention to provide a method of conducting the business of an association of sports fans that allows members to watch the live sporting event and cast votes that will affect the outcome thereof.
[0025] It is a further aspect of the invention to provide a method of conducting the business of an association of sports fans that allows its members to decide the outcome of replay challenges.
[0026] It is a further aspect of the invention to provide a method of conducting the business of an association of sports fans that allows its members to affect penalties assessed by game officials.
[0027] It is a further aspect of the invention to provide a method of conducting the business of an association of sports fans that allows its members to affect or determine the imposition of sanctions on players and teams.
[0028] It is a further aspect of the invention to provide a method of conducting the business of an association of sports fans that allows its members to affect or determine changes to existing rules.
[0029] It is a further aspect of the invention to provide a method of conducting the business of an association of sports fans that allows its members to affect or determine free agent signings and contract negotiations by individual teams.
[0030] It is a further aspect of the invention to provide a method of conducting the business of an association of sports fans in which certain demographical information is used to affect results of the member voting.
[0031] It is a further aspect of the invention to provide a method of conducting the business of an association of sports fans in which voting may take place on the Association's Internet website, or may be performed using land-based or mobile phones, or by using kiosks located at the venues themselves.
[0032] It is a further aspect of the invention to provide a method of conducting the business of an association of sports fans in which members may communicate with players, officials and commentators of note in connection with issues that are being voted upon in order to become fully informed about the issues.
[0033] It is a further aspect of the invention to provide a method of conducting the business of an association of sports fans in which the association will serve as a conduit for fans to file grievances or disputes with sports leagues and teams.
[0034] It is a further aspect of the invention to provide a method of conducting the business of an association of sports fans in which the association will serve as a mediator or arbitrator for disputes between members and sports teams or leagues.
[0035] It is a further aspect of the invention to provide a method of conducting the business of an association of sports fans in which the association provides grants to youth and high school athletic programs in which members directly determine who receives grants.
[0036] It is a further aspect of the invention to provide a method of conducting the business of an association of sports fans in which the association that provides a means for groups needing donations of new and/or used sporting goods to interact directly with other groups, and providers, who may be able to help them.
[0037] It is a still further aspect of the invention to provide a method of conducting the business of an association of sports fans in which the association provides a central source of information relating to youth sports leagues.
[0038] These aspects of the invention are not meant to be exclusive and other features, aspects, and advantages of the present invention will be readily apparent to those of ordinary skill in the art when read in conjunction with the following description, appended claims and accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0039] FIG. 1 is a flow chart showing the modules of the preferred website used in connection with the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0040] The present invention is directed to methods of conducting the business of an association of sports fans. It is preferred that the methods of the present invention be executed by an Internet web site, although the methods may also be performed by other means, such as through wireless phones, Intranets, or other art recognized means. A flowchart showing modules of the preferred website for executing the methods is shown in FIG. 1 . The coding of such a website is well within the capability of those of ordinary skill in the art of website development and, the specific code required to operate the website is not disclosed herein.
[0041] In one embodiment of the method, the association recruits fans of a number of different sports, who register as members and pay a membership fee to the Association. As part of the registration process, the new member will identify all of the sports that the fan follows in all of the sports leagues in which the fan has an interest. In addition, the fan will provide demographic information such as age, median family income, address, educational background, participation background for the sports identified to be of interest; i.e. years and/or levels played, officiated, coached, etc., and team loyalty information. This information will be used later by the Association to customize the information provided to the fan and provide targeted data to interested parties. Finally, the new member will be presented with a set of membership rules and guidelines that must be followed.
[0042] When the registration process is complete, the new member will be assigned a username and password that will allow the member to access a web site for association members. The operation of the web site is an important component of the method of conducting business of the present invention and is described in detail herein.
[0043] The Association web site preferably includes links to a number of pages relating to different sports, with separate pages relating specifically to leagues and teams, as well as pages that are generated based upon the interests of the individual fan accessing the site. In one embodiment, the web site will automatically configure itself based on the demographic information provided by the member and will provide immediate access to the information that is most relevant to him or her. This information may include scores, statistics, commentary relating to recent events, requests for input on questions pertinent to the fan's interests, results of recent polls on questions pertinent to the fan's interest, special offers targeted to fans having similar interests, links to live audio and video feeds, links to third party articles that may be of interest to the fan, weblog and discussion group postings, etc.
[0044] One unique feature of the website is the ability of members to vote on issues relating to sports of interest and to have their votes affect the result of the issue on which they are voting. In one embodiment of the method, the Association will negotiate with sports leagues to allow their members to have a direct voice in the outcome of decisions made in a live sporting event, and members will be able to watch the live sporting event and cast votes that will affect the outcome of certain decisions.
[0045] For example, the Association may negotiate with a football league, such as the Arena Football League, NFL Europe, or the like, to allow its fans decide the outcome of decisions made on replay challenges. In such a scenario, the Association's members would be shown the video replay and provided with an explanation of the rule under which the replay would be decided. Members of the Association would then view the replay and cast their votes on whether or not the ruling on the field should be upheld or overturned and the decision of the members would control the outcome of the challenge.
[0046] Another example of where member voting will affect the outcome of a decision made in a live sporting event is in the area of penalties assessed by game officials. For example, a baseball, hockey or basketball official may unfairly eject a player or manager from game, or may not see something that would cause him or her to eject that player. Similarly, a hockey player may be given a major penalty when a minor penalty should have been assessed, or vice versa. In these situations, the Association would negotiate with the league to allow member voting on these situations, the members would vote to change the outcome, and the results of the voting would be used by the officials to change the outcome of the event.
[0047] In some embodiments of the method, the Association will negotiate with sports leagues and players associations to allow fan voting to affect or determine the outcome of disciplinary decisions, such as the imposition of sanctions on players and teams. Traditionally, such sanctions have been unilaterally issued by the league office responsible for such sanctions or directly by the commissioner of the league. However, in such embodiments of the business method of the present invention, members would be allowed to vote on the appropriate sanction for the behavior of a player, coach, team executive and/or owner and the result of such voting would determine what sanctions are imposed.
[0048] For example, the National Football League reviews plays submitted to the league office each week during the season and issues fines and suspensions for certain players' behavior, such as late hits, unnecessary roughness penalties, etc. Under the method of the present invention, the Association's members would be allowed to vote on these sanctions and the results of this voting would determine whether the player is to be fined, what amount he should be fined and whether a suspension is warranted. Similarly, the fans may vote to uphold or deny sanctions imposed by the league offices; i.e. if a player receives a fine or suspension from the league, the Association's members would be allowed to vote on whether the sanction imposed was appropriate and, if the vote results in a finding that it was inappropriate, the league would need to reevaluate the sanction and issue a new sanction.
[0049] In other embodiments of the method, the Association will negotiate with sports leagues to allow fan voting to determine the result of rulemaking decisions, such as the addition of new rules and changes to existing rules. For example, the National Football League has a “competition committee”, made up of representatives of a number of teams, that proposes new rules and changes to existing rules, considers the proposals, and either approves or denies the necessary changes. In some embodiments of the method of the present invention, members of the Association would vote to approve or disapprove the adoption of new rules or changes to existing rules. This vote may be binding upon the league, or may be used to augment the function of a league committee. For example, the Association could negotiate a bicameral voting approach in which both an affirmative fan vote and a league vote would be required in order for a change to be implemented. Conversely, the Association could negotiate a system similar to that currently used by the National Football League in connection with Pro Bowl voting, in which the results of fan voting are given a certain percentage of the vote along with the votes of the coaches and players. Still other voting methods may also be negotiated and these are but examples of what procedures may be utilized.
[0050] In other embodiments of the method, the Association will negotiate with individual teams to allow fan voting to affect or determine player personnel decisions, such as free agent signings and contract negotiations. As discussed above, the Association may negotiate to allow member votes to affect such matters in a number of different ways. The member vote could be binding on the team, could augment the team's decision-making process by granting veto power or a percentage of the vote on an issue, or may merely serve as advice that the team would agree to consider when making its final decision.
[0051] In embodiments of the method that include member voting, certain demographical information may be used to affect results of the member voting. For example, in the case of votes affecting live sporting events, votes cast by members who live in the geographic area of one of the teams participating, or have identified one of the teams as being teams to which they are loyal, may be excluded from voting. Similarly, votes cast by members having experience as coaches, participants, or officials of the sports in question may be given greater weight that those of members who have no such experience. Other criteria, such as age, educational background, or other criteria agreed upon by the sports league or team and the Association may likewise be used in connection with the voting.
[0052] Member voting may take place on the Association's Internet website, or may be performed using land-based or mobile phones, or by using kiosks located at the venues themselves. In either scenario, the member will be identified by the Association by entering a unique personal identifier, and then will be allowed to vote. Similarly, where voting is taking place relative to a live event, the Association may sent wireless text messages to members seeking their immediate input and will accept and tally text message responses in the results. Regardless of how the information is sent by the member, it will be received by the Association's servers and processed in the same manner as Internet votes.
[0053] In some embodiments that include member voting, the Association will negotiate to obtain the ability of members to communicate with players, officials and commentators of note in connection with issues that are being voted upon in order to become fully informed about the issues. This communication may be in substantially real time in the form of a live web cast, or may take the form of a discussion group in which the players, officials and/or commentators review questions posed by members and respond at a later time. These responses may be text responses, may be recorded and played as video files from the website, or may be in the form of a streaming web cast at a predetermined time.
[0054] In some embodiments of the method, the members may submit questions that they would like included in polls to be voted on by the members. In some embodiments, these questions will automatically be posted while, in others, the Association will review all posted questions and choose specific questions for member votes. In still other embodiments, sports leagues, teams, players and/or officials will pose questions for member voting.
[0055] In embodiments where polling takes place, it is preferred that database demographics and poll results be disseminated to electronic, television and print media outlets. In addition, result communiqués will be dispatched to the league, player association or governing board relevant to the matter at hand.
[0056] In some embodiments of the method, the Association will serve as a conduit for fans to file grievances or disputes with sports leagues and teams. In others, the Association will serve as a mediator or arbitrator for such disputes. In other embodiments, members will have the opportunity to communicate their concerns and insight relating to a given college or professional league via weblogs and/or discussion groups. For example, the Association may set up weblogs or discussion groups relating to the NFL Draft, the Heismann Trophy award, Major League Baseball All Star selections, Bowl Championship Series match ups, NCAA basketball tournament selections, or the like.
[0057] In addition to focusing on major professional and college sports, the Association will also serve as a conduit for funding to youth and high school athletic programs. Still another unique feature of the invention is the manner in which the Association will provide such funding. The method of funding youth and high school athletic programs has two basic components; the fundraising component and the distribution component.
[0058] Looking first to the fundraising component, the Association will donate a certain percentage of each member's membership fee to a charitable foundation set up for the purpose of funding amateur athletics. During the membership registration process, the new member may choose to have this donation put into a general pool for distribution, or may designate this donation to a specific sport, a specific level of competition, such as youth, high school, national and international amateur competition, etc., a specific geographic area, and/or a specific athletic program. Similarly, monies received from the Association's sponsors, or third party donors may be likewise earmarked. Depending upon the criteria set by the donor, funds will be allocated in accordance with their wishes and added to separate “available grant” pages that will be shown on the Association's website and may be accessed by amateur athletic programs and participants wishing to receive funds.
[0059] Looking to the selection component, amateur athletic programs and participants wishing to receive funds will be allowed to periodically submit grant proposals to the Association. These proposals will preferably be prepared and submitted electronically through the website such that they may be easily posted for review by the members. In some embodiments, all members will be allowed to vote to determine which grant proposals will be accepted and which will be denied. In others, only those members whose donations were earmarked toward a specific grant criterion will be allowed to vote. In such embodiments, if a member earmarked its donation to the general fund, it would be allowed to vote on grant proposals submitted for funding by the general fund, but would not be allowed to vote on proposals submitted for restricted funds, and vice versa. For example, if a proposal were submitted for a fund allocating donations for lacrosse in the State of Florida, only those members who earmarked their donations for lacrosse in the State of Florida would be allowed to vote. In other embodiments, members earmarking donations for one applicable criterion would be allowed to vote on any proposal relevant to that criterion. Thus, if a proposal were submitted for a fund allocating money for lacrosse in the State of Florida, only those members who earmarked their donations for lacrosse or earmarked their donations for programs in the State of Florida would be allowed to vote. The results of the voting would be posted and the funding would be distributed in accordance with results of the vote.
[0060] Another key feature of the invention is the provision of a means for amateur athletic programs and participants wishing to receive funds and/or donations of new and/or used sporting goods to interact directly with companies, individuals and other groups in order to get their needs met. In some embodiments, programs and participants may post proposals for grants, or other needs, on the Association's website during periods between grant cycles so that members, other organizations and/or businesses can learn about their needs and provide assistance. In others, programs and participants who have posted proposals for grants that members have not voted to fund will be posted in a special portion of the Association's website, where companies and/or individual donors may choose to step up and provide the requested equipment and/or funds.
[0061] In still other embodiments, the Association will include a page on its website where companies, individuals and groups can post donation offers to allow amateur groups to obtain funding and/or equipment for their programs. In some such embodiments, groups having used equipment that they would like to donate rather than discard can post this on the website so that other groups may claim the equipment. In others, companies and groups with money available can post funding and/or equipment opportunities for other groups. For example, a company such as Nike could post an opportunity for a group to obtain discounted athletic equipment provided the group met certain criteria and/or agreed to display the Nike logo on its equipment or at its facility. Similarly, a company like General Mills could post an opportunity for a group to obtain funding if it provided a certain number of cereal box tops, etc. As is readily apparent, the means by which the Association assists amateur groups is varied and may take many forms.
[0062] Still another unique feature of the present invention is the provision of access to information on youth and community-based sports, and the manner in which this access is provided. In some embodiments of the present invention, groups wishing to receive funding will be required to post information about their leagues, which may include statistics, updates and highlights for access within a members only section of the Association's website. In other embodiments, members will be allowed to create their own information pages on local sports teams and leagues of interest. These pages may include photographs, links to local newspaper articles, video clips or the like, so as to allow relatives and friends to be a part of their own “Future All Star's” budding career. Further, in order to avoid the threat of on-line predators improperly using the community pages, in some embodiments, people seeking to access these pages must first obtain approval from the posting member, or the league, in order to obtain access. This may be in the form of a password that could be provided to friends and relatives, or an email request by the party seeking to access the pages.
[0063] In some embodiments of the method, the Association will negotiate to obtain access to event tickets, which will be available exclusively to members of the Association. In others, the Association will negotiate to obtain access to exclusive merchandise, which will be available exclusively to members of the Association.
[0064] Finally, in still other embodiments of the invention, the website will include a members-only section that allows members to trade, buy and sell sports memorabilia, souvenirs and collectors items.
[0065] Although the present invention has been described in considerable detail with reference to certain preferred versions thereof, other versions would be readily apparent to those of ordinary skill in the art. Therefore, the spirit and scope of the appended claims should not be limited to the description of the preferred versions contained herein. | Methods of conducting the business of an association of sports fans. The methods involve the use of direct member voting to control actions that are taken by the association and by third parties, and providing member specific information to members. | 6 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims priority under 35 U.S.C. §119(e) to U.S. Provisional Patent Application No. 60/350,139 entitled “Sequence Tile Board Game,” filed Nov. 2, 2001, the disclosure of which is herein incorporated by reference.
BACKGROUND OF THE INVENTION
The present invention relates generally to games played by multiple players. More specifically, the present invention relates to methods and apparatus for playing a sequence based guessing game for multiple players.
SUMMARY OF THE INVENTION
The object of the game is for players to move a game piece from a starting position to an ending position, with forward and backward moves controlled by the results of turning over one card out of a first group of cards, and several cards out of a second group of cards. The game is turn based and each player begins the game with a game piece at a fixed number of moves away from the winning end position. Players take turns until one player has reached the winning end position.
The advantages of the present invention will be understood more readily after a consideration of the drawings and the Detailed Description of the Preferred Embodiment.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 depicts components of a game, including player pieces, a game board, tiles, and sequence cards.
FIG. 2 shows the layout of game components at the beginning of play.
FIG. 3 depicts the method of matching graphic indicia to a sequence card.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The present invention is a board game played by at least two players. The game requires that players take turns flipping sequence cards and trying to uncover the sequence indicated on the sequence card that might be found in cards laid face down on a game board. In one embodiment, the game may be based on a well-known popular culture phenomenon, such as a comic book or cartoon. For example, the embodiment of the present invention shown in FIG. 1 is based on the popular children's comic book YU-GI-OH, by Kazuki Takahashi.
Turning to FIG. 1, a set forming a game 10 is shown, according to one embodiment of the present invention. Game 10 includes player pieces 12 , game board 14 , tiles 16 , and sequence cards 18 .
Game board 14 is divided into level indicators 20 and grid spaces 22 . Level indicators 20 are subdivided into a starting level 20 a , intermediate levels, 20 b , 20 c , and 20 d , and a winning level 20 e . The object of the game is to advance to the highest level 20 . Level indicators 20 are used in conjunction with player pieces 12 to track the progress of each player. The remainder of game board 14 is divided into multiple grid spaces 22 that are the same size as tiles 16 so that tiles 16 may be placed over, and completely cover, grid spaces 22 .
Tiles 16 include a back side 16 a and a front side 16 b . The appearance of back sides 16 a of tiles 16 are typically common to all other tiles 16 so that they appear identical. Front sides 16 b of tiles 16 and grid spaces 22 each have one of a variety of graphic indicia 24 printed thereon. Graphic indicia 24 may also include penalty indicia 26 .
Sequence cards 18 have a back side 18 a , which is typically blank, and a front side 18 b . The front sides 18 b are imprinted with a sequence 28 of different graphic indicia 24 that match the various graphic indicia 24 imprinted on tiles 16 and grid spaces 22 . Although sequence 28 of FIG. 1 includes four graphic indicia 24 , the number of graphic indicia 24 may be changed to alter game 10 complexity. Graphic indicia 24 may be depicted by a picture 30 , a color 32 , or a combination of picture and color 34 .
Each player starts the game with his or her player piece 12 positioned on his or her respective starting level indicator 20 a , shown in FIG. 2 by a circle. During play, tiles 16 are typically randomized and placed front side 16 b down on game board 14 , as shown in FIG. 2. A player turns one of the sequence cards 18 front side 18 b up to reveal the sequence 28 that that player will try to uncover on game board 14 .
A player moves to the next higher level by successfully uncovering the graphic indicia 24 in the sequence 28 called for by the over turned sequencing card 18 . The player has two chances with each tile turned over to uncover the correct graphic indicia 24 , because both the graphic indicia 24 printed on the front side of tile 16 or the graphic indicia 24 printed on grid space 22 that was uncovered may be correct. For example, if the over turned sequencing card 18 has a dark colored dragon, a light colored dragon, a character's profile, and a warrior graphic, as shown in FIG. 3, then the player must flip four of tiles 16 to reveal first a dark colored dragon, a light colored dragon, a character's profile, and finally a warrior graphic on either the flipped tile 16 or the uncovered grid space 22 . If a player successfully matches sequence 28 , then that player is awarded by moving his or her player piece 12 up a level 20 .
A player may go down a level 20 if the player uncovers a specially designated graphic indicia 24 determined to be a penalty indicia 26 . For example, if an “X” graphic indicia 24 is designated by a set of rules as the penalty indicia 26 and a player flips a tile 16 or uncovers a grid space 22 with an “X” indicia that player is assessed a penalty, which is typically to move his or her player piece 12 back one level 20 . Exceptions to this penalty rule may apply, such as if the player flips over a tile 16 with the correct indicia 24 , although penalty indicia 26 may be exposed on uncovered grid space 22 , that player is not penalized since the sequence 28 was completed.
Once a sequence 28 has been correctly matched, tiles 16 are typically randomized and replaced on game board 14 in a new configuration before the next player draws another sequence card 18 . If a sequence 28 was not correctly matched, that sequence card 18 is passed to the next player until the sequence 28 is correctly matched.
It is believed that the disclosure set forth above encompasses multiple distinct inventions with independent utility. While each of these inventions has been disclosed in its preferred form, the specific embodiments thereof as disclosed and illustrated herein are not to be considered in a limiting sense as numerous variations are possible. The subject matter of the inventions includes all novel and non-obvious combinations and subcombinations of the various elements, features, functions and/or properties disclosed herein. Similarly, where any claim recites “a” or “a first” element or the equivalent thereof, such claim should be understood to include incorporation of one or more such elements, neither requiring nor excluding two or more such elements.
Inventions embodied in various combinations and subcombinations of features, functions, elements, and/or properties may be claimed through presentation of new claims in a related application. Such new claims, whether they are directed to a different invention or directed to the same invention, whether different, broader, narrower or equal in scope to the original claims, are also regarded as included within the subject matter of the inventions of the present disclosure. | The present invention provides a board game wherein players compete to uncover tiles and board sections in an order that matches a drawn card. The game includes a game board, player pieces, tiles, and sequence cards. The object of the game is to advance through several levels of play by matching uncovered indicia to that of the sequence cards while avoiding penalty indicia. | 0 |
RELATED APPLICATIONS
This application claims priority to and benefit of U.S. Provisional Application No. 61/741,670 filed Jul. 26, 2012, the disclosure of which is incorporated herein for all purposes.
BACKGROUND OF THE INVENTION
Due to the rise of melanoma and other skin related diseases, protection of the skin from the deleterious effects of the sun has become a priority in recent years. The quest for complete protection form the sun has lead to numerous research efforts of not only effective sun blockers but also products that are extremely efficient. A product that protects a wide variety of ultra violet (UV) radiation and is effective has become a priority. The effectiveness of sunscreen products are typically listed in terms of sun protection factor (SPF). The SPF can be altered by a variety of factors including the specific sunscreen agents chosen and the type of delivery systems (formula) chosen.
Sunscreen products work based on the ability of the sunscreen actives to absorb photons in the Ultraviolet B and Ultraviolet A range (UVB and UVA respectively). Simply put according to Beers Law Absorbance of light passing through a liquid is directly related to the concentration of absorbing material in the liquid. If one notes the published absorbance of sunscreen actives approved for use in the United States it can readily be deduced that many sunscreens utilized actives at levels many times greater than that should be necessary to obtain the desired SPF. This can be attributed to several factors but certainly one that is extremely important is the sunscreen active solvent system used in the formulations.
Sunscreens have been assigned Sun Protection Factor (SPF) values by the U.S. Food and Drug Administration (FDA) since 1978. SPF is a number that refers to the sunscreen product's ability to block UVB radiation. This number does not show the blockade against ultraviolet UVA radiation. Sunscreen products with SPFs of 2 to 50 are currently available. A sunscreen product with a SPF of 15 will protect your skin 15 times longer from UVB than if you did not have sunscreen applied. The exact amount of time will vary from person to person, the altitude, and proximity to the equator. SPF 15 will block 95% of the UVB wavelengths. SPF 30 does not work twice as well however, it will provide another 3% of protection.
Broad-spectrum sunscreens were developed to absorb both UVA and UVB energy. To achieve coverage over the UVA and UVB spectra, multiple sunscreens are selected both on the basis of absorbed wavelength range as well as other properties (i.e., water resistance, hypoallergenicity). A prevailing paradigm in sunscreen formulation has been “more is better”. Many follow the approach that high SPF or more Boots stars can best be achieved by including many sunscreens in high concentrations. Because many sunscreens have decreased performance characteristics (e.g., lower SPF) when exposed to natural light, adherents of this school of formulation add more sunscreen actives than should theoretically be required to achieve a certain SPF. In so doing, they compensate for the degradation that takes place in the laboratory setting. However, this reasoning is flawed. There is markedly more photodegradation in natural sunlight, causing the actual SPF realized by the consumer to be lower.
The “more is better” paradigm also overlooks the fact that among the degradation products in photolabile sunscreens are free radicals, which can cause damage to DNA and other cellular molecules. Over time, free radical damage may become irreversible and lead to disease including cancer. Moreover, to the extent that a sunscreen is photolabile under artificial light (e.g., JCIA, COLIPA), that same composition could undergo more photodegradation, and produce more free radicals, when exposed to UVR as well as infrared and visible light under ambient conditions. Thus, a third objective of the present invention is to identify a combination sunscreen composition where after irradiation under ambient light each sunscreen active is photostable and thereby minimize the formation of potentially harmful free radicals.
Until recently, there have been three major types of sunscreen formulations: water in oil emulsion, the oil in water emulsion and the alcohol based formulation. All have their respective advantageous and disadvantageous. There have been formulation problems in making high SPF systems using oil-based sprays, including: application onto the skin and skin feel.
It has recently been discovered that the solvent effects can have a dramatic effect upon the SPF of a given formulation of sunscreen product. Solvent effects can be used to improve has a formulation's efficiency. By efficiency is meant the SPF that is obtained with a given level of sunscreen agent. The key to increasing the SPF of a formulation without altering the type of concentration of sunscreen is selecting the proper solvent.
A very useful and efficient tool for improving the SPF and absorption of a particular sunscreen is to modify the environment (i.e. the solvent) in which the active ingredients are placed. The modification of the environment can have a drastic effect on the over all performance of the sunscreen ranging from SPF, excitation wavelength, water tolerance and flammability of sunscreen.
Typically organic sunscreens absorb UV radiation by promoting electrons into an excited state. The effectiveness of the organic sunscreens are based on a couple of factors: the amount of energy (wavelength) that is required to promote an electron and how long the electron stays promoted before returning to the ground state. There are several ways that electrons can return to the ground state; they release the “stored” energy all at once and emit a different frequency of energy (fluoresces), they can transfer their energy to another molecule, or they can dissipate the energy as thermal heat. All three of these ways are directly related to the solvent the active ingredients are contained in.
Avobenzone, a common organic sunscreen, undergoes a keto/enol tautomerization. When avobenzone is placed into a polar environment, i.e. alcohol, the equilibrium lies heavily on the enol side. This results in a boost in SPF of the avobenzone. Solvent molecules can also transfer hydrogen atoms with excited molecules and “trap” them in a non-excitable state. This leaves the active sunscreen unable to promote an electron and therefore unable to absorb UV radiation. Beyer et al. used Raman spectroscopy to show that the excited state of N,N-dimethyl-p-amino-benzoic acid can accept a proton from a polar solvent resulting in loss of conjugation throughout the molecule. The interaction between active ingredients and the solvent can be easily modified and adjusted to fit the products needs.
An effective way of affecting the performance of organic sunscreens is to load them into delivery systems. Delivery systems most commonly involve amphiphilic systems, emulsions or amphiphilic macromolecules. Both emulsions and macromolecules act in the same manor. In oil in water emulsion, there are pockets of hydrophobic oil contained in the core of micelles. When hydrophobic organic sunscreens are added into the emulsion, they migrate into the hydrophobic micelle cores and remain suspended in a unified matrix. This organization provides two major advantages, firstly they pockets of actives provide a big boost in SPF and lastly the organization prevents aggregation of the organics, this removes color from the sunscreens on the skin. Macromolecules and polymers respond in the same way as emulsions, with the major difference being that the hydrophobic and hydrophilic portions of the formula are covalently attached to each other.
There has been a long felt need to provide formulations in which the SPF is increased providing longer protection with the same concentration of sunscreen. The new paradigm is less is more, that is less sunscreen actives formulated with the proper additives will provide significantly increases protection. The ability to so formulate products has been heretofore unattainable before the compounds of the present invention were developed.
FIELD OF THE INVENTION
The present invention is drawn to (a) novel polyester compounds and (b) a process for the use of the polyesters, which improves the efficiency of sunscreen actives. By efficiency is meant the increasing of the SPF (sun protection factor) in formulations containing the polyesters of the present invention (marketed under the trade name “SurfaShield™”) compared with the same amount of sun screening actives in a formulation that do not contain the polyesters of the present invention. SurfaShield is a registered trademark of SurfaTech Corporation. These esters are derived from alkoxyated polyesters cross-linked with dimer acid. These polyesters exhibit a synergistic interaction with sunscreen actives, which improves the efficiency of the sunscreen, providing a “shield” for the body from the harmful effects of the sun. The amphilic nature of these polyesters provide a novel frame work capable of both enhancing a sunscreens SPF, while allowing the capability of the hydrophobic sunscreen actives to be applied uniformly on wet skin.
THE INVENTION
Object of the Invention
One object of the present invention is to provide a series of unique cross-linked polyesters that are amphilic in nature. Amphilic is a term used to describe a macromolecule that contains both a hydrophobic (water-hating) proton and a hydrophilic (water-loving) portion covalently bonded in the same molecule. The hydrophobic portion of the polyesters encapsulates the hydrophobic sunscreen actives. This encapsulation allows for hydrophobic materials to be introduced into a polar atmosphere without precipitation.
Another objective of the present invention is to provide a vehicle to improve water solubility of antioxidants, sunscreen actives and free radical scavengers to allow for through and efficient delivery of these materials to the skin in a more efficient way.
Other objections of the invention will become clear as the specifications and disclosures sections of this patent.
All temperatures specified herein are degrees C., all percentages are percentages by weight and all patents referred to herein are incorporated herein by reference.
SUMMARY OF THE INVENTION
The present invention relates to a process for improving the efficiency of sunscreens. The term efficiency is meant by a process of increasing a sunscreens sun protection factor (SPF) as well as providing the ability of hydrophobic sunscreen actives to the surface of “wet” skin. The process comprises of the encapsulation and transport of sunscreen actives by the use of a series of unique polyesters.
The polyesters of the present invention are cross-linked sorbeth ethoxylated fatty esters crosslinked through a dimer acid ester linkage group. The linkage with dimer acid forms a covalent bond between two different sorbeth ethoxylated fatty esters. This creates the possibility of covalently linking two different macromolecules with different physical properties to the same polymer backbone. The properties of the linked groups can be the molar ratio of fatty ester groups to hydroxyl groups. These materials are amphilic in nature. This provides many interesting properties including solubility in many different solvents, ability to encapsulate hydrophobic or hydrophilic materials, and the transport of the encapsulated materials into solvents that the materials are otherwise not soluble in. The process of using these compounds for improving the efficiency of sunscreens comprises the encapsulation of the sunscreen actives and transporting them to the skin with an effective concentration of the esters of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
One aspect of the present invention is a series of esters having the following structure:
wherein;
R 1 is an alkyl having 7 to 21 carbons atoms;
R 2 is an alkyl having 7 to 21 carbons atoms;
x is an integer ranging from 1 to 10;
y is an integer ranging from 1 to 10;
a is an integer ranging from 0 to 4;
b is an integer ranging from 0 to 4, with the proviso that a+b equals 4;
c is an integer ranging from 0 to 4;
d is an integer ranging from 0 to 4, with the proviso that c+d equals 4.
Another aspect of the present invention is a series of esters prepared by the reaction of;
(a) and ethoxylated sorbeth esters conforming to the following structure:
wherein;
R is an alkyl having 7 to 21 carbons atoms;
R′ is an —C(O)—R;
x is an integer ranging from 1 to 10;
m is an integer ranging from 0 to 4;
n is an integer ranging from 1 to 4, with the proviso that m+n equals 4;
(b) a dimer acid compound selected from the group consisting of dimer acid and hydrogenated dimer acid.
Another aspect of the present invention is directed to a process for improving the efficiency of sunscreens which comprises contacting the skin with an effective protecting concentration of a composition comprising:
wherein;
R 1 is an alkyl having 7 to 21 carbons atoms;
R 2 is an alkyl having 7 to 21 carbons atoms;
x is an integer ranging from 0 to 10;
y is an integer ranging from 0 to 10;
a is an integer ranging from 0 to 4;
b is an integer ranging from 0 to 4, with the proviso that a+b equals 4;
c is an integer ranging from 0 to 4;
d is an integer ranging from 0 to 4, with the proviso that c+d equals 4.
and sunscreening actives.
A wide variety of conventional organic sunscreen actives are suitable for use herein. Sagarin, et al., at Chapter VIII, pages 189 et seq., of Cosmetics Science and Technology (1972), discloses numerous suitable actives. Specific suitable sunscreen actives include, for example: p-aminobenzoic acid, its salts and its derivatives (ethyl, isobutyl, glyceryl esters; p-dimethylaminobenzoic acid); anthranilates (i.e., o-amino-benzoates; methyl, menthyl, phenyl, benzyl, phenylethyl, linalyl, terpinyl, and cyclohexenyl esters); salicylates (amyl, phenyl, octyl, benzyl, menthyl, glyceryl, and di-pro-pyleneglycol esters); cinnamic acid derivatives (menthyl and benzyl esters, a-phenyl cinnamonitrile; butyl cinnamoyl pyruvate); dihydroxycinnamic acid derivatives (umbelliferone, methylumbelliferone, methylaceto-umbelliferone); trihydroxy-cinnamic acid derivatives (esculetin, methylesculetin, daphnetin, and the glucosides, esculin and daphnin); hydrocarbons (diphenylbutadiene, stilbene); dibenzalacetone and benzalacetophenone; naphtholsulfonates (sodium salts of 2-naphthol-3,6-disulfonic and of 2-naphthol-6,8-disulfonic acids); di-hydroxynaphthoic acid and its salts; o- and p-hydroxybiphenyldisulfonates; coumarin derivatives (7-hydroxy, 7-methyl, 3-phenyl); diazoles (2-acetyl-3-bromoindazole, phenyl benzoxazole, methyl naphthoxazole, various aryl benzothiazoles); quinine salts (bisulfate, sulfate, chloride, oleate, and tannate); quinoline derivatives (8-hydroxyquinoline salts, 2-phenylquinoline); hydroxy- or methoxy-substituted benzophenones; uric and violuric acids; tannic acid and its derivatives (e.g., hexaethylether); (butyl carbotol) (6-propyl piperonyl)ether; hydroquinone; benzophenones (oxybenzene, sulisobenzone, dioxybenzone, benzoresorcinol, 2,2′,4,4′-tetrahydroxybenzophenone, 2,2′-dihydroxy-4,4′-dimethoxybenzophenone, octabenzone; 4-isopropyldibenzoylmethane; butylmethoxydibenzoylmethane; etocrylene; octocrylene; [3-(4′-methylbenzylidene boman-2-one), terephthalylidene dicamphor sulfonic acid and 4-isopropyl-di-benzoylmethane.
Of these, 2-ethylhexyl-p-methoxycinnamate (commercially available as PARSOL MCX), 4,4′-t-butyl methoxydibenzoyl-methane (commercially available as PARSOL 1789), 2-hydroxy-4-methoxybenzophenone, octyldimethyl-p-aminobenzoic acid, digalloyltrioleate, 2,2-dihydroxy-4-methoxybenzophenone, ethyl-4-(bis(hydroxy-propyl))aminobenzoate, 2-ethylhexyl-2-cyano-3,3-diphenylacrylate, 2-ethylhexyl-salicylate, glyceryl-p-aminobenzoate, 3,3,5-tri-methylcyclohexylsalicylate, methylanthranilate, p-dimethyl-aminobenzoic acid or aminobenzoate, 2-ethylhexyl-p-dimethyl-amino-benzoate, 2-phenylbenzimidazole-5-sulfonic acid, 2-(p-dimethylaminophenyl)-5-sulfonicbenzoxazoic acid, octocrylene and mixtures of these compounds, are preferred.
More preferred organic sunscreen actives useful in the compositions useful in the subject invention are 2-ethylhexyl-p-methoxycinnamate, butylmethoxydibenzoyl-methane, 2-hydroxy-4-methoxybenzo-phenone, 2-phenylbenzimidazole-5-sulfonic acid, octyldimethyl-p-aminobenzoicacid, octocrylene and mixtures thereof.
Also particularly useful in the compositions are sunscreen actives such as those disclosed in U.S. Pat. No. 4,937,370 issued to Sabatelli on Jun. 26, 1990, and U.S. Pat. No. 4,999,186 issued to Sabatelli & Spirnak on Mar. 12, 1991. The sunscreening agents disclosed therein have, in a single molecule, two distinct chromophore moieties which exhibit different ultra-violet radiation absorption spectra. One of the chromophore moieties absorbs predominantly in the UVB radiation range and the other absorbs strongly in the UVA radiation range.
Preferred members of this class of sunscreening agents are 4-N,N-(2-ethylhexyl)methyl-aminobenzoic acid ester of 2,4-dihydroxybenzophenone; N,N-di-(2-ethylhexyl)-4-aminobenzoic acid ester with 4-hydroxydibenzoylmethane; 4-N,N-(2-ethylhexyl)methyl-aminobenzoic acid ester with 4-hydroxydibenzoylmethane; 4-N,N-(2-ethylhexyl)methyl-aminobenzoic acid ester of 2-hydroxy-4-(2-hydroxyethoxy)benzophenone; 4-N,N-(2-ethylhexyl)-methylaminobenzoic acid ester of 4-(2-hydroxyethoxy)dibenzoylmethane; N,N-di-(2-ethylhexyl)-4-aminobenzoic acid ester of 2-hydroxy-4-(2-hydroxyethoxy)benzophenone; and N,N-di-(2-ethylhexyl)-4-aminobenzoic acid ester of 4-(2-hydroxyethoxy)dibenzoylmethane and mixtures thereof.
Preferred Embodiments
In a preferred embodiment x is 1.
In a preferred embodiment x is 3.
In a preferred embodiment x is 5.
In a preferred embodiment x is 7.
In a preferred embodiment x is 10.
Examples
Sorbitol Alkoxylates
Sorbitol is 2,3,4,5,6-pentahydroxy hexanol. It has a CAS number of 50-70-4.
Sorbitol alkoxylates used in the present invention are commercially available from several sources including Siltech LLC, of Lawernceville, Ga. They are made by the addition of ethylene oxide to sorbitol. The conform to the following structure;
wherein;
x is an integer ranging from 1 to 10.
Molecular Weight
Example
X
(g/mol)
1
1
446
2
3
976
3
5
1502
4
7
2030
5
10
2822
Fatty Acids
Fatty acids useful in the practice of the present invention are items of commerce they are available as either single components or mixtures.
Fatty acids useful as raw materials in the preparation of compounds of the present invention are commercially available from a variety of sources including Procter and Gamble of Cincinnati Ohio.
The structures are well known to those skilled in the art.
R—C(O)—OH
Saturated
Example
R Formula
Common Name
Molecular Weight
6
C 7 H 5
Caprylic
144
7
C 9 H 19
Capric
172
8
C 11 H 23
Lauric
200
9
C 13 H 27
Myristic
228
10
C 14 H 29
Pentadecanoic
242
11
C 15 H 31
Palmitic
256
12
C 17 H 35
Stearic
284
13
C 19 H 39
Arachidinic
312
14
C 21 H 43
Behenic
340
15
C 26 H 53
cetrotic
396
16
C 33 H 67
geddic acid
508
Unsaturated
Example
R Formula
Common Name
Molecular Weight
17
C 17 H 33
Oleic
282
18
C 17 H 31
Linoleic
280
19
C 17 H 29
Linolenic
278
20
C 15 H 29
Palmitoleic
254
21
C 13 H 25
Myristicoleic
226
22
C 21 H 41
Erucic
338
Sorbitol Alkoxylate Fatty Esters
Sorbitol alkoxylate fatty esters were prepared by SurfaTech Corporation, of Lawrenceville, Ga. They are prepared by the esterification of sorbitol alkoxylates (examples 1-5) with fatty acids (examples 6-22). They conform to the following structure;
wherein;
R is an alkyl having 7 to 21 carbons atoms;
R′ is an —C(O)—R;
x is an integer ranging from 1 to 10;
m is an integer ranging from 0 to 4;
n is an integer ranging from 1 to 4, with the proviso that m+n equals 4.
Examples
Esterification Reactions
In addition to the ratio of polyoxyalkylene groups to fatty groups and the linkage group chosen, it is very important for the practice of the current invention resulting in a compounds of the present, to have the correct ratio of hydroxyl groups to esterified polyoxyalkylene groups. The compounds of the present invention have a wide variety of unreacted hydroxyl groups.
General Procedure
A specified number of grams of the specified alkoxylate (Examples 1-5) is added to a specified amount of fatty acid (Examples 6-22). The reaction mixture is heated to 160-180° C. Water is removed by vacuum during the reaction process. The reaction is monitored by determination of acid value. The acid value will diminish as the reaction proceeds. The reaction is cooled once the acid value fails to change over an additional two hours at temperature. The product is used without purification.
Sorbeth Pentaesters
These esters have on average five of the six ester groups esterified, leaving only one group left to react.
Sorbitol Ethoxylates
Fatty Acid
Example
Example
Grams
Example
Grams
23
1
446
6
720
24
2
976
10
1210
25
3
1502
15
1980
26
4
2030
17
1410
27
5
2882
22
1690
Sorbeth Triesters
These esters have on average three of the six ester groups esterified, leaving on average three group left to react.
Sorbitol Ethoxylates
Fatty Acid
Example
Example
Grams
Example
Grams
28
1
446
8
516
29
2
976
11
768
30
3
1502
19
834
31
4
2030
14
1020
32
5
2882
6
432
Sorbeth Monoesters
These esters have on average one of the six ester groups esterified, leaving on average five groups left to react.
Sorbitol Ethoxylates
Fatty Acid
Example
Example
Grams
Example
Grams
33
1
446
6
144
34
2
976
17
282
35
3
1502
8
200
36
4
2030
14
340
37
5
2882
6
144
Example 38
Dimer Acid
Dimer acid is an item of commerce available commercially from Henkel Corporation. It conforms to the following structure:
Example 39
Hydrogenated Dimer Acid
Hydrogenated dimer acid is an item of commerce available commercially from Henkel Corporation. It conforms to the following structure:
Reaction with Dimer Acid
A specified number of grams of the specified alkoxylate (Examples 23-37) is added to a specified amount of dimer acid (Example 38). The reaction mixture is heated to 160-180° C. Water is removed by vacuum during the reaction process. The reaction is monitored by determination of acid value. The acid value will diminish as the reaction proceeds. The reaction is cooled once the acid value fails to change over an additional two hours at temperature. The product is used without purification.
Dimer Acid
Sorbeth Esters 1
Sorbeth Ester 2
Example
Example
Grams
Example
Grams
Example
Grams
40
38
535
23
1076
33
572
41
38
535
24
2096
34
1240
42
38
535
25
3390
35
1684
43
38
535
26
3350
36
2352
44
38
535
27
4482
37
3008
45
38
535
28
908
23
1076
46
38
535
29
1690
25
3390
47
38
535
30
2282
33
572
48
38
535
31
2996
34
1240
49
38
535
32
3260
32
3260
50
38
535
33
572
23
1076
51
38
535
34
1240
24
2096
52
38
535
35
1684
25
3390
53
38
535
36
2352
26
3350
54
38
535
37
3008
32
3260
Reaction with Hydrogenated Dimer Acid
A specified number of grams of the specified alkoxylate ester (Examples 23-37) is added to a specified amount of hydrogenated dimer acid (Example 39). The reaction mixture is heated to 160-180° C. Water is removed by vacuum during the reaction process. The reaction is monitored by determination of acid value. The acid value will diminish as the reaction proceeds. The reaction is cooled once the acid value fails to change over an additional two hours at temperature. The product is used without purification.
Dimer Acid
Sorbeth Esters 1
Sorbeth Ester 2
Example
Example
Grams
Example
Grams
Example
Grams
55
39
537
23
1076
33
572
56
39
537
24
2096
34
1240
57
39
537
25
3390
35
1684
58
39
537
26
3350
36
2352
59
39
537
27
4482
37
3008
60
39
537
28
908
23
1076
61
39
537
29
1690
25
3390
62
39
537
30
2282
33
572
63
39
537
31
2996
34
1240
64
39
537
32
3260
32
3260
65
39
537
33
572
23
1076
66
39
537
34
1240
24
2096
67
39
537
35
1684
25
3390
68
39
537
36
2352
26
3350
69
39
537
37
3008
32
3260
Applications Examples
Materials and Methods
All Sunscreen formulations were tested for SPF tested using a single port Solar Light Model 15S Xenon Arc. Solar Simulator Lamp. Which has a continuous light spectrum in the UVA and UVB spectrum (290-400 nm). The spectral output of the solar simulator is filtered so that it meets the spectral output requirements for testing Sunscreen Drug Products for over-the-counter human use; Proposed Amendment of Final. Monograph, CFR Part 352,70 (b) Light Sources. Federal Register Vol 72, No. 165, Aug. 27, 2007 and the International Sun Protection Factor (SPF) Test Method, May 2006. perform SPF testing on Formulas 1 and 2 using the same 5 subjects.
To test the SPF increase of sunscreen formulations with the addition of compounds of the present invention were prepared and the sets of formulas were SPF tested on the same subjects. A typical procedure for the preparation of formulas 1-5 is as follows: Disperse A. Add B while heating to 170° F. stir until clear. Add C to A/B while mixing. Cool with stirring to 120° F. and add D. Continue cooling, QS and mix.
Formula (% w/w)
Ingredient
1
2
3
4
5
Part A
Water
74.20
67.20
69.70
62.20
57.20
Acrylates/C10-30 Alkyl
0.25
0.25
0.25
0.25
0.25
Acrylate Crosspolymer
0.05
0.05
0.05
0.05
0.05
DiSodium EDTA
Part B
Triethanolamine
1.00
1.00
1.00
1.00
1.00
Part C
Octocrylene
3.00
3.00
3.00
3.00
3.00
Octisalate
3.00
3.00
3.00
3.00
3.00
Oxybenzone
2.00
2.00
2.00
2.00
2.00
Avobenzone
1.00
1.00
1.00
1.00
1.00
Stearic Acid
2.00
2.00
2.00
2.00
2.00
Glyceryl Monostearate
3.00
3.00
3.00
3.00
3.00
SE
Benzyl Alcohol
1.00
1.00
1.00
1.00
1.00
Dimethicone
0.50
0.50
0.50
0.50
0.50
C12-15 Alcohols
8.00
8.00
8.00
8.00
8.00
Benzoate
Example 41
—
5.00
2.50
10.00
15.00
Octyldodecyl citrate
—
2.00
2.00
2.00
2.00
crosspolymer
Part D
Parabens/Phenoxyethanol
1.00
1.00
1.00
1.00
1.00
Formula 6
Formula 7
Ingredient
(% w/w)
(% w/w)
C12-15 Alcohols
30.30
—
Benzoate
Mineral Oil
30.30
—
Octyl Palmitate
30.30
—
Spider Ester ESO
—
91.00
(sorbeth 2 hexaoleate)
Octocrylene
3.00
3.00
Octisalate
3.00
3.00
Oxybenzone
2.00
2.00
Avobenzone
1.00
1.00
Formulas 1-7 were prepared in the United States by a research consultant and tested in an independent test laboratory. Formulas 8-13 were prepared by SurfaTech Corporation and tested by an independent test laboratory.
Shown in Table 3, SunQuencher Concentrate® was prepared by a series of dilutions of the formula listed in table 4. The results are summarized below.
Ingredient
%
Example 42
65.00
Octyldodecyl citrate
10.00
crosspolymer
Octocrylene
8.33
Octisalate
8.33
Oxybenzone
5.55
Avobenzone
2.80
Formula
Ingredient
8
9
10
11
12
13
Example 42
0.00
7.58
22.75
0.00
13.00
39.00
Octyldodecyl
0.00
1.16
3.50
0.00
2.00
6.00
citrate
crosspolymer
Octocrylene
2.90
2.90
2.90
5.00
5.00
5.00
Octisalate
2.90
2.90
2.90
5.00
5.00
5.00
Oxybenzone
1.94
1.94
1.94
3.33
3.33
3.33
Avobenzone
0.98
0.98
0.98
1.68
1.68
1.68
C12-15
45.66
44.26
34.97
42.50
35.00
20.00
Alcohols
benzoate
Caprylic/Capric
45.66
44.26
34.97
42.50
35.00
20.00
triglyceride
The use of compounds of the present invention in the formulation has a dramatic affect upon the SPF of formulations having the same concentration of sunscreen. In other words it makes the sunscreen more effective. Lower levels of sunscreen can be used to obtain the same SPF as formulations using traditional SPF esters
The uniformity of the SPF values developed on formulations made and tested by two different labs, one in North America and the other in Europe, is both unexpected and very important. It is well known in the industry that different testing laboratories can obtain significantly different results on the same formula. With this in mind, it is important to note that the SPF results from each separate test 1, 2, and 3 were obtained from the same subjects. For example the same 5 subjects tested by the same clinicians obtained an average SPF of 19 on Formula 1 and an average SPF of 32 on formula 2. Likewise formulas 3, 4, and 5 were tested on the same subjects. Formulas 6 and 7 were tested on the same 3 subject test panel.
The results from formulas 6 and 7 clearly show that on the same subjects the formula consisting entirely of Spider ester ESO as a diluent performed remarkably better than the similar oil made with common oil ingredients Octyl Palmitate, Mineral Oil and C12-15 alcohols Benzoate. Formulas 3, 4, and 5 showed similar results to formula 2, suggesting that in this particular type formulation a broad range of ESO percentages could be used to enhance the SPF. Table 5 shows the results.
Formula
% Example 41
SPF
Formula type
1
0.0
19
OW Emulsion
2
5.0
32
OW Emulsion
3
2.5
35.0
OW Emulsion
4
10.0
35.0
OW Emulsion
5
15.0
30.0
OW Emulsion
6
0.0
16.0
Oil
7
91.0
29.0
Oil
8
0.0
14.8
Oil
9
7.6
19.3
Oil
10
22.8
30.2
Oil
11
0.0
18.1
Oil
12
13.0
26.8
Oil
13
39.0
58.9
Oil
Formulas 6 and 8 are practically identical and the SPF values obtained by the two independent labs was practically identical, SPF 14.8 and 16. Interestingly, formulas 7 and 10 had practically identical SPFs, 29 and 30.2 respectively, but whereas formula 7 had 91% ESO, formula 10 had 22.75%. This suggests that there is an optimum amount of polar solvent needed to increase SPF, and adding additional polar solvent neither helps nor hinders SPF.
Material
1A
1B
1C
1D
Octylcrylene
3.00
3.00
3.00
3.00
Octylsalicyate
3.00
3.00
3.00
3.00
Oxybenzone
2.00
2.00
2.00
2.00
Avobenzone
1.00
1.00
1.00
1.00
Example 42
0.00
9.00
18.00
27.00
C 8 C 10 Triglycerde
91.00
82.00
73.00
64.00
Result
1A
1B
1C
1D
SPF
14.8
19.3
25.2
30.2
Increase of SPF
—
30.4%
70.3%
104.1%
UVA/UVB
1.21
1.25
1.04
0.98
While the illustrative embodiments of the invention have been described with particularity, it will be understood that various other modifications will be apparent to and can be readily made by those skilled in the art without departing from the spirit and scope of the invention. Accordingly, it is not intended that the scope of the claims appended hereto be limited to the examples and descriptions set forth hereinabove but rather that the claims be construed as encompassing all the features of patentable novelty which reside in the present invention, including all features which would be treated as equivalents thereof by those skilled in the art to which the invention pertains | The present invention is drawn to a process for improving the efficiency of sunscreens using a series of polyesters based upon sorbeth ethoxylates esterified with fatty acids, then crosslinked with dimer acid. These polyesters exhibit a synergistic interaction with sunscreen actives improving the efficiency providing a “shield” for the body from the harmful effects of the sun. These sorbitol alkoxylates are then reacted with dimer acid, resulting in a series of novel polyesters. The linking of the two spider esters together with dimer provide an amphilic macromolecule possessing both hydrophilic and hydrophobic portions covalently bonded to the same molecule, this provides both a boost in sun protection factor (SPF) and the ability for the sunscreen actives to be applied to wet skin. | 2 |
BACKGROUND OF THE INVENTION
The present invention relates to the field of seismic exploration. More particularly, the invention relates to a method for determining optimal explosive characteristics for specific seismic survey conditions.
Holes are drilled in rock for excavation blasting, mining operations, and many other purposes. For example, explorative searches for hydrocarbons, minerals, and other products require the physical penetration of geologic formations. Seismic operations typically detonate explosive charges to generate shock wave source signals for penetrating subsurface geologic formations. The shock waves are reflected from subsurface geologic structures and interfaces and the reflected energy is detected with sensors such as geophones at the surface. These transducers reduce the reflected energy into signals which are recorded for processing.
In many land-based geophysical seismic operations, vibrator trucks contact the soil and discharge energy into subsurface geologic formations. However, survey regions frequently comprise mountainous, tropical, or other regions inaccessible to seismic trucks. Because of accessibility constraints and the large source energy provided by explosive materials, explosive charges detonated in shot-holes provide a preferred source of seismic source energy. Shot holes up to four inches wide and between two and thirty meters deep are commonly drilled in surface geologic formations to allow placement of the explosives. The explosive charges are typically placed in the bottom of the shot-hole and are detonated to generate shock waves transmitted into the subsurface geologic formations.
Seismic shot-holes require different parameters than excavation blast holes because the objective of shot-holes is not to displace or fracture rock, but to efficiently transfer elastic shock wave energy downwardly into subsurface geologic formations. Accordingly, shot-hole equipment and drilling techniques are relatively specialized.
The diameter of conventional explosive charges is smaller than the shot-hole diameter to facilitate placement of the explosives into the lower shot-hole end. The resulting annulus between the explosive charge and the shot-hole wall often reduces the efficiency with which the shock wave energy is transmitted to the subsurface geologic formations. Because of this reduction in efficiency, one technique promotes the use of gaseous explosives to eliminate the void space between the explosive and the borehole wall. U.S. Pat. No. 3,752,256 to Mollere (1973) disclosed a method for positioning a combustion chamber within soil to generate seismic source energy. U.S. Pat. No. 3,976,161 to Carman (1976) disclosed an auger for inserting an explosive gas mixture into loose soil.
A large portion of the shock wave energy is discharged upwardly through the shot-hole because of the relatively low resistance provided by the open hole. To limit this energy loss, plugs are placed in the shot-hole as shown in U.S. Pat. No. 4,066,125 to Bassani (1978). U.S. Pat. No. 4,736,796 to Amall et al. (1988) disclosed other techniques for sealing shot-holes with cement, gravel, and bentonite.
Explosives have provided a seismic energy source since the inception of seismic exploration, however little effort has been committed to the performance of explosive materials. Obstacles to explosive evaluation include unavailability of information regarding the impact of certain explosive parameters, the lack of effective techniques for field testing such parameters, lack of techniques for evaluating field test data and the high cost of conducting the multi-variant experiments required to evaluate the explosives.
Various techniques have been developed to control the shape and directivity of seismic energy discharges. U.S. Pat. No. 3,908,789 to Itria (1975) disclosed a technique for controlling the explosive material length. Control over detonation of an explosive material was disclosed in U.S. Pat. No. 4,053,027 to Oswald (1977), wherein a first and second energy pulse was generated during the same seismic event. Numerous publications have addressed the mechanics of energy wave transmission through various soil conditions.
Regional seismic operations require multiple shothole locations for a seismic survey, and large surveys can require thousands of shotholes. The average cost for each shothole multiplied by the number of shotholes significantly determines the economic efficiency of the survey and the data sets obtainable from a survey design. Seismic exploration is expensive to conduct and adequate data quality is sometimes difficult to obtain in certain geologic conditions. Drilling depth and on-site personnel and equipment time are significant cost factors. Accordingly, a need exists for improved techniques for efficiently determining the source parameters for seismic shotholes in areas inaccessible by heavy equipment.
SUMMARY OF THE INVENTION
The present invention provides a method for selecting a seismic energy source for use in a selected seismic survey area. The method comprises the steps of assessing selected physical properties of soil within the seismic survey area, of testing reaction of the soil response to selected seismic energy source characteristics, of generating a test model of a selected seismic energy source initiation within the soil, of estimating the far-field seismic response model of said seismic energy source initiation from said near-surface test model, of conducting a seismic event within the selected seismic survey area to measure seismic data initiated by said seismic event, and of comparing said far-field seismic response model to the seismic data initiated by said seismic event
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates a schematic diagram of a seismic survey area.
FIG. 2 illustrates one embodiment of a method practiced in accordance with the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The invention provides a method for improving the quality of seismic data in geophysical operations. The method is performed by determining the physical characteristics of the geologic formations, of developing and testing an explosives model for the area, of calibrating the model against actual tests, and of utilizing the model to conduct detailed explosive parameter testing.
FIG. 1 illustrates a representative diagram for a seismic survey area. Source 10 is initiated to transmit seismic source energy into soil 12 , and geophones 14 record reflected seismic source energy for future processing. Multiple shots are typically conducted within a selected survey area boundary of geologic interest.
After the boundaries of a survey area are identified, such area is examined to determine relevant characteristics of the shallow and deep geologic formations within such survey area. The surface or near surface geologic formations are assessed (at 20 , in FIG. 2) to select representative test sites based on characteristics such as rock or soil type, moisture characteristics, degree and depth of weathering, and other factors. Core samples are taken at each test site and the core samples are analyzed to determine porosity, density, compressional and shear wave velocities, elastic and dynamic moduli, and stress-strain relationships under uni-axial and tri-axial pressures. As used herein, the term “soil” includes aggregates, sediments, rock, organic material, sand, and other materials comprising the Earth surface.
Following these determinations of rock or soil type, experiments are designed and conducted to test (at 22 , in FIG. 2) the performance of different explosive types at the survey test sites. Different types of explosive charges are discharged at each test site and the results are detected with an array of geophones. Such geophones preferably comprise three component geophones. Various parameters of the explosive charges are evaluated during such tests, including the velocity of detonation, density, charge diameter relative to hole diameter, impedance of the explosion reaction products relative to the impedance of the surrounding rock or soil, charge shape, charge length, gas generation, energy release time, tamping material, total energy, shock energy, gas or bubble energy, and other parameters.
The geophone data is processed with analysis routines to determine which combination of explosive parameters yielded the optimum data quality. Such processing includes spectral analysis to determine the relative amplitude of the signal and noise energy over selected frequency ranges. Such analysis routines are conducted for each explosive shot for each test site. The spectra from such spectral analysis are averaged at selected frequencies to create a composite spectrum for each explosive charge type, and the range of deviation and average deviation from the composite spectra is calculated at selected frequencies across the bandwidth of interest. Individual and composite spectra from each explosive charge type are compared individually and in different combinations to determine the effect of each parameter within the bandwidth of interest. Parameters producing desired results are identified, and such parameters can be subjected to sensitivity analysis with various modeling methodology. Desirable parameters include increased signal energy, increased signal-to-noise ratio, increased signal consistency, and decreased noise.
Accurate explosive modeling (at 24 , in FIG. 2) is conducted by preparing a two or three dimensional model of the formation and of the explosive charges. Near surface formation parameters characterizing geologic formation conditions proximate to the explosive charges are derived from core sample measurements, well logs, and test data. Such parameters can include but are not limited to porosity, density, compressional and shear wave velocities, elastic and dynamic moduli, and stress-strain relationships under uni-axial and tri-axial pressures.
Predictions regarding the deep geologic formations are performed so that particle velocities and displacements can be modeled. The deeper formations may not be cored, and information regarding such formations may be derived from prior seismic data, well logs, or published data. The model is extended vertically to the maximum depth of interest and laterally to the maximum offset of interest. Lateral variations in geologic formation parameters may or may not be incorporated into the model depending upon availability of information and model accuracy sought. Depending upon the modeling codes used, dispersion or anisotropy effects may be incorporated within the model.
The model for the explosive charges consists of equations of state for the specific explosives tested. Such equations of state can be determined from cylinder expansion or bubble test data or from published values.
Following formation of a model, numerical simulation of specific explosive charge types is initiated (at 26 , FIG. 2 ). Langrangian or Eulerian hydrodynamic codes can simulate explosion of each specific charge type within the near surface configuration, and approximating the seismic source geometry proposed. The explosion progress and the response of surrounding rock or soil are simulated at discrete time intervals throughout the explosive charge detonation. Depending upon the type of waves or Earth configuration being modeled, such calculations may be performed in two or three dimensions. Such simulations are computationally intensive and may require multiple steps. A boundary within the rock is selected around the explosive charge. When the energy from an explosive charge reaches the selected boundary the magnitude and direction of the particle motion at each cell along the boundary is recorded and is used as input to a more extensive model. This process is continued until the range of particle motion is small enough to suggest elastic response of the rock. At this point the particle motion values are taken and are reinserted into another modeling program capable of extending the elastic response calculations to a distance approximating the larges geophone offsets to be recorded during the seismic survey.
A seismic event is initiated within the selected seismic survey area to measure seismic data caused by the seismic event (at 28 , FIG. 2 ). The final results are displayed as a series of graphs or traces representing a synthetic version of the parameter tests. These synthetic traces are compared (at 30 , FIG. 2) to the actual traces (parameter test data) for some combination of the explosive formulations tested. If the synthetic and actual data match within an acceptable bound, the test area model is calibrated.
The evaluation metrics include the presence of observed test data, the times of specific events in the record, the relative amplitudes of the events with depth and offset, and the noise characteristics in the data. If the synthetic traces and actual traces do not match within an acceptable bound, the model parameters are adjusted and the model is run again. This process is continued iteratively until the synthetic and actual data match within an acceptable bound.
After a test model area has been calibrated, sensitivity tests for the explosive parameters can be conducted. Sensitivity tests are conducted by varying a single parameter and re-running the model to determine the parameter change required to produce a certain change in the simulated seismic data. Such tests can be repeated for various magnitudes and directions of change for a single parameter until the data sensitivity to such parameter is identified. Sensitivity tests can be repeated for other parameters until the relative importance of each parameter is known.
From this analysis of the relative importance of explosive charge parameters and the corresponding sensitivity of each parameter, predictions for the improvement of explosive material and configuration can be made to improve data quality or the efficiency of shot operation. Multiple combinations of parameters can be evaluated without requiring additional field tests. By comparing model results to other model results or to actual test data, estimates for the optimum set of parameters can be determined. Predictions for the performance of various explosive or propellant type energy sources can be made, and new explosive formulations can be evaluated. For example, explosive compositions can be varied to change the explosive density or detonation velocity, to match explosive byproduct impedance to the surrounding rock, to alter the energy release time, to change the total charge energy, or to change the partitioning of the total energy between shock and gas energy. Moreover, new explosive forms can be modelled, including changes to the length, shape, and phase (whether liquid, gas, gel, solid, particulate, or composite) of explosives or propellants.
Additionally, the present invention permits predictions regarding the near-surface soil response to seismic energy sources at different elevations within the soil. These predictions are extremely useful in reducing the shot hole depth necessary to accomplish desired seismic energy coupling. By modeling such responses with the calibrated test model, calculated predictions can be made to compare additional drilling costs for deeper shot holes against the potential savings in reduced energy charges. Economic predictions can be made in view of local issues such as environmental sensitivities, boundary zones between land and water, and changes in acoustic energy source capabilities. The invention facilitates survey strategies regarding parameters such as charge size, type and shape, depth-of-burial, tamping, rock or soil type, and other variables.
Although the invention has been described in terms of certain preferred embodiments, it will become apparent to those of ordinary skill in the art that modifications and improvements can be made to the inventive concepts herein without departing from the scope of the invention. The embodiments shown herein are merely illustrative of the inventive concepts and should not be interpreted as limiting the scope of the invention. | A method for identifying optimal seismic energy source configurations for a selected seismic survey area. Physical properties of the surface or near-surface soil or rock are assessed and are tested to determine the response of such soil to energy source characteristics and geometries. A test model for a source is generated and is projected to create a far-field seismic response model. A seismic event is initiated within the survey area to measure seismic data, and such measured data is compared against the far-field seismic response model. Differences can be assessed to permit modifications to the model, and the model can be tested for different types and configurations of seismic source energy sources. | 6 |
FIELD OF THE INVENTION
This invention relates to a method of carrying out a gas combustion process with recovery of a part of the heat present in the combustion gases.
BACKGROUND OF THE INVENTION
In a number of processes, such as glass melting, in the metallurgical industry etc., the thermal energy required is obtained by burning gaseous products or hydrocarbons particularly natural gas, that can be easily converted into gaseous products. The combustion products (flue gas) released in such processes still contain a substantial amount of thermal energy in the form of sensible heat.
It is known that a part of this heat can be recovered by using the flue gas for preheating the air required for the combustion process. For this purpose use is often made of a metal radiation recuperator (a heat exchanger in which heat is transferred by radiation). The degree in which heat can be recovered, however, is highly limited by the temperature maximally permitted by the metal of the recuperator. In practice, this means that the air required for the combustion cannot be preheated beyond a temperature of about 800° C. The temperature of the flue gas to be discharged to the chimney is still about 700° C.
In order to make better use of the residual heat of the flue gases, it has been proposed that the gas can be used to thermally convert a methane-containing (natural) gas mixture with steam. In a so-called thermochemical recuperator (reformer) heat is transferred from the flue gas to a reacting natural gas-steam mixture which is passed over a steam reforming catalyst at high temperature and is converted into a mixture of hydrogen, carbon monoxide and carbon dioxide. With this reactor much heat is absorbed which is released again in the combustion of the resulting gas mixture (compare "The Thermochemical Recuperator System, Advanced Heat Recovery" by Donald K. Fleming and Mark J. Khinkis, paper presented by the 12th Energy Technology Conference and Exposition, Washington, D.C., Mar. 25-27, 1985).
The heat of the flue gases leaving the reformer is then transferred, optionally, after an intermediate stage in which the gas/steam mixture is preheated, to a steam boiler in which the steam is generated for the reforming process.
Although the use of the recuperator/reformer combination may in principle lead to a substantial increase in thermal efficiency, its practical realization has not been possible because of the incontrollability of the process in its non-stationary phase. This also applies when a part of the flue gas is passed from the furnace to the chimney either directly or via the recuperator, quite apart from the accompanying economic losses.
The major causes of the above are that during the starting-up phase of the combustion furnace and therefore previous to the equilibrium or stationary phase in which relatively large amounts of heat are dissipated in the process system the heat content and the temperature of the flue gases are so high that the flue gases cannot be passed through the reformer and preheaters. During the starting-up phase the reformer is in fact not or still insufficiently cooled by the endothermic reforming reactions, so that it would be damaged by the occurring high temperature. Similar problems occur when the phases of the process which take place after the recuperator must be discontinued, e.g., for replacement of the catalyst in the reformer or because of other failures.
SUMMARY OF THE INVENTION
According to the invention it has been found that an excellent controllability of the process and therefore a good practical usability are obtained when a cooling medium is supplied to the flue gases before introducing them into the reformer, and preferably after they have passed the recuperator and the flue gas bypass.
In principle, any cooling medium, such as water, can be supplied to the flue gas. Preferably, however, air is used for the purpose. The amount of air to be supplied can be readily determined by means of the temperature of the flue gas leaving the combustion furnace, on the one hand, and the reformed gas temperature, on the other hand. This can be carried out using a known per se method by means of temperature sensors in the flue gas introduced into the reforming reactor and in the reformed gas leaving the reforming reactor, the signals of the sensors being used for controlling the amount of cooling medium. In this connection it has been established that supplying 10% air having ambient temperature, based on the total volume of the flue gas, will lead to a decrease of temperature of 100° C. The amount of air to be admixed depends on the place where it is admixed. Because air is preferably admixed after the recuperator and the gas bypass and the temperature of the gases introduced into the reforming reactor may be up to 1100° C., while it may not be higher than 700° C. during the non-stationary phase, the amount of air supplied to the flue gas is initially about 40%, based on the total gas volume, which amount will gradually decrease to 0% during the starting-up phase.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will be more fully understood by referring to the following detailed description in conjunction with the accompanying drawings, of which:
FIG. 1 is a schematic representation of the method of the invention;
FIG. 2 is a schematic representation of the temperatures that occur during the "starting-up" phase of the method of the invention; and
FIG. 3 is a schematic representation of the temperatures that occur during the "steady-state" phase of the method of the invention.
DETAILED DESCRIPTION OF THE INVENTION
The method according to the invention is schematically shown in FIG. 1. The combustion gas, e.g. having a temperature of 1300° C., flows from the furnace (1) and then traverses the air recuperator (2), the steam reformer (3), the gas/steam preheater (4) and is then passed via steam boiler (5) to the flue gas fan (6) and the chimney. At (17) a gas bypass conduit is indicated which generally branches from the flue gas conduit before the reformer. Combustion air is supplied via fan (8) through conduit (7) and an optionally present preheater, which is not shown, said combustion air being preheated in recuperator (2). The medium to be burned, especially natural gas, is supplied to the reformer (3) via conduit (9), the preheating section (4) and the desulfurizer (10). Water is supplied to steam boiler (5) via conduit (11), the demineralizing unit (12). Steam together with the gas flowing from the desulfurizer (10) is supplied to the reformer (3) via conduit (13). The gases flowing from the reformer are supplied to the combustion furnace via conduit (14). At (15) a conduit is shown which air or another cooling medium, such as water, can be supplied to the recuperator (2) or the reformer (3) by means of valves or taps (16). During the non-stationary phase of the process a hydrocarbon to be burned is supplied via conduit (18).
The invention will be illustrated by the following examples.
EXAMPLE I
On the basis of the data concerning respectively the normal operation and the starting-up of a glass furnace having a capacity of 400 tons of glass a day, this example shows the effect on the process variables of the addition of a cooling medium (air of water) to the flue gases.
The data are grouped in Table A. The temperature of the flue gas just before the recuperator is 1350° C. The alternative "O" indicated in the table is the condition in which the entire process, including the reforming reactions, is in the "steady state". In alternatives 1 through 6 the different possibilities of starting-up the entire process are indicated, i.e. starting from only the use of the recuperator to the realization of the entire process using the complete equipment. During the starting-up phase a relatively small part of the flue gases is passed through the reformer. The temperature of the flue gas entering the reformer is decreased from 1030° C. to about 700° C. by admixing air or water. This is necessary because during the starting-up phase the reformer and the preheater are not yet cooled by the gas/steam reaction, and the wall temperature of the reformer must not exceed a specific value. The table shows that during the starting-up phase a substantial part of the flue gas is passed directly to the chimney via the bypass. The reason for this is that the reactions in the reformer develop only slowly, so that the available heat content of the flue gas is so large that it cannot be passed entirely to the steam boiler. Once steam is produced, natural gas can be passed over the reformer. The initial amount must be low, while it can be increased slowly.
Alternatives 1 through 6 indicate the result for a bypass branching before (upstream of) or after (downstream of) the recuperator. As the results show, hardly more heat is transferred by the recuperator when air is admixed before the recuperator. This results in that the (natural) gas consumption is higher and that the chimney system must be much larger so as to enable the processing of the large amount of flue gas.
It further appears from the data that admixture of air after the gas bypass and after the recuperator leads to the most favorable results. Finally, it appears from the data that admixture of water, preferably after the gas bypass, leads to a smaller amount of flue gas than is obtained by admixture with air.
TABLE A__________________________________________________________________________Different alternatives for cooling flue gas when switching over from TCRAlternative 0 1 2 3 4 5 6__________________________________________________________________________Branch bypass: -- after recu- after recu- before recu- before recu- after recu- before recu- perator perator perator perator perator peratorMedium admixed in flue gas -- air air air air water waterlocation admixture -- before after before after after before bypass bypass bypass bypass bypass bypassflue gas temperature beforerecuperator (°C.) 1350 1350 1350 724 724 1350 724flue gas temperature afterrecuperator (°C.) 1083 1029 1029 700 700 1029 700air temperature beforerecuperator (°C.) 350 40 40 40 40 40 40air temperature afterrecuperator (°C.) 800 500 500 100 100 500 100amount of natural gasKmol/h 116 189 189 286 286 189 286amount of air to furnace(Kmol/h) 1035 1703 1703 2577 2577 1703 2577amount of air/water toflue gas (Kmol/h) 0 1192 260 3247 260 77 529amount of flue gas toreformer (Kmol/h) 1432 690 690 690 690 507 507amount of flue gas viabypass (Kmol/h) 0 2468 1536 5496 2409 1537 2960total amount of flue gas(Kmol/h) 1432 3158 2227 6186 3099 2041 3464required power air blower(Kw) 16 46 46 153 153 46 153Explanation TCR stationary condition starting-up the TCR__________________________________________________________________________
EXAMPLE II
In this example the temperature in the different phases of the process during the starting-up phase of a glass furnace of 400 tons of glass a day is schematically indicated in FIG. 2.
______________________________________ Composition of natural gas: (mol %)______________________________________ CO.sub.2 0.89 CH.sub.4 81.34 N.sub.2 14.32 C.sub.2 2.89 C.sub.3 0.38 C.sub.4 0.18______________________________________
Gas flow in Kmol/h:
Air: 1703 natural gas: 189 (direct to furnace, not via reformer)
Reformed gas: -steam: 208 (pressure build-up)
Air for admixture: 260
Flue gas to reformer: 690
Flue gas to bypass: 1536
total of flue gas: 2227
______________________________________Gas composition (mol %) H.sub.2 H.sub.2 O CO CO.sub.2 CH.sub.4 N.sub.2 O.sub. 2______________________________________Reformed gas -- -- -- -- --Flue gas -- 18.3 -- 11.9 -- 68.8 1.0______________________________________ power (Mw)______________________________________Air preheat --Steam boiler 2.87Gas/steam preheat --Reformer --Recuperator 6.62Furnace 15.65______________________________________
EXAMPLE III
In this example the temperatures in the different phases of the process during the "steady state" phase of an operated glass furnace for 400 tons of glass a day are schematically indicated in FIG. 3.
Composition of natural gas: the same as in Example II.
Gas flows in Kmol/h:
Air: 1035 natural gas: 116
Reformed gas: 494 steam: 208
Air for admixture: 0
Flue gas to reformer: 1432
Flue gas to bypass: 0
total of flue gas: 1432
______________________________________Gas composition:(mol %) H.sub.2 H.sub.2 O CO CO.sub.2 CH.sub.4 N.sub.2 O.sub.2______________________________________Reformed gas 56.7 18.8 10.9 6.5 3.8 3.4 0.6Flue gas -- 30.2 -- 11.7 -- 57.4 0.7______________________________________ Power (Mw)______________________________________Air preheat 2.79Steam boiler 2.87Gas/steam preheat 1.00Reformer 6.10Recuperator 4.17Furnace 15.65______________________________________
Examples I and II show that the amount of air to be admixed can be readily adjusted--especially by determining the highest desired temperature during the different phases of the process--until the stationary condition has been reached and admixture of air to the flue gas is no longer necessary. | A method of carrying out a gas combustion process with recovery of the heat from the combustion gases, which comprises passing said gases during the stationary condition of the process through a recuperator in which a part of the heat released is used for heating the air required for the combustion, and then passing the gases through a reformer in which a part of the residual heat is used for converting fresh gas to be burned with steam, in which method at least during the non-stationary conditions of the process a cooling medium is supplied to the combustion gases before introducing them into the reforming reactor. | 8 |
RELATED APPLICATIONS
[0001] This application is a continuation of U.S. patent application Ser. No. 13/685,604, filed Nov. 26, 2012, which is a continuation of U.S. patent application Ser. No. 13/607,557, filed Sep. 7, 2012, the entire disclosure of which is incorporated herein by this reference.
TECHNICAL FIELD
[0002] The present disclosure relates to a distributed file system, and more particularly, to pro-actively self-healing of a file in a distributed file system.
BACKGROUND
[0003] Data may be stored as unstructured data, for example, in files and directories in a file system. A distributed file system may store multiple copies of a file and/or directory on more than one storage server machine to help ensure that, in case of a hardware failure and/or system failure, the data should still be accessible. If a storage server machine experiences a failure, the storage server machine may be unavailable, but changes can still be made to the data on the copies of the data on the available storage server machines. The data on the storage server machine that is down may be stale, which is data that no longer is a current version of the data. When the failed storage server machine is powered back up, the changes which were made to the other copies of the data should be propagated to the failed storage server machine. The process of updating the stale data on the storage server machine may be known as “self-healing.” In traditional self-healing solutions, self-healing is driven by a client device and a mount point to the file system. Such conventional self-healing solutions use a significant amount of client resources, which may impact the performance of the client device. Such conventional self-healing solutions do not start until a client application accesses a file, thus causing the client application to wait until the file is self-healed before the client application can access the file.
BRIEF DESCRIPTION OF THE DRAWINGS
[0004] The present disclosure will be understood more fully from the detailed description given below and from the accompanying drawings of various implementations of the disclosure.
[0005] FIG. 1 illustrates an example system architecture, in accordance with various implementations.
[0006] FIG. 2 is a block diagram of an implementation of a pro-active self-healing module.
[0007] FIG. 3 is a flow diagram illustrating an implementation for a method for pro-actively self-healing a file prior to the file being accessed by an application.
[0008] FIG. 4 is a block diagram of an example computer system that may perform one or more of the operations described herein.
DETAILED DESCRIPTION
[0009] Described herein are a method and apparatus for pro-actively self-healing a file prior to the file being accessed by an application. A cluster of storage server machines may store a copy of data in a replication domain to help prevent data loss. A cluster is a set of linked storage servers working together closely. For example, each of a cluster of storage server machines A-D may store a copy of a file-XYZ. Storage server machine-A may experience a system failure and may be unavailable for a period of time. While storage server machine-A is down, changes may be made to the copies of file-XYZ that reside on storage server machine-B, storage server machine-C, and storage server machine-D. File-XYZ on storage server machine-A is a stale copy of data and copies of file-XYZ on storage server machine-B, storage server machine-C, and storage server machine-D are fresh copies of the data. A fresh copy of a file contains the most current version of the data of the file. A stale copy of a file does not contain the most current version of the data of the file.
[0010] When storage server machine-A is back up and running and re-connecting to the cluster of storage servers, the stale file-XYZ on storage server machine-A should be updated. A storage server that is connecting to a cluster of storage servers is hereinafter referred to as a “recovered storage server.” The process of updating the data on the recovered storage server machine to reflect the current version of the data is hereinafter referred to as “self-healing.” Self-healing can include overwriting stale data in a file with current data. In traditional self-healing solutions, self-healing is driven by a client device, which may or may not be in a cluster, and a mount point to the file system. Typically, client devices would access the files in the file system by performing a mount operation on the file system. Mounting takes place before a computer (e.g., client device) can use any kind of storage device on the file system. A client device can only access files on mounted media. Once the mount operation is performed, the client device can read the files and folders. Such conventional self-healing solutions use a significant amount of client resources, which may impact the performance of the client device. Traditional self-healing solutions do not start until a client application accesses a file, thus causing the client application to wait until the file is self-healed before the client application can access the file.
[0011] Implementations of the present disclosure describe storage server machines that host a pro-active self-healing module, which is described in greater detail below, to initiate the self-healing process on a file without waiting for a client application to first access the file. The pro-active self-healing module can detect that the recovered storage server (e.g., storage server machine-A) is connecting to the cluster of storage servers (e.g., set of storage server machines B-D) and can pro-actively start the self-healing of the files (e.g., file XYZ on storage server machine-A) at the recovered storage server.
[0012] FIG. 1 is an example system architecture 100 for various implementations. The system architecture 100 can include a cloud 150 which can provide virtual machines, such as virtual machines 123 A-B. There can be any number of virtual machines 123 A-B in the cloud 150 . Each virtual machine 123 A-B can be hosted on a physical host machine 120 A-B configured as part of the cloud 150 . For example, virtual machines 123 A-B may be respectively hosted on host machines 120 A-B in cloud 150 . Each host machine 120 A-B can be a server computer system, a desktop computer or any other computing device. The host machines 120 A-B can communicate to each other via a network (not shown), which may be may be a private network (e.g., a local area network (LAN), a wide area network (WAN), intranet, or other similar private networks) or a public network (e.g., the Internet). The host machines 120 A-B can be located in a data center. The cloud 150 can be provided by a cloud provider.
[0013] Users can interact with applications 104 executing on the virtual machines 123 A-B using client computer systems, such as client device 102 . An application 104 can be any type of application including, for example, a web application, a desktop application, a database management application, a browser application, etc. Client devices 102 can be connected to host machines 120 A-B via a network 108 , which may be may be a private network (e.g., a local area network (LAN), a wide area network (WAN), intranet, or other similar private networks) or a public network (e.g., the Internet). The client device 102 can be a mobile device, a PDA (personal digital assistant), a laptop, a desktop computer, or any other computing device.
[0014] The virtual machine 123 A-B can be instantiated on the host machine 120 A-B using a virtual machine image file 173 A-B that may be stored in an image repository. Multiple copies of the virtual machine image file 173 A-B can be stored in an image repository on the disks 170 A-B for redundancy to prevent data loss. For example, virtual machine image file 173 B, which may be a copy of virtual machine image file 173 A, may be stored on disk 170 B and managed by storage server machine 140 B. The image repository can represent a single data structure or multiple data structures (databases, repositories, files, etc.) residing on one or more mass storage devices, such as magnetic or optical storage based disks 170 A-B, solid-state drives (SSDs) or hard drives.
[0015] The virtual machine image file 123 A-B can identify the base operating system and the software package(s) (e.g., file system client 125 A-B, application 104 ) to be loaded on a host machine 120 A-B for instantiating a virtual machine 123 A-B. A file system client 125 A-B allows a virtual machine 123 A-B to communicate with the file system 101 and perform operations (e.g., read, write) on the data (e.g., data files 171 A-) that is stored in the file system 101 .
[0016] The cloud 150 can include a distributed file system 101 connected to the host machines 120 A-B via a network (not shown). The network may be a public network, a private network, or a combination thereof. A distributed file system 101 can be a network attached storage file system that includes one or more storage server machines 140 A-B and any number of disks 170 A-B coupled to the storage server machines 140 A-B. A storage server machine 140 A-B can include a network-accessible server-based functionality (e.g., storage server 143 A-B) or other data processing equipment. The storage server machines 140 A-B can include, and are not limited to, any data processing device, such as a desktop computer, a laptop computer, a mainframe computer, a personal digital assistant, a server computer, a handheld device or any other device configured to process data.
[0017] The storage server machines 140 A-B can be clustered in a replication domain to store multiple copies of data (e.g., data files 171 A-B, virtual machine image files 173 A-B) on various disks 170 A-B to prevent data loss in case one of the storage servers machine 140 A-B is unavailable, for example, due to a system failure or a hardware failure. A data file 171 A-B can store data that can be accessed by a client application (e.g., application 104 ). Each storage server 143 A-B can manage the data (e.g., files 171 A-B, files 173 A-B) being replicated in the cluster using a replication directory hierachy, which is a directory structure that contains the files being replicated amongst the clustered storage servers 143 A-B. The storage servers 143 A-B can propagate any changes that are made to the files in their corresponding replication directory hierarchy to the other copies of the data that are stored on the other disks and/or managed by other storage servers 143 A-B. For example, disk 170 B may store a file 171 B. A copy of file 171 B may be stored on disk 170 A. When a change is made to file 171 B, the storage server machine 140 B, which may manage file 171 B, can contact storage server 140 A, which may manage file 171 A, to make the same change in file 171 A.
[0018] When a storage server machine 140 A-B is unavailable, for example, the storage server machine 140 A may have experienced a system failure, changes can be made to the copies of the data (e.g., data files 171 A-B, virtual machine image files 173 A-B) using another storage server machine, such as storage server machine 140 B, that is available. When storage server machine 140 A becomes available, for example, storage server machine 140 A is re-booted and/or reconnecting to the cluster, the files in the replication directory hierarchy in the storage server machine 140 A may be stale. The files may be stale in that the files in the replication directory hierarchy in the recovered storage server machine (e.g., storage server machine 140 A) may not match the copies of the file in the other storage server machines, such as storage server machine 140 B, that were available. A stale copy of the file does not contain the most current version of the data of the file. A fresh copy of the file contains the most current version of the data of the file.
[0019] The machines (e.g., storage server machines 140 A-B, host machines 120 A-B) can include a pro-active self-healing module 127 A-D to pro-actively self-heal files (e.g., virtual machine image file, data file) in a replication directory hierarchy in a recovered storage server. The machines (e.g., storage server machines 140 A-B, host machines 120 A-B) may be in a distributed system which allows any of the pro-active self-healing modules 127 A-D to initiate the self-healing of the files at the recovered storage server. For example, the self-healing of the file may be initiated and performed by a storage server that detects a recovered storage server is rejoining the cluster. The pro-active self-healing module 127 A-D does not wait until a file at the recovered storage server is accessed by a client application (e.g. application 104 ) in order to start the self-healing process. In one implementation, the pro-active self-healing module 127 A-D is a daemon, which is a process that is running in the background. In some operating systems, a daemon is a computer program that runs as a background process, rather than being under direct control of an interactive user. The pro-active self-healing module 127 A-D can detect that the recovered storage server is rebooted and/or re-connected to the cluster and can automatically initiate the self-healing process on each file in the replication directory hierarchy at the recovered storage server. The pro-active self-healing module 127 A-D can read data from a fresh copy of the file on another storage server machine, and write the fresh data over the file in the replication directory hierarchy that is being self-healed. In one implementation, the pro-active self-healing module 127 A-D automatically self-heals all of the files in the replication directory hierarchy that contain stale data. The pro-active self-healing module 127 A-D can crawl the replication directory hierarchy, evaluates each file, and self-heals the files that have stale data.
[0020] FIG. 2 illustrates a block diagram of one implementation of a pro-active self-healing module 200 . The pro-active self-healing module 200 may correspond to a pro-active self-healing module 127 A-D in a machine 120 A-B, 140 A-B of FIG. 1 . The pro-active self-healing module 200 can include a storage server identifier sub-module 201 , a directory crawler sub-module 203 , and a self-healing sub-module 205 . Note that in alternative implementations, the functionality of one or more of the sub-modules can be combined or divided.
[0021] The storage server identifier sub-module 201 can identify a recovered storage server. The storage server identifier sub-module 201 can monitor network connections to the storage servers in the cluster. The storage server identifier sub-module 201 can detect when a recovered storage server is establishing a network connection to the cluster. The storage server identifier sub-module 201 can be configured to listen for network events (e.g., link detected). In one implementation, the storage server identifier sub-module 201 periodically requests a link status for various networks ports.
[0022] The directory crawler sub-module 203 can locate the replication directory hierarchy in a directory structure of the identified recovered storage server. The replication directory hierarchy can include a top-level directory, one or more sub-directories, one or more levels for the sub-directories, and files. The directory crawler sub-module 203 can be configured to locate a specific volume name or part of a volume name to identify the replication directory hierarchy in the recovered storage server. The volume name and/or part of the volume can be specified in configuration data 253 that is stored in the data store 250 that is coupled to the directory crawler sub-module 203 . The directory crawler sub-module 203 can identify each file in the located replication directory hierarchy.
[0023] The self-healing sub-module 205 can self-heal a file at the recovered storage server. In one implementation, the self-healing sub-module 205 automatically self-heals each file in the replication directory hierarchy at the recovered storage server that contains stale data. The self-healing sub-module 205 can evaluate each file in the replication directory hierarchy at the recovered storage server and self-heal the files that contain stale data. For example, the self-healing sub-module 205 can compare the content of a file in the replication directory hierarchy at the recovered storage server to a fresh copy 251 of the corresponding file residing in the local data store 250 . For example, the self-healing sub-module 205 can compute a hash for each of the content of the files (e.g., fresh copy of the file and file being self-healed) and compare the hash values to each other. In another example, the self-healing sub-module 205 can compute a checksum for each of the content of the files and compare the checksum values to each other. The self-healing sub-module 205 can compare the files to each other using change logs.
[0024] The change log for a file (e.g., fresh copy of the file and file being self-healed) can be stored in an extended attribute of the file. The files can have an extended attribute that stores change log data. The change log can include information identifying operations that have succeeded on each version of the file. Change logs can be stored in a distributed manner with each copy of the file, where each storage server machine that stores a copy of a file can maintain a change log in an extended attribute of the corresponding file. Each copy of the file, for example on different storage servers, can store a part of the change log in an extended attribute of the file. For example, storage server machine-A maintains a change log for file-XYZ in an extended attribute in the local copy of file-XYZ and storage server machine-B maintains a change log for file-XYZ in an extended attribute in the local copy of file-XYZ.
[0025] In one implementation, the self-healing sub-module 205 uses full-file lock self-healing to self-heal a file. In full-file lock self-healing, the self-healing sub-module 205 can acquire a lock on the entire file and the self-healing sub-module 205 may not permit write access to any application while the entire file is locked. When the self-healing process is complete, the self-healing sub-module 205 can release the full-file lock and the file can be accessed for read and write operations.
[0026] In another implementation, the self-healing sub-module 205 uses granular self-healing to self-heal a file. In granular self-healing, the self-healing sub-module 205 can acquire a full-file lock on the file to inspect and extract data from one or more change logs corresponding to the file to identify which storage server machines contain a fresh copy of the file. The self-healing sub-module 205 can acquire a lock on a region (e.g., 128 kilobytes, 64 kilobytes) of the file and release the full-file lock. The self-healing sub-module 205 can use a checksum to determine whether the locked region should be self-healed. The file may have some regions that contain data that is up to date and should not be self-healed. If a region should be self-healed, the self-healing sub-module 205 can change the stale data in the locked region to the current data by reading data for a corresponding region in a fresh copy from a storage server machine (e.g., storage server machine-B) that contains a fresh copy of the file and writing the current data over the stale data in the locked region in the stale file. The self-healing sub-module 205 can iteratively acquire a lock on a next region of the file at the recovered storage server and release the lock on the preceding region to maintain control of the file. The self-healing sub-module 205 can grant write access to the unlocked regions of the file while a locked region is being self-healed.
[0027] For example, while the file is being self-healed, the self-healing sub-module 205 may receive a write request to access the file from an application. If the write request is for the region that is currently locked, the self-healing sub-module 205 can instruct the application to wait. If the write request is for another region of the stale file that is unlocked, the self-healing sub-module 205 can provide write access to the requested region during the self-healing of the locked region of the file. When the self-healing sub-module 205 receives a read request, the self-healing sub-module 205 can redirect the request to a storage server machine (e.g., storage server machine-B) that contains a fresh copy of the file. When the last region of the file is self-healed, the self-healing sub-module 205 can acquire a full-file lock on the file, release the lock on the last region, update the change log to indicate the file is self-healed, and release the full-file lock. The self-healing sub-module 205 can self-heal each file in the storage server machine.
[0028] The data store 250 can be a persistent storage unit. A persistent storage unit can be a local storage unit or a remote storage unit. Persistent storage units can be a magnetic storage unit, optical storage unit, solid state storage unit, electronic storage units (main memory), or similar storage unit. Persistent storage units can be a monolithic device or a distributed set of devices. A ‘set’, as used herein, refers to any positive whole number of items.
[0029] FIG. 3 is a flow diagram of an implementation of a method 300 of pro-actively self-healing a file prior to the file being accessed by an application. Method 300 can be performed by processing logic that can comprise hardware (e.g., circuitry, dedicated logic, programmable logic, microcode, etc.), software (e.g., instructions run on a processing device), or a combination thereof. In one implementation, method 300 is performed by a pro-active self-healing module 127 A-D in a machine 120 A-B, 140 A-B of FIG. 1 .
[0030] At block 301 , processing logic identifies a recovered storage server, which is a storage server that becomes unavailable in a cluster of storage servers and is re-connecting to the cluster. Processing logic may determine that the network connection of a storage server is lost and may receive a message from the recovered storage server, for example, when the recovered storage server is powered back on and/or rejoins the cluster of storage servers.
[0031] At block 303 , processing logic locates a file in the recovered storage server and determines whether the file contains stale data and should be self-healed at block 305 . Processing logic can locate the replication directory hierarchy in a directory structure of the identified recovered storage server, for example, by searching for a particular volume name as specified by configuration data. The file can be a file in the replication directory hierarchy that has not yet been accessed, for example, by a client application. In one example, the file is copy of a virtual machine image file that is stored in a data store and has not been accessed. In another example, the file is a copy of a data file for a particular application and has not yet been accessed. For example, the file may be word processing file for a word processing application. Method 300 and/or portions of method 300 may be iterative. The number of iterations can be based on the number of files in a replication directory hierarchy in the recovered storage server. At block 303 , processing logic can crawl through the entire replication directory hierarchy at the recovered storage server and determine whether each file in the replication directory structure contains stale data.
[0032] For example, processing logic may determine that the data in a file at the recovered storage server does not match the data in a fresh copy of the file at another storage server. In another example, processing logic may determine that the data in a file at the recovered storage server matches the data in a fresh copy of the file at another storage server. If the file does not contain stale data and should not be self-healed (block 305 ), processing logic determines whether there is another file in the replication directory hierarchy in the recovered storage server at block 309 . If there is another file, processing logic returns to block 303 to locate another file in the replication directory hierarchy that has not yet been accessed by a client application. If the file contains stale data (block 305 ), processing logic self-heals the file at block 307 . Processing logic can self-heal the file using granular self-healing or full-file lock self-healing.
[0033] FIG. 4 illustrates an example machine of a computer system 400 within which a set of instructions, for causing the machine to perform any one or more of the methodologies discussed herein, may be executed. In alternative implementations, the machine may be connected (e.g., networked) to other machines in a LAN, an intranet, an extranet, and/or the Internet. The machine may operate in the capacity of a server or a client machine in client-server network environment, or as a peer machine in a peer-to-peer (or distributed) network environment.
[0034] The machine may be a personal computer (PC), a tablet PC, a set-top box (STB), a Personal Digital Assistant (PDA), a cellular telephone, a web appliance, a server, a network router, a switch or bridge, or any machine capable of executing a set of instructions (sequential or otherwise) that specify actions to be taken by that machine. Further, while a single machine is illustrated, the term “machine” shall also be taken to include any collection of machines that individually or jointly execute a set (or multiple sets) of instructions to perform any one or more of the methodologies discussed herein.
[0035] The example computer system 400 includes a processing device 402 , a main memory 404 (e.g., read-only memory (ROM), flash memory, dynamic random access memory (DRAM) such as synchronous DRAM (SDRAM) or DRAM (RDRAM), etc.), a static memory 406 (e.g., flash memory, static random access memory (SRAM), etc.), and a data storage device 418 , which communicate with each other via a bus 430 .
[0036] Processing device 402 represents one or more general-purpose processing devices such as a microprocessor, a central processing unit, or the like. More particularly, the processing device may be complex instruction set computing (CISC) microprocessor, reduced instruction set computing (RISC) microprocessor, very long instruction word (VLIW) microprocessor, or processor implementing other instruction sets, or processors implementing a combination of instruction sets. Processing device 1202 may also be one or more special-purpose processing devices such as an application specific integrated circuit (ASIC), a field programmable gate array (FPGA), a digital signal processor (DSP), network processor, or the like. The processing device 402 is configured to execute instructions 422 for performing the operations and steps discussed herein.
[0037] The computer system 400 may further include a network interface device 408 . The computer system 400 also may include a video display unit 410 (e.g., a liquid crystal display (LCD) or a cathode ray tube (CRT)), an alphanumeric input device 412 (e.g., a keyboard), a cursor control device 414 (e.g., a mouse), and a signal generation device 416 (e.g., a speaker).
[0038] The data storage device 418 may include a machine-readable storage medium 428 (also known as a computer-readable medium) on which is stored one or more sets of instructions or software 422 embodying any one or more of the methodologies or functions described herein. The instructions 422 may also reside, completely or at least partially, within the main memory 404 and/or within the processing device 402 during execution thereof by the computer system 400 , the main memory 404 and the processing device 402 also constituting machine-readable storage media.
[0039] In one implementation, the instructions 422 include instructions for a pro-active self-healing module (e.g., pro-active self-healing module 200 of FIG. 2 ) and/or a software library containing methods that call modules in a pro-active self-healing module. While the machine-readable storage medium 428 is shown in an example implementation to be a single medium, the term “machine-readable storage medium” should be taken to include a single medium or multiple media (e.g., a centralized or distributed database, and/or associated caches and servers) that store the one or more sets of instructions. The term “machine-readable storage medium” shall also be taken to include any medium that is capable of storing or encoding a set of instructions for execution by the machine and that cause the machine to perform any one or more of the methodologies of the present disclosure. The term “machine-readable storage medium” shall accordingly be taken to include, but not be limited to, solid-state memories, optical media and magnetic media.
[0040] Some portions of the preceding detailed descriptions have been presented in terms of algorithms and symbolic representations of operations on data bits within a computer memory. These algorithmic descriptions and representations are the ways used by those skilled in the data processing arts to most effectively convey the substance of their work to others skilled in the art. An algorithm is here, and generally, conceived to be a self-consistent sequence of operations leading to a desired result. The operations are those requiring physical manipulations of physical quantities. Usually, though not necessarily, these quantities take the form of electrical or magnetic signals capable of being stored, combined, compared, and otherwise manipulated. It has proven convenient at times, principally for reasons of common usage, to refer to these signals as bits, values, elements, symbols, characters, terms, numbers, or the like.
[0041] It should be borne in mind, however, that all of these and similar terms are to be associated with the appropriate physical quantities and are merely convenient labels applied to these quantities. Unless specifically stated otherwise as apparent from the above discussion, it is appreciated that throughout the description, discussions utilizing terms such as “identifying” or “locating” or “determining” or “self-healing” or “examining” or “comparing” or “acquiring” or “providing” or the like, refer to the action and processes of a computer system, or similar electronic computing device, that manipulates and transforms data represented as physical (electronic) quantities within the computer system's registers and memories into other data similarly represented as physical quantities within the computer system memories or registers or other such information storage devices.
[0042] The present disclosure also relates to an apparatus for performing the operations herein. This apparatus may be specially constructed for the intended purposes, or it may comprise a general purpose computer selectively activated or reconfigured by a computer program stored in the computer. Such a computer program may be stored in a computer readable storage medium, such as, but not limited to, any type of disk including floppy disks, optical disks, CD-ROMs, and magnetic-optical disks, read-only memories (ROMs), random access memories (RAMs), EPROMs, EEPROMs, magnetic or optical cards, or any type of media suitable for storing electronic instructions, each coupled to a computer system bus.
[0043] The algorithms and displays presented herein are not inherently related to any particular computer or other apparatus. Various general purpose systems may be used with programs in accordance with the teachings herein, or it may prove convenient to construct a more specialized apparatus to perform the method. The structure for a variety of these systems will appear as set forth in the description below. In addition, the present disclosure is not described with reference to any particular programming language. It will be appreciated that a variety of programming languages may be used to implement the teachings of the disclosure as described herein.
[0044] The present disclosure may be provided as a computer program product, or software, that may include a machine-readable medium having stored thereon instructions, which may be used to program a computer system (or other electronic devices) to perform a process according to the present disclosure. A machine-readable medium includes any mechanism for storing information in a form readable by a machine (e.g., a computer). For example, a machine-readable (e.g., computer-readable) medium includes a machine (e.g., a computer) readable storage medium such as a read only memory (“ROM”), random access memory (“RAM”), magnetic disk storage media, optical storage media, flash memory devices, etc.
[0045] In the foregoing specification, implementations of the disclosure have been described with reference to specific example implementations thereof. It will be evident that various modifications may be made thereto without departing from the broader spirit and scope of implementations of the disclosure as set forth in the following claims. The specification and drawings are, accordingly, to be regarded in an illustrative sense rather than a restrictive sense. | Techniques for pro-active self-healing in a distributed file system are disclosure herein. In accordance with one embodiment, a method is provided. The method comprises prior to detecting an access request by a client application to an image on a storage server, identifying, by a self-healing daemon executed by a processing device, a first region of the image comprising stale data. A partial lock on the image is acquired. The partial lock prevents access to the first region of the image. Responsive to acquiring the partial lock, the self-healing daemon provides access to a second region of the image file comprising data other than the stale data. | 6 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority under 35 U.S.C. §119(a) to DK Application No. PA 2008 01774, filed Dec. 12, 2008. This application also claims the benefit of U.S. Provisional Application No. 61/122,062, filed Dec. 12, 2008. Each of these applications is incorporated by reference herein in its entirety.
TECHNICAL FIELD
[0002] The present invention relates to a method for controlling the operation of a wind turbine and a wind turbine.
BACKGROUND
[0003] In conventional predictive maintenance or condition based maintenance of a wind turbine component, the component operational condition is being monitored. If, in the monitoring process, a clear degradation in the component performance has been found and the deterioration has been over a given threshold, an action is triggered that the maintenance will be carried out. This usually relies on a monitoring system to detect such changes. The parameters in monitoring are usually the ones that reflect vibration, temperature, acoustic or pressure but not limited to these parameters.
SUMMARY
[0004] Embodiments in accordance with aspects of the invention provide an advantageous technique for monitoring and controlling the operation of a wind turbine component in order to increase component life time and minimize required maintenance services of the wind turbine component.
[0005] One embodiment in accordance with aspects of the invention relates to a method for controlling the operation of a wind turbine, and includes the steps of
[0006] determining a first measure of a mechanical input of a component of the wind turbine, and concurrently,
[0007] determining a second measure of a mechanical output of the component,
[0008] determining an operating frequency response function of the component from an analysis of the relation between the first measure and the second measure,
[0009] comparing the operating frequency response function with a predetermined operating frequency response function and determining a possible deviation between the two, and
[0010] controlling the operation of the wind turbine so as to alter the mechanical input to the component in response to the deviation.
[0011] The method is intended to control the operation of a wind turbine so as to prolong the operational lifespan of a wind turbine component by monitoring the condition of the component and controlling the mechanical input when the component shows signs of wear. An exemplary technique for monitoring and controlling the operation of the wind turbine component in order to increase component life time and minimize required maintenance services of the wind turbine component is hereby ensured.
[0012] The frequency response function of a mechanical component can give a good indication of the operating condition of the component. The control and operation of the wind turbine can be administered by observing any changes in the frequency response curve or function in relation to a reference frequency response curve for the mechanical component, which in turn may indicate that physical changes may have occurred.
[0013] In one aspect, altering the mechanical input to the component is done by altering the pitch of one or more wind turbine rotor blades. By altering the pitch of the rotor blades, it can be ensured that loads on various components of the wind turbine, such as pitch-bearings, main shaft, gear-box, main-bearing yaw-bearing, etc., are reduced. The reduction and control of the wind turbine in turn ensures that wear is minimized.
[0014] In another aspect, altering the mechanical input to the component is done by altering the rotational speed of the wind turbine rotor. By altering the rotational speed it can be ensured that dynamical loads on various components of the wind turbine, such as the main bearing, the gear-box, etc., are reduced. This in turn ensures that wear of the specific components is reduced. Even further, this aspect can be combined with other strategies for altering the mechanical input to the component, for example, by pitching one or more wind turbine rotor blades.
[0015] In yet another aspect, altering the mechanical input to the component results in the maximum torque at the input of the component being decreased. By reducing the maximum torque at the input of a component, e.g. the gear-box, it is ensured that the level of load and torque fluctuations of that component are also decreased. Hereby it is ensured that maximum levels of load and fluctuation are not reached and the risk of failures is decreased.
[0016] In a further aspect, altering the mechanical input to the component results in the power in one or more predefined frequency ranges being reduced. It is hereby ensured that loads that impact the component at one or more predefined frequency ranges, such as around the components natural frequency, are reduced as impacts at or around these frequency ranges often results in the highest degree of wear of the component.
[0017] In an even further aspect, determining an operating frequency response function is executed at predefined intervals. Hereby it is ensured that the control of the operation of the wind turbine can be performed at intervals, for example, initiated by a suspected degeneration of a wind turbine component that requires that another control strategy of the wind turbine, or initiated by a sudden change in the mechanical condition of the component.
[0018] In other aspects, controlling the operation of the wind turbine so as to alter the mechanical input to the component in response to the deviation is done in case the determined deviation exceeds a predetermined threshold. By not altering the mechanical input to the component before the deviation exceeds a certain threshold, it is ensured that the mechanical input is not constantly altered due to small deviations that might be determined, and certain errors in the determination of the response function, due to for example measure errors or measurements in noisy environments, can be avoided.
[0019] In another aspect, the value of the threshold can be dynamically changed during operation. By being able to change the threshold during operation, optimal control of the operation of the wind turbine can be achieved. The change of the value of the threshold can be done on the basis of, for example, load measurements, wind velocities, turbulence, etc.
[0020] In a further aspect, the frequency response function comprises at least an amplitude function. Hereby it is ensured that the determination of the deviation is based at least upon the amplitude or magnitude of the load impacts on the components and that the wind turbine can be controlled in relation hereto.
[0021] In an even further aspect, the frequency response function comprises at least a phase function. Hereby it is ensured that the determination of the deviation is based at least upon a timely relation of the load impacts on the components and that the wind turbine can be controlled in relation hereto.
[0022] In yet another aspect, the component of a wind turbine is a gearbox. By applying the above-described method to a wind turbine gearbox, it is ensured that the gear box can be operated on load levels which ensures a prolonged lifetime compared to gearboxes that are operated at substantially full load levels.
[0023] In a further aspect, the component of a wind turbine is a bearing of the wind turbine. By applying the above-described method to a wind turbine bearing, it is ensured that loads acting on the bearing can be controlled in a way that the lifetime of the bearing is increased.
[0024] In another aspect, the predetermined operating frequency function is determined substantially at the time of installation. By determining the operating frequency function at the time of the installation, it is ensured that a frequency function of the newly installed components is determined, i.e., at a time where wear and tear has not changed the mechanical characteristics of the components. Therefore, a reference frequency function is determined to which any subsequent obtained functions can be compared and any subsequent changes of the frequency function can be detected, indicating wear.
[0025] An embodiment in accordance with the invention also relates to a wind turbine prepared for performing a method according to any of the mentioned aspects.
BRIEF DESCRIPTION OF THE DRAWINGS
[0026] The invention will be described in the following with reference to the figures in which:
[0027] FIG. 1 schematically illustrates a typical setup for determining the frequency response of a wind turbine component;
[0028] FIG. 2 schematically illustrates a fictive frequency response curve (amplitude vs. frequency) as an output spectrum of a fictive simple mechanical wind turbine component as a response to a known applied force at the input of the component;
[0029] FIG. 3 schematically illustrates how one component performance parameter, e.g., the amplitude of one resonant peak of the output spectrum from a mechanical component, may vary over time due to changes in the frequency response function of the component;
[0030] FIG. 4 schematically illustrates in one embodiment of the invention how the input of the component is controlled in a way such that the operating frequency response curve gets normalized or optimized to be substantially equal to an original reference frequency response curve;
[0031] FIG. 5 schematically illustrates the impact of an optimization of the operating frequency response curve of a mechanical wind turbine component;
[0032] FIG. 6 a schematically illustrates the level of power production from installation time to where the lifetime for the wind turbine component conventionally ends; and
[0033] FIG. 6 b illustrates the level of power production for a wind turbine according to various embodiments of the invention.
DETAILED DESCRIPTION
[0034] Any mechanical or electric/mechanical component or system endures a wear-out process before it fails. It is of great interest to verify when a degradation process starts and how long the remaining useful life is.
[0035] In conventional predictive maintenance or condition based maintenance, the component operational condition is being monitored. If, in the monitoring process, a clear degradation in the component performance is found and the deterioration is over a given threshold, an action is triggered to ensure that the maintenance will be carried out. This process usually relies on a separate conditioning monitoring system to detect such changes. Parameters to be monitored are usually, but not limited to, ones that reflect vibration, temperature, acoustic response or pressure.
[0036] Embodiments in accordance with aspects of the invention utilize the frequency response function of a mechanical component to give a good indication of the operating condition of the component.
[0037] The frequency response function of a mechanical component or system is a characteristic of the system that has a measured response resulting from a known applied input. This function has the purpose of identifying the natural frequencies, and damping ratios and mode shapes of the mechanical structure or component.
[0038] The natural frequency of the component is the frequency at which the component would oscillate if it were disturbed from its rest position and then allowed to vibrate freely. Many mechanical structures, such as various wind turbine components, are complex structures and may comprise multiple natural frequencies.
[0039] To measure the frequency response function of a mechanical system, it is necessary to measure the spectra of both the input force to the system and the vibration response. The frequency response function can thus be defined as the spectrum of the vibration of the component divided by the spectrum of the input force to the mechanical component or system.
[0040] The frequency response function may comprise measures of the parameters, amplitude, frequency and/or phase.
[0041] A typical setup for determining the frequency response is schematically indicated in FIG. 1 where an “output”-spectrum of the vibration is established by, for example, output monitoring means 3 (comprising at least one sensor 4 ) as a response to a known applied force, for example, measured by input monitoring means 1 (comprising at least one sensor 2 ) at the input of the component. The transfer function of the component is indicated by 9 .
[0042] In one embodiment, a signal processor may be used to receive the output spectrum of the vibration from the output monitoring means 3 , to receive the known applied force measured by the input monitoring means 1 , and to execute algorithms in software routines to control operation of the wind turbine based upon the data received from the output monitoring means 3 and the input monitoring means 1 , as described herein.
[0043] FIG. 2 schematically illustrates a fictive frequency response curve 5 (amplitude vs. frequency) as an output spectrum of a fictive simple mechanical wind turbine component as a response to a known applied force at the input of the component.
[0044] It can be seen that the frequency response curve 5 comprises a peak at f res,norm which is a natural frequency of the component.
[0045] According to one embodiment of the invention, a reference frequency response curve 5 may be measured and/or determined for a wind turbine component when the component is substantially new in operation.
[0046] According to another embodiment of the invention, a reference frequency response curve 5 may be measured and/or determined after the wind turbine component has been installed for a certain time and an initial operating period has been completed.
[0047] Any changes in the frequency response curve or function in relation to a reference frequency response curve for a mechanical component may indicate that physical changes may have occurred. Changes can occur, for example, if a failure operating mode occurs or if the component is in a wear-out phase.
[0048] The curve 6 on FIG. 2 schematically illustrates such an event where the frequency response function has changed. The curve may change regarding both in relation to the values of natural frequencies, the damping ratios, and mode shapes. The change or changes on the frequency response may occur suddenly, which may indicate a sudden structural change in the component, for example, due to break down, or the change or changes may occur slowly over time, which may originate, for example, from wear and/or aging in the component.
[0049] As an explanatory example for a wind turbine component, with a reference frequency response curve 5 , for example, long time wear may change the curvature to follow the curve 6 , i.e., both the amplitude and frequency of the peak f res,norm have changed to new values at f res,2 .
[0050] As earlier described, in conventional predictive maintenance or condition based maintenance strategies for wind turbine components, the component operational condition is being monitored. If, in the monitoring process, a clear degradation in the component performance is found, for example, by the change of the frequency response curve 6 in relation to the values of natural frequencies, the damping ratio and/or mode shapes, and the deterioration is over a given threshold, an action is triggered to ensure that maintenance will be carried out.
[0051] In the time prior to reaching the threshold, the frequency response parameters can be monitored.
[0052] FIG. 3 schematically illustrates how one component performance parameter 7 , for example, the amplitude of one resonant peak of the output spectrum from a mechanical component, may vary over time due to changes in the frequency response function of the component.
[0053] From a reference time, e.g. the time of installation (t=0), the amplitude of the resonant peak is measured to be substantially constant (nom.) over time until a time where physical changes start to occur (t=1). Changes can occur, for example, if the component is in a wear-out phase.
[0054] For this illustrative example, which represents the time dependent change of the frequency response curve 5 to the changed frequency response curve 6 , the remaining useful lifetime for the component may end at t=2, where the component requires scheduled maintenance and/or repair or even worse; is worn-out and likely to fail. The amplitude of the resonant peak of this example is at this point decreased to a level lower than at nominal (nom.).
[0055] For other embodiments of the invention, the component performance parameter 7 may increase in value due to wear-out.
[0056] According to various embodiments in accordance with aspects of the invention, when this change of the performance parameter 7 is monitored or the change is monitored to exceed a certain level, the input of the component is controlled in a way such that the operating frequency response curve 8 gets normalized or optimized to be substantially equal to the original reference frequency response curve 5 so as to compensate for the changes in the frequency response function of the component. This is schematically illustrated in FIG. 4 for one embodiment of the invention, where the input to the component is controlled such that the present operating frequency response curve 8 is optimized to be substantially equal to the original or reference frequency response curve 5 .
[0057] FIG. 5 schematically illustrates the impact of such above mentioned optimization of the operating frequency response curve 8 of a mechanical wind turbine component.
[0058] From a reference time, e.g., the time of installation (t=0), the amplitude of, for example, a resonant peak is measured to be substantially constant (nom.) over time until a time where physical changes start to occur (t=1). The remaining useful lifetime for the component may conventionally end at t=2, but according to embodiments of the invention, the input to the component is controlled such that the component output spectrum gets normalized or optimized to the reference level (nom.).
[0059] By this continuous adaption of the input to the component, the remaining useful lifetime is prolonged, i.e., the amplitude of the component performance parameter will not start to decrease from nom. level before time t=3 and the expected remaining useful lifetime for the component may end, for example, at t=4.
[0060] A consequence of an implementation of aspects of the invention is that the lifetime of the wind turbine components is prolonged and the wind turbine can be operated for longer periods without need for, for example, closing down the turbine for service, i.e., the time between service is prolonged. Hereby it is feasible to produce more power.
[0061] This is schematically illustrated for various embodiments of the invention in FIGS. 6 a and 6 b.
[0062] FIG. 6 a illustrates the level of power production from installation time (t=0) to the time t=2 where the lifetime for the wind turbine component conventionally ends and the wind turbine must be closed down for maintenance or repair. The power produced may be regarded as the hatched area on the figure.
[0063] FIG. 6 b illustrates the level of power production for a wind turbine according to various embodiments in accordance with aspects of the invention.
[0064] From installation time (t=0) the wind turbine is controlled according to the above-described technique which often has the result that the input force to the wind turbine component is reduced, for example, at a time before t=2, i.e., at a time before where the lifetime for the wind turbine component conventionally ends. Hereby the component output spectrum gets normalized or optimized to a reference level. By reducing the input force to the wind turbine, the produced power may also be reduced at a time before t=2 as indicated on the figure. Hereby the wind turbine can be operated further, such as to the time t=4, where a similar normalization/optimization is performed, for example, by reducing produced power and the wind turbine can be operated even further. It can be seen that the power produced over time, i.e., the hatched area, is increased and that the normalization/optimization process may be iterative, i.e., repeated a plurality of times at certain time intervals.
[0065] Hereby the wind turbine component and the wind turbine as such can be operated over a longer period of time without requiring maintenance or service; in other words, the time between services is increased.
[0066] This can be exploited in a way that the wind turbine does not need to be interrupted, for example, during the high wind season, but still can be operated to produce power even though this might be at a level lower than rated. This in turn means that maintenance is postponed to the low wind season. | A method for controlling the operation of a wind turbine includes determining a first measure of a mechanical input of a component of the wind turbine, and concurrently, determining a second measure of a mechanical output of the component, determining an operating frequency response function of the component from an analysis of the relation between the first measure and the second measure, comparing the operating frequency response function with a predetermined operating frequency response function and determining a possible deviation between the two, and controlling the operation of the wind turbine so as to alter the mechanical input to the component in response to the deviation. A wind turbine that implements such a method is also disclosed. | 5 |
CROSS-REFERENCE TO RELATED APPLICATIONS
The present application is related to, claims the earliest available effective filing date(s) from (e.g., claims earliest available priority dates for other than provisional patent applications; claims benefits under 35 USC §119(e) for provisional patent applications), and incorporates by reference in its entirety all subject matter of the following listed application(s) (the “Related Applications”) to the extent such subject matter is not inconsistent herewith; the present application also claims the earliest available, effective filing date(s) from, and also incorporates by reference in its entirety all subject matter of any and all parent, grandparent, great-grandparent, etc. applications of the Related Application(s) to the extent such subject matter is not inconsistent herewith.
1. U.S. provisional patent application 61,392,566 entitled “Micro Optic Fiber Launch TIRFM”, naming Guy G. Kennedy and David Warshaw as inventors, filed Oct. 13, 2010.
BACKGROUND
1. Field of Use
These teachings relate generally to a system and method for microscopy illumination in general and more particularly to an adjustable TIRFM illumination apparatus.
2. Description of Prior Art
Various mechanisms are often employed in fluorescence microscopy applications to restrict the excitation and detection of fluorophores to a thin region of the specimen. Elimination of background fluorescence from outside the focal plane can dramatically improve the signal-to-noise ratio, and consequently, the spatial resolution of the features or events of interest. Total internal reflection fluorescence microscopy (TIRFM) exploits the unique properties of an induced evanescent wave or field in a limited specimen region immediately adjacent to the interface between two media having different refractive indices. In practice, the most commonly utilized interface in the application of TIRFM is the contact area between a specimen and a glass cover-slip or tissue culture container. A collimated light beam propagating through one medium and reaching, such an interface is either refracted as it enters the second medium, or reflected at the interface, depending upon the incident angle and the difference in refractive indices of the two media. Total internal reflection is only possible in situations in which the propagating light encounters a boundary to a medium of lower refractive index. Its refractive behavior is governed by the well known Snell's Law.
Although light no longer passes into the second medium when it is incident at angles greater than the critical angle, the reflected light generates a highly restricted electromagnetic field adjacent to the interface, in the lower-index medium. This evanescent field is identical in frequency to the incident light, and because it decays exponentially in intensity with distance from the interface, the field extends at most a few hundred nanometers into the specimen in the z direction (normal to the interface).
In a typical experimental setup, fluorophores located in the vicinity of the glass-liquid or plastic-liquid surface can be excited by the evanescent field, provided they have potential electronic transitions at energies within or very near the wavelength bandwidth of the illuminating beam. Because of the exponential falloff of evanescent field intensity, the excitation of fluorophores is restricted to a region that is typically less than 100 nanometers in thickness. By comparison, this optical section thickness is approximately one-tenth that produced by confocal fluorescence microscopy techniques. Because excitation of fluorophores in the bulk of the specimen is avoided, confining the secondary fluorescence emission to a very thin region, a much higher signal-to-noise ratio is achieved compared to conventional wide field epifluorescence illumination. This enhanced signal level makes it possible to detect single-molecule fluorescence by the TIRFM method.
Generally, two types of TIRF illumination are known in the prior art. The first prior art illumination is by means of a prism. The fluorescence is collected through an objective and is formed at a charge-coupled-device (CCD) camera. It is understood that the TIRF illumination is performed on the side pointing away from the objective. This has the disadvantage that the specimen to be studied has to be prepared on the prism, because the evanescent lighting field is excited at the boundary surface between the prism and the specimen. This type of preparation is expensive. In contrast thereto, specimens are prepared as a rule on a thin cover glass. The sample is generally prepared on a glass surface coupled to the prism using a coupling medium of glycerol, or oil. This is an inconvenient method and difficult to set up and align. It typically restricts the sample from Brightfield imaging.
In the second type of TIRF illumination disclosed, for example in FIG. 9 of WO 20061127692 A2, the specimen can be prepared by a standard procedure on a cover glass because here the TIRF illumination is performed through the microscope objective.
Typically, however, this arrangement has had the disadvantage that the microscope objective has to possess a high numerical aperture in order to make it possible to have a large angle of incidence necessary for high resolution for the excitation light T. As a result, there are increased demands upon the glasses used whereby the number of glass types available is reduced. For example, immersion media and front lenses with a correspondingly higher index of refraction have to be used. In addition, the number of lenses for image correction has to be increased, as a rule, so that manufacturing expense rises and transmission decreases. If the specimen for the TIRF excitation is illuminated with different light wavelengths, so must the angle of incidence, in order to guarantee a high resolution, for all the wavelengths to be identical, the complexity of the microscope and with it its manufacturing expense increase further.
Although there were disadvantages to through the lens TIRF the challenges stated are generally well addressed in current objective lens design. While through the lens TIRF is not as pure as Prism type TIRF due to internal reflections and auto fluorescence within the objective lens assembly, in practice they perform extremely well.
However, commercial solutions to implement these new lenses into microscopy systems have been thus far complex and expensive; using a light path which is either common or redundant to an EPI illumination light path.
For example, referring to FIG. 1 there is shown a schematic diagram illustrating prior art conventional TIRF combined with Far field fluorescence. The prior art configuration shown in FIG. 1 includes objective lens 92 , dichromatic assembly 94 , prism 910 , camera 912 , a conventional TIRF assembly 930 , and an EPI Lamp assembly 79 .
The dichromatic assembly 94 comprises fixed filters 95 , 96 and dichromatic mirror 97 . The simplified representation of the conventional TIRF assembly 930 includes lenses 89 a , 89 b , and 89 c . Also shown is a laser source 89 d . Similarly the EPI Lamp assembly 79 includes lenses 79 a and 79 b . The assembly also includes a light source 79 c and reflector 79 d.
Still referring to FIG. 1 it can be seen that the emitted light paths for the camera 912 , the TIRF assembly 930 , represented by 91 c , 91 d and 91 e , 91 f , respectively are redundant to the EPI light paths generated by the EPI Lamp assembly 79 (not shown for clarity).
Thus, it will be readily appreciated that prior art solutions are complex, as well as expensive. In order to have both TIRF and Far field fluorescence capability, the hardware associated with each capability needs be stacked, one over the other. This adds redundancy to the optical path and about 3 inches to the height of a microscope.
Therefore, there exists a need for a robust, but less complex, adjustable TIRFM illuminator apparatus
BRIEF SUMMARY
The foregoing and other problems are overcome, and other advantages are realized, in accordance with the presently preferred embodiments of these teachings.
In accordance with one embodiment of the present invention an adjustable total internal reflectance microscopy (TIRFM) illuminator apparatus is provided. The apparatus includes an optical fiber for transmitting an optical light wavelength and a fiber axial translator for focusing the optical light wavelength. The fiber axial translator is mechanically adjustable in at least one-degree-of freedom for focusing the optical wavelength. The apparatus also includes at least collimating optical element connectable to the at least optical fiber for optically coupling, the optical light wavelength to an objective lens.
The invention is also directed towards a method for optically coupling light to the back aperture of a high numerical aperture microscopy objective lens for total internal reflectance microscopy (TIRFM). The method includes pumping a light wavelength through an optical fiber and providing an optical element for optically collimating and coupling the light wavelength to the objective lens. The method also includes providing a fiber axial translator connected to the at least one optical fiber, wherein the fiber axial translator is adapted to focus the at least one light wavelength optically coupled to the objective lens. The method further includes mechanically coupling the apparatus to the objective lens and adjusting the mechanical coupling such that the light wavelength exceeds or does not exceed a critical angle associated with TIRFM illumination.
In accordance with another embodiment of the present invention an apparatus an adjustable total internal reflectance microscopy (TIRFM) illuminator apparatus is provided. The apparatus includes an objective lens adaptable to TIRFM and an optical fiber for transmitting an optical light wavelength. Also provided is a fiber axial translator. The fiber axial translator is mechanically adjustable in at least one-degree-of freedom for focusing the optical light wavelength through the objective lens. The apparatus includes a collimating optical element connectable to the optical fiber for coupling the focused light to the objective lens. Further provided is a mechanical coupling for coupling the fiber, translator and optical element to the objective lens. The mechanical coupling is adjustable in at least one degree of freedom to adjust the optical light wavelength to exceed, or not exceed a critical angle of incidence associated with TIRFM illumination.
BRIEF DESCRIPTION OF THE DRAWINGS
The subject matter which is regarded as the invention is particularly pointed out and distinctly claimed in the claims at the conclusion of the specification. The foregoing and other objects, features, and advantages of the invention are apparent from the following detailed description taken in conjunction with the accompanying drawings in which:
FIG. 1 is a schematic diagram illustrating prior an conventional TIRF combined with Far field fluorescence;
FIG. 2 is a schematic diagram illustrating an adjustable total internal reflectance microscopy (TIRFM) illuminator apparatus invention described herein;
FIG. 3 is a schematic diagram illustrating fiber axial translation in accordance with the invention shown in FIG. 2 ;
FIG. 4 is a schematic diagram illustrating alternative optical configurations with additional micro optics in accordance with the invention shown in FIG. 2 ;
FIG. 5 is a schematic diagram illustrating an alternate configuration of the TIRFM illuminator apparatus in accordance with the invention shown in FIG. 2 ; and
FIG. 6 is a schematic diagram illustrating another alternate configuration of the TIRFM illuminator apparatus in accordance with the invention shown in FIG. 2 .
DETAILED DESCRIPTION
Referring now to FIG. 2 there is shown a schematic diagram illustrating an adjustable total internal reflectance microscopy (TIRFM) illuminator apparatus invention described herein. It will be understood that any suitable microscope or microscopy system may be used in accordance with the present invention.
Still referring to FIG. 2 , the adjustable total internal reflectance microscopy (TIRFM) illuminator apparatus 40 includes optical fiber 10 , scaffolding tubing 30 to hold internal tubing and fiber optic 10 , ball lens 31 , and linear translator components 20 , 22 . It will be appreciated that optical fiber 10 may be any suitable optical fiber, including, but not limned to, polarization-maintaining optical fiber.
Also shown in FIG. 2 is objective lens 36 , image plane 41 , refracted light 42 . Objective lens 36 includes back aperture lens 32 and front lens 34 . It will be understood, that in its simplest operation laser light 13 is refracted first by back aperture lens 32 and then by front lens 34 such that refracted light 42 does not pass into a second medium (e.g., sample slide) when it is incident at angles greater than the critical angle and is reflected by the second medium; however, the reflected light generates a highly restricted electromagnetic field adjacent to the interface, in the lower-index medium. This evanescent field is identical in frequency to the incident light, and because it decays exponentially in intensity with distance from the interface, the field extends at most a few hundred nanometers into the specimen in the z direction (normal to the interface). In practice the “second medium” is typically preceded by refractive index matching oil, then a glass sample slide, and then it is reflected at the glass/water interface. There could be two or more mediums for the light to transmit through before it reaches an interface for total internal reflection.
As noted earlier, because of the exponential falloff of evanescent, field intensity, the excitation of fluorophores is restricted to a region that is typically less than 100 nanometers in thickness. Typically, this optical section thickness is approximately one-tenth that produced by confocal fluorescence microscopy techniques; and, because excitation of fluorophores in the bulk of the specimen is avoided, confining the secondary fluorescence emission to a very thin region, a much higher signal-to-noise ratio is achieved compared to conventional wide field epifluorescence illumination. This enhanced signal level makes it possible to detect single-molecule fluorescence by the TIRFM method.
Still referring to FIG. 2 , it will be appreciated that by spatially adjusting the horizontal relationship between linear translator components 20 , 22 the wavelengths (because the fiber can transmit multiple wavelengths at the same time) and frequency of the incident light 42 , and therefore the penetration depth of the evanescent field and subsequent fluorophores excitation region, is changeable and focusable. The linear translator components 20 , 22 primarily changes the size of the light bundle impinging on the back aperture of the objective lens also affecting the size of the illumination area on the sample slide. Translating the whole apparatus 40 , will change where the light bundle impinges on the back aperture and thus alter the TIR angle which controls the TIRF penetration depth.
It will also be appreciated that system may be adjusted such that the laser light does not meet the critical angle for TIR illumination or the location of TIR within the field of view. This benefit feature allows for partial TIR, EPI fluorescence, and Darkfield illumination. The TIR adjustment capacity in the location in the field of view, TIR focus capacity, and TIR angle adjustment are important distinctions and improvements over prior systems with dedicated systems.
Still referring to FIG. 2 , it will be appreciated that ball lens 31 may be any suitable collimating optical element, such as, for example, but not restricted, to, a ball lens or a half ball lens.
Referring also to FIG. 3 , there is shown a schematic diagram illustrating fiber axial translation in accordance with the invention shown in FIG. 2 . As shown, item 20 and item 22 are components of the fiber axial translator 40 a for linear translation of the fiber; or, in other words, used to focus the laser light 13 emitted by ball lens assembly 15 . It will be appreciated that any suitable linear translator could be used. Lens assembly 16 is fastened to tubing 12 by means of a suitable adhesive 16 .
Referring also to FIG. 4 , there is shown a schematic diagram illustrating alternative optical configurations with additional micro optics in accordance with the invention shown in FIG. 2 . FIG. 4 illustrates alternative configurations using lenses, and micro optics to refract the light such that it aligns to the optical axis of the microscope.
Still referring to FIG. 4 , the objective lens assembly 36 is optically coupled to half ball lens 61 through micro prism 63 a . Alternatively, objective lens assembly may be optically coupled to micro prism 63 b through half ball lens 62 with light from fiber optic contained within housing 64 impinging on prism 63 b first and supporting the lens assembly. In alternate configurations prisms 63 , 63 a , and 63 b could be substituted with a suitable micro mirror.
Still referring to FIG. 4 , dashed line 68 represents the mechanical coupling between the adjustable TIRFM illuminator apparatus 40 and objective lens assembly 36 . It will be appreciated that mechanical coupling between the adjustable TIRFM illuminator apparatus 40 and objective lens assembly 36 ensures alignment of the light is stabile when the objective lens 36 (or sample) is translated during focusing.
It will be appreciated that a novel feature of the present invention lies in the mechanical coupling 68 which is adapted to mechanically translated the adjustable TIRFM illuminator apparatus 40 perpendicular to the objective lens optical axis to adjust the angle of incidence at the glass/water interface (see FIG. 2 , X axis 41 ). This feature enables “Farfield TIRF” also known as “Dirty TIRF”, and also simple Farfield fluorescence without TIRF.
As noted earlier, prior art solutions combined multiple mirrors on to one substrate. This multi reflective point mirror is a specific design to work with particular objective lens geometry. Such a mirror requires alignment between the objective lens, and associated light beams. This design limits laser alignment to a narrow region determined by the mirror design. In contrast, the present invention does not require a separately mounted and aligned mirror as the light is directed directly from the adjustable TIRFM illuminator apparatus 40 to the objective lens 36 .
Referring also to FIG. 5 , there is shown a schematic diagram illustrating an alternate configuration of the TIRFM illuminator apparatus 40 in accordance with the invention shown in FIG. 2 . The configuration shown in FIG. 5 includes objective lens 102 , prism 1010 , camera 1012 , focus lens 1011 , fiber 107 , and adjustable TIRFM illuminator apparatus 40 .
Still referring to FIG. 5 it can be seen that the emitted light paths for the camera 1012 , adjustable TIRFM illuminator apparatus 40 , represented by 101 c , 101 d and 101 e , 101 f , respectively, are independent light paths. Also shown is adjustor 108 . Adjustor 108 translates the TIRFM illuminator apparatus 40 horizontally to adjust the point where the light 101 f impinges upon the back aperture of the objective lens 102 a . This adjustment makes it easier for the user to adjust the TURF angle with respect to the X-axis 103 , and reinforces a feature not possible with the prior art fixed mirror approach. It is understood that adjustor 108 can adjust one or more degrees-of-freedom, e.g., x-y, pitch, yaw, and roll, in addition to focus.
Referring also to FIG. 6 there is shown a schematic diagram illustrating another alternate configuration of the TIRFM illuminator apparatus in accordance with the invention shown in FIG. 2 . The configuration shown in FIG. 6 includes dichromatic mirror assembly 94 , objective lens 102 , prism 1010 , camera 1012 , focus lens 1011 , fiber 107 , adjustable TIRFM illuminator apparatus 40 , adjustor 108 , and an EPI Illuminator assembly 79 .
The dichromatic assembly 94 comprises fixed filters 95 , 96 and dichromatic mirror 97 . The EPI Lamp assembly 79 includes lenses 79 a and 79 b . The assembly 79 also includes a light source 79 c and reflector 79 d.
It will be appreciated that the invention disclosed herein presents several advantages over prior art solutions. For example, the adjustable TIRFM illuminator apparatus 40 with mechanical coupling to the objective lens assembly provides: adjustable focus control to change the fluorescence field of view; translates with the objective lens; dichromatic mirrors are not required; excitation filters are not required; allows conventional bright-field, and EPI fluorescence light path to be used, even simultaneously; small efficient design can be integrated into existing; inexpensive construction; and multiple wavelength excitation light possible. Likewise, the disclosed invention also eliminates the need to have the objective lens designed as a dedicated lens for only a very specific imaging purpose. For example, this could be a limitation if the light were brought to the from of the objective lens, rather than the back of the objective lens.
It should be understood that the foregoing description is only illustrative of the invention. Thus, various alternatives and modifications can be devised by those skilled in the art without departing from the invention. Accordingly, the present invention is intended to embrace all such alternatives, modifications and variances that fall within the scope of the appended claims For example; a microscope may be equipped with several adjustable TIRFM apparatuses as disclosed herein. They may be used simultaneously, or individually. This may prove useful when requiring polarization control or when a single optical fiber limits wavelength bandwidth. Similarly, light sources such as Light Emitting Diodes and LASERS may be miniaturized and integrated with a micro lens. | A new apparatus and method of delivering light to the hack aperture of a High Numerical Aperture (NA) Microscopy Objective lens for Total Internal Reflectance Microscopy (TIRFM) is provided. The apparatus and method include pumping light generated by a laser through an optical fiber which is optically coupled to the objective lens by a collimating optical element, such as, for example a lens or prism. The apparatus and method also include providing a fiber axial translator which is mechanically adjustable for focusing the laser light optically coupled to the objective lens. The apparatus also includes a mechanical coupler for mechanically coupling the apparatus to the object lens such that the laser light optically coupled to the objective lens can be adjusted to exceed, or not exceed, a critical angle associated with TIRFM illumination. | 6 |
TECHNICAL FIELD
[0001] The present invention relates to an automated method for setting clearances between rocker arms and associated rocker arm actuated engine components, such as inlet and exhaust valves in the cylinder(s) of internal combustion engines.
BACKGROUND
[0002] As is well known in the art, the operation of inlet and exhaust valves in internal combustion engines is often controlled by a rocker arm that reciprocates about a rocker shaft. A first end of the rocker arm, located on a first side of the rocker shaft, is reciprocated by a push rod connected to a cam follower, which in turn is driven by a cam mounted on a camshaft. The second end of the rocker arm, located on the second side of the rocker shaft, drives the valve stem of an inlet or exhaust valve that is spring-biased into a normally closed position. Each inlet valve and each exhaust valve has an associated rocker arm. When the valves associated with a particular piston are fully closed (i.e. when the piston is in its top dead center (TDC) position on the compression stroke of a four stroke engine), a certain predetermined clearance is required between the second end of the rocker arm and the end of the valve stem which is contacted by the rocker arm in operation of the engine. This clearance must be set within fine tolerances, typically of the order of +/−{fraction (2/1000)} inch (0.051 mm). The process of setting this clearance is referred to herein as “valve clearance setting” and is commonly referred to in the art as “tappet setting” in the United Kingdom or “valve lash setting” in the USA.
[0003] The valve clearance is typically adjusted by means of a threaded adjustment screw that extends through the first end of the rocker arm and is seated in a cup formed in the end of the push rod. The adjustment screw may be locked in the required position by a lock nut, or may be a friction screw or the like which does not require a lock nut.
[0004] The combination of the cam, cam follower, push rod, adjustment screw, rocker arm and rocker shaft is referred to herein as the “valve drive train”.
[0005] Conventionally, valve clearances are adjusted manually, by use of a feeler gauge which is inserted between the second end of the rocker arm and the end of the valve stem whilst manually adjusting the adjustment screw at the first end of the rocker arm. This process is labor intensive, time consuming and relatively inaccurate/inconsistent. It would clearly be desirable to automate the process of valve clearance setting. To date, however, attempts at automation have failed to deliver satisfactory results.
[0006] One previously proposed method of performing automatic valve clearance setting utilizes an automatic machine tool for adjusting the adjustment screw, a linear position sensor which senses the position of the second end of the rocker arm and a linear actuator having a clip member which engages the rocker arm on the second side of the rocker shaft and which is capable of pushing the rocker arm in its valve-actuating direction and pulling the rocker arm in the opposite direction. This method comprises the steps of pushing the second end of the rocker arm in its valve-actuating direction to a predetermined zero position (reference datum) in which the second end of the rocker arm contacts the end of the valve stem but does not displace it from its normally closed position, pulling the rocker arm in the opposite direction by an amount sufficient to remove all backlash from the valve drive train, and adjusting the adjustment screw against the pulling force until the position sensor indicates that the second end of the rocker arm is at a predetermined distance (the required valve clearance) from the zero position. As used herein, “backlash” refers generally to clearances between adjacent, mutually coupled components and is not restricted to clearances between relatively rotatable components. The backlash in the valve drive train additionally includes backlash between the rocker shaft and its mounting pedestals.
[0007] This previous method has been found to be unsatisfactory in practice, failing to provide consistently accurate setting of valve clearances. The present inventors have determined that this prior method does not take sufficient account of variations in the relative positions of the various elements of the valve drive train caused by backlash in the valve drive train and movement of the rocker arm during the setting process, and does not take sufficient account of variations in the dimensions of the valve drive train elements between individual valves of an engine and between different engines.
SUMMARY OF THE INVENTION
[0008] A method and an apparatus for setting a predetermined clearance in an internal combustion engine between a rocker arm and a rocker arm actuated engine component are disclosed. The rocker arm is rotatably mounted on a rocker shaft for reciprocating movement relative thereto, and the rocker arm has a first end located on a first side of the rocker shaft and a second end located on a second side of the rocker shaft. The first end of the rocker arm has an adjustment screw extending therethrough to act on an end of a push rod. The second end of the rocker arm is movable in a first, component-actuating, direction and in a second direction opposite to the first direction and has a component engaging surface co-operating with a portion of the rocker arm actuated engine component. At least a portion of the rocker arm actuated engine component is biased in the second direction towards a first position and is movable against the bias in the first direction towards a second position.
[0009] In one aspect of this invention, a method for setting a predetermined clearance between a rocker arm and a rocker arm actuated engine component comprises the steps of (a) setting the rocker arm to a zero position and recording the zero position as a reference datum; (b) rotating the adjustment screw to adjust the position of the rocker arm to a first reference position; (c) rotating the adjustment screw through a reference angle and recording a corresponding second reference position thereof; (d) calculating a coefficient from the difference between the first and second reference positions and the reference angle; (e) using the coefficient to calculate an angular rotation of the adjustment screw corresponding to the predetermined clearance; and (f) rotating the adjustment screw on the basis of the calculated angular rotation to set the predetermined clearance relative to the reference datum.
[0010] In another aspect of this invention, an apparatus for setting a predetermined clearance between a rocker arm and a rocker arm actuated engine component comprises an electronic controller, a rocker arm actuator responsive to the electronic controller to selectively rotate the rocker arm relative to the rocker shaft, a rocker arm position sensor operably connected with the electronic controller to record with the electronic controller the position of the second end of the rocker arm, and an adjustment screw rotator responsive to the electronic controller to selectively rotate the rocker arm adjustment screw. The electronic controller is programmed to (a) a cause the rocker arm actuator to set the rocker arm to a zero position and record the zero position as a reference datum, (b) cause the adjustment screw rotator to rotate the adjustment screw to adjust the position of the rocker arm to a first reference position and then rotate the adjustment screw through a reference angle, (c) record a corresponding second reference position of the rocker arm, (d) calculate a coefficient from the difference between the first and second reference positions and the reference angle, (e) use the coefficient to calculate an angular rotation of the adjustment screw corresponding to the predetermined clearance, and (f) cause the adjustment screw rotator to rotate the adjustment screw on the basis of the calculated angular rotation to set the predetermined clearance relative to the reference datum.
[0011] Other features and aspects of this invention will become apparent from following description and accompanying drawings
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] [0012]FIG. 1 is a graph showing variations in the position of the second end of a rocker arm against the angle of rotation of a valve adjustment screw while performing a valve clearance setting operation in accordance with a preferred embodiment of the present invention.
[0013] [0013]FIG. 2 is a schematic elevational view of part of a rocker arm assembly and an associated valve stem and of components of an automated system for setting the valve clearance in accordance with the preferred embodiment of the present invention.
[0014] [0014]FIGS. 3A to 3 L are a series of views similar to that of FIG. 2, illustrating the sequence of operations represented by the graph of FIG. 1.
DETAILED DESCRIPTION
[0015] Referring first to FIG. 2, a rocker arm 10 is rotatably mounted on a rocker shaft 12 for reciprocating movement relative thereto in a first, valve-actuating, direction A and in a second opposite direction B. The rocker arm 10 has a first end 14 located on a first side of the rocker shaft 12 and a second end 16 located on a second side of the rocker shaft 12 . The first end 14 of the rocker arm has an adjustment screw 18 extending therethrough and engaging a cup 19 formed in an end of a push rod 20 . In this embodiment, the adjustment screw 18 has an associated lock nut 21 . It will be understood that if the adjustment screw 18 were a friction screw or the like then the lock nut 21 would not be required. The adjustment screw 18 is rotatable in a first angular direction (clockwise, in this embodiment, for a right hand thread) for downwards movement towards the push rod 20 and in a second angular direction (anti-clockwise, in this embodiment) for upwards movement away from the push rod 20 . The second end 16 of the rocker arm 10 has a valve engaging surface 22 co-operating with an end 24 of a valve stem 26 which is resiliently biased in the direction B towards a first position (normally closed) and which is movable towards a second (open) position by rotation of the rocker arm 10 in the first direction A.
[0016] For the purposes of performing the method of the present invention, there is provided a rocker arm actuating means, suitably a linear actuator 27 such as a pneumatic cylinder device, adapted to selectively engage the rocker arm 10 on the second side thereof so as to rotate the rocker arm 10 in the first direction A. The linear actuator 27 can be moved in and out of engagement with the rocker arm 10 and is preferably adapted to apply a predetermined force to the rocker arm 10 . The linear actuator 27 may be any of a variety of known types and will not be described in detail herein.
[0017] Also provided is a position sensing means, suitably a linear position sensor 28 , for monitoring the position of the second end 16 of the rocker arm 10 . The linear position sensor 28 may be any of a variety of known types and will not be described in detail herein. The sensor 28 should have an accuracy better than the required tolerance of the valve clearance setting, suitably of the order of +/−0.01mm. The small range of movement of the rocker arm 10 during the valve clearance setting process is such that the arcuate movement of the rocker arm 10 about the rocker shaft 12 may be treated as linear.
[0018] Also provided is an adjustment screw actuator means, suitably a machine tool 30 , for rotating the adjustment screw 18 in its first and second angular directions. In this embodiment the machine tool 30 has a first, inner rotary actuating element 32 for engaging and rotating the adjustment screw 18 and a second, outer rotary actuating element 34 , co-axial with the first element 32 , for engaging and rotating the lock nut 21 . The first rotary actuating element 32 has associated therewith an angle sensor 36 , for measuring the angular rotation of the element 32 . The second rotary actuating element 34 has associated therewith a load sensor 38 for measuring the force applied to the lock nut 21 and an angle sensor 40 , for measuring the angular rotation of the element 34 . The machine tool 30 and its associated sensors may be any of a variety of known types and will not be described in detail herein.
[0019] The machine tool 30 , linear actuator 27 , linear position sensor 28 , and the sensors 36 , 38 and 40 of the machine tool 30 , are connected to a control system 42 , such as a digital computer, which provides automatic control of the valve clearance setting process. Control systems of this type are well known in the art and will not be described in detail herein.
[0020] The adjustment screw 18 and associated rotary actuator 32 are preferably of the Torx™ head type.
INDUSTRIAL APPLICABILITY
[0021] [0021]FIGS. 1 and 3A to 3 L illustrate the valve clearance setting process, which will now be described in detail.
[0022] At the beginning of the process, the relevant piston of the engine is in its top dead center (TDC) position so that the relevant valve is fully closed and the rocker arm 10 is in the correct orientation for the valve clearance setting process. The lock nut 21 is also at a pre-set position on the adjustment screw 18 .
[0023] As shown in FIG. 3A, the linear actuator 27 is engaged on the second side of the rocker arm 10 and operated to apply a predetermined force, less than the resilient bias force urging the valve stem 26 into its first position, to the rocker arm 10 so as to move the rocker arm 10 in the first direction A to a zero position in which the valve engaging surface 22 contacts the end 24 of said valve stem 26 without displacing the valve stem 26 from its first position. This zero position is recorded as a reference datum, using the linear position sensor 28 . This is illustrated at point 50 in FIG. 1. At this point the adjustment screw 18 is also shown as having zero degrees of angular rotation.
[0024] Referring to FIG. 3B, the linear actuator 27 is moved away out of engagement with the rocker arm 10 . The machine tool 30 is applied to the adjustment screw 18 and lock nut 21 , pushing the adjustment screw 18 into engagement with the cup 19 of the push rod 20 and at the same time displacing the rocker arm 10 and the linear position sensor 28 in the direction B, and eliminating backlash through the push rod 20 and cam follower. At this stage a check may be performed to ensure that the linear position sensor 28 has been displaced in the direction B by a pre-determined minimum value (typically of the order of 0.05 mm); i.e. that there has been a movement of the rocker arm 10 . This ensures that the lock nut pre-set was correct.
[0025] As shown in FIG. 3C, the outer rotary actuator 34 of the machine tool 30 is operated to unfasten the lock nut 21 by one turn, whilst the adjustment screw 18 is held at zero degrees rotation by the inner rotary actuator 32 , in order to allow subsequent adjustment of the adjustment screw 18 .
[0026] As shown in FIG. 3D, the lock nut 21 is held while the adjustment screw 18 is rotated in its first direction until the linear position sensor 28 indicates a predetermined displacement of the second end 16 of the rocker arm 10 in the direction A, moving the valve stem 26 in the first direction to a third position intermediate its first and second positions (point 52 in FIG. 1.). The predetermined displacement is typically of the order of 2 mm, selected to be greater than or equal to a minimum value sufficient to place the valve drive train in tension with the backlash between the various drive train components biased in one direction. The value is sufficiently small that the arcuate movement of the second end 16 of the rocker arm 10 can be regarded as linear.
[0027] As shown in FIG. 3E, the adjustment screw is then rotated in its second direction through a first predetermined angle, displacing the rocker arm 10 by a small amount in the second direction B ( 54 in FIG. 1). This predetermined angle, typically of the order of 90 degrees, is selected to be sufficient to neutralize the backlash at least between the rocker arm 10 and rocker shaft 12 and, preferably, between the adjustment screw 18 and the rocker arm 10 . Generally speaking, this means that the backlash between the rocker arm 10 and the rocker shaft 12 is shifted in the opposite direction from that caused by the previous displacement of the rocker arm 10 in the direction A, moving the clearance between the rocker arm and rocker shaft from one side of the rocker shaft to the other. This takes the process to point 56 in FIG. 1.
[0028] The process described thus far comprises setting a zero position (reference datum) for subsequent measurements of the linear position of the second end 16 of the rocker arm 10 and then adjusting the rocker arm position in such a way as to neutralize backlash affecting the position of the rocker arm which might compromise the accuracy of the subsequent process steps.
[0029] At point 56 in FIG. 1, the linear position of the second end 16 of the rocker arm 10 relative to the zero position is recorded as a first reference position A1 (FIG. 3F). Next (FIG. 3G), the adjustment screw 18 is rotated further in its second direction through a predetermined reference angle 0 (suitably 360 degrees) and the corresponding rocker arm position is recorded as a second reference position A2 (point 58 in FIG. 1). Next (FIG. 3H, step 60 in FIG. 1), a coefficient X is calculated as follows:
X =( A 2 −A 1)/θ mm /degree
[0030] i.e. X represents mm of linear movement of the second end 16 of the rocker arm 10 per degree of rotation of the adjustment screw 18 , under the neutral backlash conditions established by the preceding adjustments of the rocker arm position. This has the effect of compensating for variables present in the valve drive train, including rocker shaft tolerances etc., and the coefficient X is specific to the particular combination of rocker arm and adjustment screw. This would not be achieved by calculating the value of X from position measurements made without previously adjusting the rocker arm position to neutralize backlash as described or by calculating X directly from the nominal pitch of the adjustment screw 18 or the like.
[0031] Next (FIG. 3I, step 62 in FIG. 1), the lock nut 21 is tightened slightly (“snugged”) by a predetermined force applied by the machine tool 30 . This induces a slight additional movement of the rocker arm 10 in the second direction B. To compensate for this, the adjustment screw 18 is rotated in its second angular direction until the second end 16 of the rocker arm 10 is displaced by a small predetermined correction distance d in the direction A relative to the zero position. The distance d is an arbitrary small value that is just large enough to be measured accurately by the position sensor 28 , typically of the order of 0.03 mm (point 63 in FIG. 1). This step is not required if the adjustment screw does not have a lock nut.
[0032] Next (FIG. 3J, step 64 in FIG. 1), the angular rotation R of the adjustment screw 18 corresponding to the linear displacement required to set the desired clearance gap C relative to the zero position is calculated as follows:
R =( C+d )/ X.
[0033] Typical values of C might be 0.203 mm (0.008 inch) for an inlet valve and 0.457 mm (0.018 inch) for an exhaust valve.
[0034] The adjustment screw 18 is then rotated in its second angular direction through the angle R to achieve the desired clearance C between the rocker face 22 and the end 24 of the valve stem 26 , thus setting the required valve clearance gap (FIG. 3L, point 66 in FIG. 1). The lock nut 21 is then tightened fully by applying a predetermined force thereto. Finally, the clearance is checked using the linear position sensor 28 to ensure that the clearance is within the required tolerance relative to the zero position.
[0035] The invention thus provides a method of reliably and accurately setting a valve clearance gap in an automatic process. While this invention has been described in the context of an engine having two valves per cylinder wherein the valves are acted upon directly by the rocker arms, those skilled in the art will recognize that this invention is equally applicable to engines have more than two valves per cylinder in which multiple valves are simultaneously actuated by a single rocker arm that acts upon a connecting structure or so-called “bridge” joining such valves for movement together. Those skilled in the art will also recognize that this invention is applicable to setting the clearance between a rocker arm and any other rocker arm actuated engine component, such as the tappet of a mechanically actuated unit fuel injector for example.
[0036] Although the preferred embodiments of this invention have been described herein, improvements and modifications may be incorporated without departing from the scope of the invention. | A method for automatically setting valve clearances in internal combustion engines (also known as “tappet setting” or “valve lash setting”) comprises a series of steps in which a rocker arm is set to a zero position that is recorded as a reference datum and an adjustment screw is then operated to set the rocker arm to a first reference position. The adjustment screw is then rotated through a predetermined angle so that the rocker arm is moved to a second reference position. The difference between the first and second reference positions and the predetermined angle are used to determine a coefficient relating the angular movement of the adjustment screw to linear movement of the rocker arm. The coefficient is then used to calculate the angular rotation of the adjustment screw required to set a predetermined valve clearance relative to the zero position. The initial adjustment of the rocker arm position serves to neutralize backlash in the valve drive train prior to setting the valve clearance. The method and associated apparatus may also be used to set the clearance between a rocker arm and other rocker arm actuated engine components. | 8 |
TECHNICAL FIELD
The present invention relates to a method of and systems for managing electronic mail (email) messages and particularly, but not exclusively, for tracking related email messages. One email message may be related to another, for example, because it is a reply to the other.
BACKGROUND
Email has become a critical communications service. For many individuals, the volume of received email messages is becoming extremely difficult to manage on a day-to-day basis. The increasing volume of messages can make it difficult to follow the thread of an email conversation or discussion. For example, if a message is sent asking a question to a number of recipients, it may be difficult to ensure that all the recipients have answered the question simply by looking at the messages received.
Typically, client email systems can organise email by a number of factors such as date received, sender or subject heading. Many email systems also enable a series of rules to perform functions on each message depending on the information in the message header or body. For instance, a message may be placed in a certain email folder if received from a particular sender.
Rules are globally applied to all received emails and any message which conforms to a particular rule has a function applied to it. Therefore, rules cannot relate to a particular sent message and therefore do not help to relate received messages to sent messages.
U.S. Pat. No. 5,040,141 discloses a system for administering email having an email client which stores information relating to a message in a table according to whether an answer is required to the message. The email client is required for both sender and recipient to enable the system to function.
Email message fields are defined by the Internet Engineering Task Force email standard RFC 2822. This standard sets out the format for messages to ensure parity across networks and to enable any email client to correctly interpret messages. Similarly, RFC 2821 sets out the standard for the Simple Mail Transport Protocol (SMTP), which governs the sending and propagation of email in a network.
SUMMARY OF THE INVENTION
The present invention provides a method of and systems for managing email that make it less difficult to track related email messages and therefore follow the thread of an email conversation.
According to a first aspect of the present invention there is provided a method of managing email messages comprising the steps of:
sending at least one sent message having a plurality of sent fields; storing information from at least one of the plurality of sent fields of the at least one sent message; receiving at least one received message having a plurality of received fields; and comparing information from at least one of the plurality of received fields with the stored information to identify if the at least one sent message relates to the at least one received message.
According to a second aspect of the present invention there is provided an email content management system comprising:
means for storing information relating to at least one sent message having a plurality of sent fields; and means for comparing at least one received message having a plurality of received fields to the stored information to identify if the at least one received message relates to the at least one sent message.
According to a third aspect of the present invention there is provided an email client system having an email content management system according to the second aspect of the invention.
According to a fourth aspect of the present invention there is provided a computer program product directly loadable into an internal memory of a digital computer comprising software code portions for performing the steps of the first aspect of the invention when said product is run on a computer.
According to a fifth aspect of the present invention there is provided a computer system comprising an execution environment for running an application and an email client system having an email content management system according to the second aspect of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
Embodiments of the present invention will now be described with reference to the accompanying drawings, in which;
FIG. 1 shows a schematic of a prior art email system;
FIG. 2 shows a schematic of an email system comprising an email management system of the present invention;
FIG. 3 shows an embodiment of a control table of the present invention;
FIG. 4 shows a schematic of an embodiment of an email client of the present invention; and
FIG. 5 shows a representation of email messages organised according to the present invention.
DETAILED DESCRIPTION OF THE INVENTION
Throughout the figures, like reference numerals refer to like items.
Referring to FIG. 1 , a prior art email system 10 comprises an email client 12 , an address store 14 , at least one Mail Transfer Agent (MTA) server 16 and a MTA delivery server 18 . The email client 12 is operated by an originating user 20 and the MTA delivery server 18 delivers messages to a recipient 22 , usually by way of an additional email client (not shown).
The email client 12 comprises a Graphical User Interface (GUI) 24 which allows the originating user 20 to operate the email client 12 . The GUI 24 enables a number of processes to be accessed including a create message process 26 and a read (consult) message process 28 .
The email standard RFC2822 defines the formatting of a message as well as the information that should be appended during the propagation of messages through a network. In particular, RFC2822 defines a message identifier header field, a trace header field and a reference header field.
The message identifier field, sometimes written msg-id or message-id, must be present in an email message and provides a unique identifier for a particular message.
Mail transfer agents append the trace header field to a message as it propagates through a network. Typically, the trace field contains information relating to the receipt of the message from another computer (usually a MTA), such as, name or Internet Protocol (IP) address of sending and receiving computer, and date and time of receipt.
The reference header field contains information about messages from which the present message depends. These are usually termed “parent” messages. Any message that is forwarded or replied to has its msg-id appended to the references header field. Specifically, the reference header field contains the information contained in the reference header field of the parent message and the msg-id of the parent message.
When the create message process 26 is instructed by the originating user 20 to send a message, the message is formatted according to Simple Mail Transfer Protocol (SMTP) standards and then delivered to a SMTP stack 30 . If the MTA server 16 is available, the message or messages are submitted by the SMTP stack 30 to the MTA server 16 . If the MTA server 16 is unavailable, the SMTP stack 30 queues the message or messages until the MTA server 16 can be contacted. Once the MTA server 16 has received the message, the message will be forwarded as appropriate through a network 32 , which is usually the Internet, until it reaches the MTA delivery server 18 . The recipient 22 may then download the message from the MTA delivery server 18 and access its contents.
The read message process 28 displays messages to the originating user 20 from a mailbox 34 . The mailbox 34 downloads any message from the network 32 for the originating user 20 . In this context, a received message is one that is downloaded from the network 32 for the user 20 .
It should be appreciated that a “sent message” may include a message in the process of being sent and a “received message” may include a message in the process of being received.
Referring to FIG. 2 , in accordance with the present invention, the email client 12 comprises a content management system 36 . The create message process 26 delivers sent messages to the content management system 36 . The content management system 36 updates a control table 40 ( FIG. 3 ) with information from the sent message. In this example, the control table 40 has the following control fields:
(a) message identifier (msg-id)—populated by the unique identifier code as provided for by the standards set out in RFC2822; (b) list of recipients; (c) status—indicates whether the message, as identified by the msg-id field, has been replied to; (d) content modified—indicates if the original message content has been modified; and (e) check date—sets a deadline response date for which a reply is due.
It should be appreciated that other control fields may be used depending on the information that is required by the system.
The control table 40 is updated with the msg-id of the sent message in the msg-id field, the list of recipients in the list of recipients field and a due date in the check date field.
Once the control table 40 has been updated, the content management system 36 submits the message to the SMTP stack 30 . The SMTP stack 30 then delivers the message to the MTA server 16 as described previously.
The read message process 28 now receives messages from the content management system 36 , which in turn receives messages from the mailbox 34 . When the content management system 36 receives a received message from the mailbox 34 , the header fields of the received message are checked. If the received message is related to a sent message in the control table 40 , information is extracted from the received message and recorded in the control table 40 .
The content management system 36 compares received messages with the information stored in the control table 40 . In particular, the recipients fields, the trace header fields and references header field are examined for recipient addresses and msg-ids of messages already in the control table 40 . Where matches are found, the control table 40 is updated with information about the received message and, if necessary, the matching message is updated to show that a reply has been found.
In this context, the recipients fields include any fields containing addresses for which a sent message should be delivered. For example, the list of recipients fields could include a “TO” field, a “CC” field and a “BCC” field.
The content management system 36 also monitors information in the control table 40 periodically. In this example, a check date field is included in the control table 40 . The content management system 36 compares the current date and time with the check date and time, as well as checking the status, for each message in the control table 40 . If a check date is overdue and the status field indicates a reply is still required from at least some recipients, a reminder message is automatically sent to the recipients who have not yet replied.
Referring to FIG. 4 , an embodiment of the email client 12 of the present invention is shown in more detail. The content management system 36 includes the control table 40 and a trace field update 42 . The trace field update 42 inserts and updates information from received and sent messages to the control table 40 .
Referring to FIG. 5 , an example of a hierarchical organization of messages according to the present invention is shown. A received message which is identified as being related to a sent message is shown as a child. It is also possible to identify if the message has been forwarded prior to receiving a reply by analyzing the references field. As mentioned previously, the references field contains all the msg-ids of parent messages, making it possible to organize messages according to hierarchy. Furthermore, by combining information from the control table 40 relating to the status of each message with the organized messages, a readily identifiable and accurate picture of the message history is created.
A user of the present invention does not require that recipients of messages also are users of the present invention. Email message header fields which are defined by the RFC 2822 standard are used exclusively to track and monitor message responses. Therefore any email client will provide information to enable the present invention natively.
Improvements and modifications may be incorporated without departing from the scope of the present invention. | An electronic mail management system and method is disclosed comprising a control table for storing information related to sent and received messages of an email client, wherein the stored information relates to header fields of the received and sent messages and, in particular, to fields as defined in Internet Engineering Task Force standard RFC 2822. The system monitors the control table to identify received messages which relate to sent messages and also to identify sent messages which have not been responded to by the recipients of the sent message. The email client displays received messages stored in the control table hierarchically according to the related sent message and also displays the status of the messages in the control table. | 6 |
FIELD OF THE INVENTION
This invention relates to modular buildings having wall sections that are prefabricated and joined together using bolts and more particularly to a shim located between panels adjacent to bolts.
BACKGROUND OF THE INVENTION
It has become increasingly popular, particularly in the construction of commercial and industrial buildings and facilities to use prefabricated wall sections that are constructed off site and subsequently joined together at the building site. The panels are manufactured in a factory setting and can be either a standard shape or custom built. One source of such modular building systems is available from the Canam Manac Group of Canada under the trademark of MUROX™.
The panels are typically formed from a frame work of structural steel members. A generally rectangular outlined shape is typically produced. The outer edges of the panel usually comprise the main structural members that provide the panels with rigidity. For example, a pair of vertical members are often used on each upright edge of the panel. The vertical members are typically formed as channel-shaped beams in which the bottom leg of the channel comprises the outer edge of the panel while the upright legs of the channel extend inwardly toward the center of the panel. At least two horizontal cross members are provided at the top and bottom edges of the panel. The cross members extend horizontally between the two channel-shaped vertical members and are usually joined to the channel-shaped vertical members by welding, bolting, riveting or another acceptable joining technique. The interior of the panel can be filled with a variety of insulation materials and other fillings. Utilities can be prearranged inside the panel. Each side of the panel can be provided with an appropriate skin covering. Panels are brought to a building site and assembled together using bolts that typically join two of the channel-shaped upright members together so that the panels are arranged side by side to form a completed wall. In general the vertical U-shaped members are joined using bolts that pass through holes in each of the members. The holes can be predrilled in each panel before assembly, or can be drilled on site after the panels have been aligned with each other. Bolts are used to lock the panels together at the construction site.
Since horizontal members are prone to expand and contract due to thermal expansion, it is desirable to include expansion joints between panels. A variety of techniques have been used to create expansion joints. Typically, packing or other spacers can be prearranged between specific panels to allow groups of panels to expand and contract. In a standard size building expansion can account for an inch or more of horizontal movement over the length of a wall. A disadvantage to providing expansion joints is that it often slows down the construction process and can induce inaccuracies and misalignments in the joining of building panels. For this reason, joints are often established only where specifically needed along the length of the wall.
It is therefore an object of this invention to provide a method and apparatus for quickly and reliably accounting for expansion and contraction in assembled modular building panels.
SUMMARY OF THE INVENTION
A method and apparatus for providing for expansion and contraction in modular building panels, according to this invention, overcomes the disadvantages of the prior art by providing a quickly insertable shim structure that can be placed between modular building panels adjacent bolt that secures the panels together. The shim is inserted into a gap formed between two adjacent members that are to be joined from a location external to the panels. The shim is U-shaped so that it passes over a bolt for securing the members together. When the bolt is tightened, the shim forms a permanent gap-forming structure. The adjacent members can be vertical members or horizontal members. This shim is inserted at a location on the adjacent members between interconnected transverse members so that the transverse members can expand into the gap with corresponding flexure about the shim of the adjacent members.
The gap between the two upright members enables the horizontal members to flex the upright members slightly toward and away from each other, thus allowing each joint between panels to act as an expansion joint. Typically, a bolt hole or other fastening location is provided midway between a pair of horizontal members on confronting vertical members. The vertical members are unjoined adjacent respective horizontal members allowing free expansion and contraction relative to the gap. It is contemplated that the shim can also be provided midway along confronting horizontal members, as well, enabling panels on adjacent floors or levels to be joined with quickly created expansion gaps. The shim, in particular allows expansion joints to be established quickly, reliably and accurately between every joined modular panel in a structure.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing and other objects and advantages of the invention will become more clear with reference to the following detailed description as illustrated by the drawings in which:
FIG. 1 is a partially exposed perspective view of a pair of building panels to be joined with a shim according to this invention;
FIG. 2 is a partially exposed perspective view of the panels of FIG. 1 being secured;
FIG. 3 is a somewhat schematic side view illustrating thermal expansion into the gap between building panels;
FIG. 4 is a perspective view of a typical shim according to this invention;
FIG. 5 is a plan view of the shim of FIG. 4;
FIG. 6 is a more-detailed cut-away perspective view of a pair of modular building panels secured with a shim according to his invention; and
FIG. 7 is a somewhat schematic side view of vertical and horizontal panels joined using shims according to this invention.
DETAILED DESCRIPTION
FIG. 1 details a basic technique for joining two modular wall panels of a building according to this invention. The wall panels, as described above, each comprise a spaced-apart channel-shaped vertical members 20, 22 and 24 in which the flat base 26, 28 and 30, respectively, projects outwardly and a pair of parallel legs 32, 34 and 36, respectively, form the side plates, extending inwardly from each respective base. Each base, in this embodiment, is tied to an opposing base by a pair of top and bottom horizontal frame members 40 and 42, respectively. The bottom frame members 42 each include holes for receiving anchor bolts 44 that secure the bottom horizontal members 42 to a foundation 46. Respective nuts 48 are used to secure the bottom horizontal members 42 to the foundation 46. It is contemplated that a variety of securing structures can be used to anchor panels to a foundation including adhesives, rods and weldments. Note that terms left, right, top and bottom are used herein as conventions for purposes of illustration, and that in practice, any orientation is contemplated.
Between the top and bottom horizontal members 40 and 42 is located airspace 50 that can be filled with a variety of filling materials such as insulation 52. Any acceptable wall surface can be located along the interior and exterior faces of each panel to enclose the insulation or other filling material within the panel and to define the interior and exterior walls of the structure. For example, dry wall or corrugated metal can be located along an interior wall. Corrugated metal, brick work or another suitable material can be used along an exterior wall. Appropriate polymer or other membranes can be provided as a vapor barrier on the interior and/or exterior faces of each panel.
Located on each vertical member 20, 22 and 24, approximately midway between the top and bottom horizontal members 40 and 42 is positioned a through hole 60, 62 and 64, respectively. The through holes are aligned vertically so that adjacent through holes 62 and 64 overlap each other. The holes can be provided to each vertical member, as appropriate, before the panels are positioned at the building site. Alternatively, holes can be drilled on site using an appropriate drilling device and drilling fixture. Similarly, while one hole is provided between horizontal members 40 and 42, a plurality of holes can be provided between the members. The provision of holes is subject to the dynamics of the panels which will be described further below. The holes 60, 62 and 64 receive fasteners which, in this embodiment, comprise threaded bolts 70 and corresponding nuts 72. Self-threading bolts, rivets of various types, or other fasteners can be employed according to alternate embodiments.
In construction, panels are aligned as shown in FIG. 1 with respective adjacent holes 62, and 64 placed in an overlapping relationship. The panels are moved toward each other double arrow 78 so that a gap g still remains between the panels. This gap can be approximately 1/4 inch. or less according to one embodiment. The gap is shown as oversized in this illustration for purposes of clarity. Slots, (not shown) can be provided in the bottom horizontal member 42 to enable the panels to slide over a limited distance in the direction of the double arrow 78 enabling the gap to be varied while the panels are still mounted on the anchor bolts 44. In general the nuts 48 of the anchor bolts 44 are not tightened until the vertical members are permanently secured to each other by the bolt 70 and nut 72. In order to maintain an appropriate gap g an insertable shim 80 is provided at the bolt 70 to maintain the gap g between the vertical members 22 and 24. The shim 80 includes a pair of leg members 82 that define an open slot 84 with a base member 86 that joins the two leg members 82. The slot 84 is received by the bolt 70. Typically, the width of the slot is the same or larger than the outer diameter of the bolt 70. The shim 80 according to this embodiment has a shape that advantageously enables it to be inserted from either the interior or exterior side of the panels easily during panel assembly.
With reference to FIG. 2, once the shim is inserted, the bolt 70 and nut 72 can be tightly secured using, for example, a hand-operated socket wrench 90. The thickness t of the shim will define the final thickness of the gap g. Tightening of the bolt 70 may cause the panels to move toward each other (double arrow 78) which, in turn, causes the bottom horizontal members 42 to slide relative to their anchor bolts 44 and anchor nuts 48. Alternatively, the gap g can be predefined to be approximately the same as the thickness t of the shim 80. As such, little or no movement of the panels relative to each other along the direction of the double arrow 78 will occur. In this example, the anchor bolts 44 and nuts 48 can be secured tightly before the nut 70 and bolt 72 are tightened around the shim 80. Typically, the bolt 70 and nut 72 are tightened by accessing each of the bolt and the nut to either the interior or exterior face of each panel. Typically, the nut and bolt are accessed before a final covering surface is applied to the respective interior or exterior face. Insulation and other materials surrounding the bolt are moved to side to enable access. The materials can be replaced, or alternatively, small panels of insulation and other filling materials can be inserted adjacent the bolt locations after the securing process is completed. During the securing process weather stripping or other gap filling insulation 100 can be inserted into the gap g between the panels. This insulation is typically soft and playable for reasons to be described below.
FIG. 3 details schematically thermal expansion experienced by wall panels following assembly. The top and bottom horizontal members 40 and 42, respectively are shown expanding toward each other and into the gap g. The gap g, therefore, provided room for expansion of the horizontal members. This expansion causes associated deflection in the vertical members 22 and 24 about the centrally located shim 80. Likewise, contractions of the horizontal members 40 and 42 (not shown) causes deflection of the vertical members 22 and 24 away from each other about the shim 80. The relative spacing of the vertical members 22 and 24 about the shim 80 does not change. Typically the deflection is small enough that it occurs elastically (e.g., without plastic or permanent deformation of the vertical and horizontal members). Maintaining a gap g between the panels using the shim 80 enables the joint between each of the panels to act automatically as an expansion joint. Hence, specially expansion joints need not be provided at specific locations along the walls of a modular building constructed according to this embodiment. Likewise, the construction of automatic expansion joints according to this invention is fast, easy and uniformed using the easily insertable shim 80 according to this invention.
FIGS. 4 and 5 further detailed the dimensions of a shim 80 according to one embodiment of this invention. It is contemplated that shims having a variety of sizes and thicknesses t can be utilized for different applications According to a conventional application the average joint expands at least 1/32 inch. Hence, the gap must be larger than this expansion distance. In this embodiment, the thickness t is approximately 1/4 inch. Structural steel rated at 36 KSI is used to form the shim. The bolt diameter varies from between 5/8 inch and 1 and 1/4 inch. Accordingly, the width W1 of the slot is typically between 5/8 inch and 11/4 inch. The width WI maybe oversized by 1/16 inch or more with respect to the bolt diameter. The vertical members are conventional channel beams formed by hot rolling processes. The gauge of the steel used is conventional and depends upon the size and load characteristics of the panel. Horizontal members are typically sixteen gauge structural steel. There are arc welded, riveted or bolted to the vertical members. They are formed by a colt forming process according to a preferred embodiment. The overall width W2 of the shim in one embodiment is approximately 3 inches. The overall length L1 of the shim is approximately 4 inches. The length L2 between the end wall of the base 86 and the end of the slot 84 is approximately 1 inch. These dimensions can be varied, and the materials used can also be varied depending on the particular application, configuration and size of the panels employed.
FIG. 6 is an exposed view of an assembled modular building section including the joint 110 formed between two panels. A gap g1 is formed at the joint 110 between two internally disposed vertical channel members 122 and 124. Insulation 130 and 132 has been provided around the channels. Modules, according to this invention can include a variety of openings including the windows 134 and 136. The windows, in this embodiment, are supported on horizontal cross-members 138. Between horizontal members is provided the shim 180 according to this invention that is secured about the bolt 170 and nut 172. The shim and its nut and bolt are typically provided to join the vertical members 122 and 124 before covering materials 190, 192 and insulation 194 is applied to the face(s) of the modules. In this embodiment, the outer covering 192 comprises a sheet material such as concrete board or stress-skin paneling. The inner covering 190 comprises a corrugated steel sheet.
FIG. 7 illustrates both horizontal and vertical assembly of modules 200, 202 and 204 according to an embodiment of this invention. Note the module 202 includes a window hole 206 according to this invention formed between non-structural vertical members 208 and 210. The modules 202 and 204 are joined according to the above described embodiment between adjacent structural vertical members 212 and 214 using a shim 216 of a type generally described in this invention. A bolt 218 and nut 220 secures the joint. The joint is positioned between respective horizontal members 222, 224 on each module 202 and 204 to enable flexure into the gap g2 as described above. The top horizontal member 222 on module 202 is also secured to a bottom horizontal member 230 on the upper module 200. A shim 234 of a type described above is provided adjacent the bolt 240 and nut 242 that secures the modules 200 and 202 together. The joint is formed between respective vertical members 250 and 252 on the module 200. This enables flexure, based upon expansion of the vertical members into the gap g3 formed between the modules 200 and 202. Hence, the shim assembly according to this invention can be used to quickly define expansion gaps between both vertical seams and horizontal seams between modules. It is contemplated, primarily, that interconnections, using the shims according to this invention, be located along free, unconnected portions of adjacent members so that expansion of the interconnected members (at their respective connection points with the joined members) can occur freely.
The foregoing has been a detailed description of preferred embodiments of the invention. This description can be modified without departing from the spirit or scope of the invention. For example, while the shim is shown as a rectangular member, the outer perimeter of the shim can define any acceptable perimeter shape, such as circular, ovular or trapezoidal. It is contemplated mainly that the shim includes a pair of legs with a notch therebetween for receiving a bolt or other fastener. Likewise, a variety of shapes of vertical and horizontal members can be employed. For example, vertical and/or horizontal members can comprise square or rectangular-cross-section members. While not shown, modules can include a variety of support structures and/or preassembled utilities. In particular, modules can include supporting structures for supporting floor and/or ceiling joist according to this invention. It is particularly noted that two channel members, that form vertical members, when joined together define, essentially, a full I-beam for supporting such a joist. Accordingly, this description is meant to be taken only by way of example, and not to otherwise limit the scope of the invention. | A method and apparatus for providing for expansion and contraction in modular building panels provides a quickly insertable shim structure that can be placed between modular building panels adjacent bolt that secures the panels together. The shim is inserted into a gap formed between two adjacent members that are to be joined from a location external to the panels. The shim is U-shaped so that it passes over a bolt for securing the members together. When the bolt is tightened, the shim forms a permanent gap-forming structure. The adjacent members can be vertical members or horizontal members. This shim is inserted at a location on the adjacent members between interconnected transverse members so that the transverse members can expand into the gap with corresponding flexure about the shim of the adjacent members. | 4 |
CROSS-REFERENCE TO RELATED APPLICATION DATA
[0001] This application claims the benefit of and priority to Provisional U.S. Patent Application Ser. No. 62/085,974, filed Dec. 1, 2014, the disclosure of which is incorporated herein in its entirety.
BACKGROUND
[0002] Loads such as lumber and the like can be packaged as a plurality of stacked individual units formed into a 3-dimensional bundle. The bundles are secured by strap that is tensioned and sealed around the bundle. Bundles typically include corner protectors that extend along portions of the edges of the load, between the bundle and the straps that encircle the load and the corner protectors. Corner protectors are flat or planar members that are bent around and secured to the corner of the load. Known corner protectors include polymeric angled elements and fibrous, e.g., cardboard or paperboard elements.
[0003] Kasel, U.S. Pat. No. 5,619,838 discloses an apparatus and method for applying edge protectors that includes edge protector applicator assemblies positioned on a frame on either side of the load. The assemblies include grippers that receive and support flat, board-like edge protectors and laterally move to bring the protectors into proximity with the load. The strap, which is then positioned and tensioned around the load and protectors, folds the edge protectors around the load corners. Tensioning of the strap creates the movement that folds the protectors.
[0004] Kasel, U.S. Pat. No. 7,428,865 discloses a press-type strapping machine in which edge protectors are applied to the corners of loads that are pressed (compressed) and secured with a strap. Here too, corner protectors are brought into contact with the load by grippers and the corner protectors are formed or bent by the strap as it is pulled onto and tensioned around the load.
[0005] While such devices function well, the corner protectors may not properly fold along the edge of the load. As such, the protectors may not seat properly on the load and may be subject to being torn or struck and dislodged from the load.
[0006] Preformed edge protectors are also known. However, the preformed protectors require additional steps in the manufacture of the corner protectors. Moreover, excess space is required to store the preformed protectors both in storage and on a strapping machine, and automated systems to position such protectors on a load are limited.
[0007] Accordingly, there is a need for an apparatus and method to fold and apply corner edge protectors on a load during a strapping operation. Desirably, such an applicator receives a planar edge protector and folds the edge protector to conform to the corner of the load, prior to positioning the protector on the load. More desirably still, the applicator discharges the folded edge protector onto the load as the strap is positioned around the load so that it is pulled by and captured between the strap and load and is secured to the load by the tensioned strap. Still more desirably, the edge protectors can be stored on the strapping machine in a flat state to reduce storage requirements.
SUMMARY
[0008] A device for forming and applying an edge protector to a corner of a load works in conjunction with a strapping machine that positions and tensions strap around the load. The device receives an edge protector as a flat element, folds the edge protector to conform to the corner of the load and discharges the folded edge protector onto the load as the strap is positioned around the load. In this manner, the edge protector is pulled by the strap and is captured between the strap and load, and is secured to the load by the strap as it is tensioned and sealed to itself.
[0009] The device includes a shuttle operably movable between a home position distal from the load and an application position proximal the load. The shuttle includes a breaker assembly having a fixed portion and a movable portion. The movable portion is movable between a first position in which it is generally planar with the fixed portion and a second position in which it is generally transverse to the fixed portion. In an embodiment, the movable portion is pivotally mounted to the fixed portion. The breaker assembly includes a shoe and defines a receiving region between the shoe and the fixed and movable portions. The shuttle includes a load contact portion.
[0010] As the shuttle moves off of the home position, the movable portion pivots from the first position to the second position to fold the edge protector to about a 90 degree angle. Further movement of the shuttle and contact of the load contact portion with the load discharges the folded edge protector for receipt on the load. The edge protector is received on the load, between the load and the strap, as the strap is pulled onto the load so that when the strap is tensioned, it secures the folded edge protector on the load.
[0011] In an embodiment, the device includes a support that defines a track. The shuttle is operably mounted to the support and the movable portion includes a track engaging member, such as a roller, that cooperates with the track for pivoting the movable portion from the first position to the second position as the shuttle moves from the home position to the application position.
[0012] The shuttle includes a pusher element, such as a pusher finger, operably connected to the load contact portion to push the edge protector from the receiving region in a direction transverse to a direction of movement of the shuttle along the track when the load contact portion contacts the load. In an embodiment, one or more retention elements hold the edge protector in the receiving region. The retention elements can be, for example, a spring loaded finger, a ramped projection or both.
[0013] The device can include an edge protector magazine for storing a plurality of edge protectors, for example, a stack of edge protectors, separating individual edge protectors from the stack and feeding individual edge protectors to the breaker assembly. In an embodiment, the edge protectors are separated from the stack as they are fed to the breaker assembly. A reciprocating element can be used to push individual edge protectors from the stack to feed the edge protectors to the breaker assembly. In an embodiment, an edge protector magazine can be associated with each breaker assembly.
[0014] A method for forming and applying an edge protector to a corner of a load as strap is pulled onto and tensioned around the load to capture and secure the edge protector between the strap and the load, includes receiving an edge protector in a flat state in a breaker assembly and holding the edge protector in the breaker assembly. The edge protector is conveyed toward the load in a conveying direction, and is folded about 90 degrees to substantially conform to a corner of the load. The edge protector is pushed from the breaker assembly in a direction transverse to the conveying direction as strap is pulled onto and tensioned around the load. In this manner the edge protector is captured between the strap and the load, and is secured to the load by the tensioned strap.
[0015] In a method, folding the edge protector can be carried out during the step of conveying the edge protector toward the load. The method can include carrying the breaker assembly on a shuttle and conveying the shuttle toward the load. The method further includes positioning and tensioning a strap around the load such that the edge protector is captured between the strap and the load and is held against the load by the tensioned strap. Because the edge protector is pushed out of the breaker assembly, when the strap is pulled around the load, it contacts the edge protector and pulls the edge protector onto the load.
[0016] In that the edge protector is formed or bent before it is secured to the load (before the strap pulls the edge protector onto the load), the opportunity for misfeeding the edge protector, for the edge protector to not fold in the proper location or for the edge protector to not sit properly on the corner of the load is greatly reduced if not eliminated.
[0017] It will be apparent that edge protectors can be positioned on any or all of the corners of the load at the same time or essentially the same time, as the strap is positioned, tensioned and secured around the load. During the step of encircling the load with the strap, the folded edge protector can be drawn from the breaker assembly into contact with the load.
[0018] In an embodiment, the edge protector can be temporarily held in the breaker assembly during the steps of conveying and folding the edge protector. The method can further include storing at least two edge protectors, separating one of the edge protectors from the other and feeding the separated edge protector to the breaker assembly.
[0019] These and other features and advantages of the present invention will be apparent from the following detailed description, in conjunction with the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] FIG. 1 is a front view of a strapping machine, specifically a lumber press, on which the present apparatus for forming and applying edge protectors can be used;
[0021] FIG. 1A is a perspective illustration of a load of lumber with a pair of edge protectors on an top/side corners of the load and a band of strap positioned around the lumber and the edge protectors;
[0022] FIG. 2 is a partial front view of the apparatus separate from the lumber press;
[0023] FIG. 3 is a front perspective view of an embodiment of an edge protector applicator assembly, the illustrated assembly being the right-hand side assembly of FIG. 2 ;
[0024] FIG. 4 is an exploded view of the assembly, the illustrated assembly being the left-hand side assembly of FIG. 2
[0025] FIG. 5 is a perspective view of an angle breaker assembly, the illustrated assembly being the left-hand side assembly of FIG. 2 ;
[0026] FIG. 6 is an exploded view of an angle breaker assembly, the illustrated assembly being the right-hand side assembly of FIG. 2 ;
[0027] FIG. 7 is an exploded view of an example of an edge protector magazine;
[0028] FIG. 8 is a perspective similar to FIG. 3 showing an edge protector in place in the breaker assembly;
[0029] FIGS. 9A and 9B are front and rear perspective views of the right-hand side assembly showing the edge protector in place in the breaker assembly prior to folding;
[0030] FIGS. 10A and 10B are front and rear perspective views of the assembly with the edge protector in place and with the edge protector folded;
[0031] FIGS. 11A and 11B are front and rear perspective views of the assembly with the edge protector in place and folded, and showing the position of the edge protector when pressed to the load and as the edge protector is ejected from the assembly;
[0032] FIG. 12 is a photograph of a side view of the breaker assembly, showing the spring loaded finger and the ramp projection;
[0033] FIG. 13 is a photograph of a bottom view of the breaker assembly; and
[0034] FIG. 14 is a side view similar to FIG. 12 , showing the breaker assembly with an edge protector in the receiving region.
DETAILED DESCRIPTION
[0035] While the present device and method are susceptible of embodiment in various forms, there is shown in the figures and will hereinafter be described an embodiment of the device with the understanding that the present disclosure is to be considered an exemplification of the device and method and is not intended to be limited to the specific embodiment illustrated and method described.
[0036] Referring to the figures and in particular to FIG. 1 , there is shown an example of a strapping machine 10 , and as illustrated, a lumber press and strapper. The strapping machine 10 is configured to compress a load L, such as lumber and to position, tension and seal strap S to itself around the load L, with edge protectors E positioned between the strap S and the load L, as illustrated in FIG. 1A .
[0037] The machine 10 includes a press 12 to compress the load L, and a strapping system 14 , such as that disclosed in Kasel, U.S. Pat. No. 7,428,865, which patent is commonly assigned with the present application and is incorporated herein by reference. The strapping system 14 includes a sealing head 16 that seals the overlapping courses of strapping material S to itself. Those skilled in the art will recognize and appreciate the lumber strapper 10 as well as other strapping devices with which the present edge protector applicator 18 can be used.
[0038] The strapping system 14 positions strap S around the load L, tensions the strap S and seals the strap S to itself Edge protectors E are positioned at the corners C, between the strap S and the load L to protect the load L from damage by the strap S. It will be understood that although the figures show edge protectors E on the top/side corners C of the load L, edge protectors E can be applied to the bottom/side corners of the load L as well.
[0039] The edge protector applicators 18 work in conjunction with the strapping system 14 . The applicators 18 receive an edge protector as a flat element, fold the edge protector to conform to the corner C of the load L and discharge the folded edge protector E onto the load as the strap S is positioned around the load L. In this manner, the edge protector E is pulled by the strap S as the strap S is pulled onto the load L, and is captured between the strap S and load L and is secured to the load L by the tensioned and sealed strap S.
[0040] FIG. 2 illustrates left and right-hand side edge protector applicators 18 and the associated edge protector magazines 20 to store a plurality of edge protectors E and feed individual edge protectors E to their respective applicators 18 . Each applicator 18 includes a support plate 22 , a linear rail 24 , a shuttle 26 and a drive 28 . Each shuttle 26 moves along its rail 24 , driven by its drive 28 , between a position at which an edge protector E is fed to the applicator 18 (an outboard position) and a position at which the edge protector E is brought into contact with the load L and ejected from the applicator 18 (an inboard position). Reference may be made to a single shuttle, however, it will be understood that there are both left- and right-hand shuttles. It will also be appreciated that although the figures show edge protector applicators 18 applying edge protectors E to the top/side corners C of the load L, the applicators can be used to apply edge protectors to the bottom/side corners of the load L as well.
[0041] Referring to FIGS. 3-6 , in an embodiment, the shuttles 26 move along their rails 24 between the inboard and outboard positions by actuation of the drives 28 which drive threaded or screw drive shafts 30 . The shuttles 26 include a threaded receiver 32 that cooperates with their respective shafts 30 to move the shuttles 26 back and forth along the rails 24 . Sensors 34 mounted to the applicators 18 monitor the positions of the shuttles 26 . In an embodiment, the sensors 34 are mounted to the shuttles 26 . It will, however, be appreciated that various types of drives can be used to move the shuttles 26 and that the sensors 34 can be mounted in a variety of locations and manners to monitor the positions of the shuttles 26 .
[0042] The shuttles 26 include a breaker assembly 36 that is configured to receive an edge protector E in a flat state (see, e.g., FIGS. 8 and 9A ) and fold, bend or break the protector E into a corner that is at or about a 90 degrees (see, e.g., FIGS. 1A, 10A and 11A ) to conform to the corners C of the load L. It will be understood that the material from which the edge protector is formed, e.g., paperboard or cardboard, will bend or fold and will be deformed, but that it may return, to some minor extent, to its pre-folded shape. As such, the final configuration, prior to being applied to the load and secured by the strap is described as at or about 90 degrees.
[0043] In an embodiment, the breaker assembly 36 includes a fixed member 38 , a movable member 40 and a shoe 42 a, 42 b (collectively 42 ) associated with each the fixed 38 and movable 40 member. In an embodiment, the fixed and movable members 38 , 40 are plates and oppose the shoes 42 to define a receiving region 44 for receiving the flat edge protectors E. The receiving region 44 is formed as a recess or channel in which the flat edge protector E is inserted and held. The movable plate 40 is pivotally mounted to the fixed plate 38 by a hinge or pivot 46 . The movable plate is pivotable between about 0 degrees and 90 degrees relative to the fixed plate 38 so that a flat edge protector E is received in the receiving region 44 when the movable plate 40 is in the 0 degree position, and when the movable plate 40 pivots it folds or breaks the edge protector E to about 90 degrees.
[0044] The movable plate 40 includes an arm 48 and a roller 50 extending outwardly and downwardly from a rear thereof that engages a track 52 in the support plate 22 . The track 52 has an angled or sloping edge 54 along which the roller 50 rides. When the shuttle 26 is in the outboard or home position (see, FIGS. 9A and 9B ), the roller 50 is elevated so that the movable plate 40 is in the 0 degree position. As the shuttle 26 moves off the home position (toward the load or toward the inbound position, see FIGS. 10A and 10B, and 11A and 11B ), the roller 50 is urged downward which pivots the movable plate 40 to fold or break the edge protector E.
[0045] The breaker assembly 36 includes a pusher assembly 54 to push the edge protector E from the assembly 36 when the folded edge protector E approaches or contacts the load L. The pusher assembly 54 includes a contact arm 56 , a pivot plate 58 and a pusher element 60 , such as the illustrated pusher finger. The pivot plate 58 is mounted to the fixed plate 38 by a pivot pin 62 at an end of the plate 38 . The contact arm 56 is mounted to an end of the pivot plate 58 opposite the pivot 62 . The contact arm 56 extends downwardly so as to contact the load L as the shuttle 26 approaches the load L. The pusher finger 60 is formed on or extends from the pivot plate 58 , through a slotted opening 64 in the pivot plate 58 and is positioned in the breaker assembly receiving region 44 , extending downwardly toward the shoe 42 . As the shuttle 26 moves to the load L, the contact arm 56 contacts the load L, which pivots the pivot plate 58 and moves the pusher finger 60 into the receiving region 44 to push the edge protector E from the receiving region 44 . A spring 66 on the breaker assembly 36 returns the pusher finger 60 to the home position. A slot 68 in the shoe 42 accommodates the pusher finger 60 when in the home position to prevent the finger 60 from interfering with the breaker assembly 36 receiving and securing the edge protector E in the receiving region 44 .
[0046] In an embodiment, the breaker assembly 36 can include one or more retention elements to positively secure the edge protector E in the receiving region 44 . In an embodiment, a spring loaded finger 70 in the fixed plate 38 applies pressure on the edge protector E and holds it against the shoe 42 as the shuttle 26 moves and as the edge protector E is folded. The finger 70 is spring loaded, so that the edge protector E remains in place, but is forced out of the receiving region 44 when the pusher finger 60 exerts sufficient force on the edge protector E to dislodge it from the between the finger 70 and the shoe 42 . The breaker assembly 36 can also include a ramped projection 72 extending into the receiving region 44 . Either or both the spring loaded finger 70 and the ramp 72 can be used to hold the edge protector E in the receiving region as the edge protector E is received in the breaker assembly 36 , folded, and conveyed toward the load L.
[0047] Referring now to FIGS. 2 and 7 there is shown an embodiment of the magazine assembly 20 for storing a plurality of edge protectors E, such as in a stack K, separating individual edge protectors E from the stack and feeding the separated edge protector E to the breaker assembly 36 . The magazine assembly 20 includes, generally, a storage magazine 74 , a reciprocating feeder 76 and a drive 78 . The storage magazine 74 is configured to store a plurality of flat edge protectors E in, for example, a stack K and to supply edge protectors E to the feeder 76 . The feeder 76 includes a reciprocating plate 80 having a thickness about the same as or slightly less than that of the edge protectors E. A rack gear 82 is mounted to a side of the plate 80 opposite the side that contacts the edge protectors E. Rails 84 mounted to the magazine assembly 20 cooperate with linear bearings 86 mounted to the plate 80 to facilitate the reciprocating movement of the plate 80 .
[0048] In an embodiment, the drive 78 is mounted to the assembly 20 and a drive gear 88 is mounted to the drive 78 . The drive gear 88 is operably connected to the rack gear 82 to provide the reciprocating movement of the plate 80 .
[0049] An opening 90 at the discharge of the magazine 74 is sized to permit only a single edge protector E from being discharged from the magazine 74 at a time. Separation of individual edge protectors E from the stack K is accomplished by cooperation of the feeder plate 80 (which has a thickness about the same as or slightly less than that of the edge protectors E), along with the opening 90 at the bottom of the magazine 74 (which is slightly larger than the thickness of one edge protector E). As such, as the plate 80 reciprocates, it contacts an edge protector E along an edge of the plate 80 . The edge protector E is pushed from the stack K, out through the opening 90 at the discharge of the magazine 74 . As the edge protector E is pushed, it is fed into the receiving region 44 in the breaker assembly 36 , between the fixed/movable members 38 / 40 and the shoe 42 , and is captured and held in the receiving region 44 by the spring loaded finger 70 , the ramp 72 or like holding device. It will be appreciated that while the figures show a magazine assembly 20 and structure to feed edge protectors E from a bottom of the magazine 74 to the breaker assembly 36 (and the bottom of the load L), the magazine assembly 20 and breaker assembly 36 can be configured to supply edge protectors E to an overhead assembly to supply edge protectors E to a location at the top of the load L.
[0050] In operation, a load L is present in the strapping machine 10 and the shuttles 26 are in the home or outboard positions, distal from the load. The magazine assembly drives 78 are actuated and the feeder plates 80 reciprocate to feed edge protectors E into the receiving regions 44 of the breaker assemblies 36 . The edge protectors E are held in place in the breaker assemblies 36 (in the receiving regions 44 ) by the spring loaded fingers 70 , ramps 72 or like holding device.
[0051] The breaker assemblies 38 move out of the home position, along their linear rails 24 , toward the load L. As the breaker assemblies 36 begin to move, the rollers 50 contact the support plate tracks 52 and pivot the movable plates 40 to fold or “break” the edge protectors E. The shuttles 26 continue to move toward the load L. As the shuttles 26 approach the load L, the contact arms 56 contact the load L which pivot the pivot plates 58 and move the pusher fingers 60 into contact with the edge protectors E, which in turn pushes the edge protectors E out of the breaker assemblies' receiving regions 44 in a direction transverse to the movement of the shuttle 26 . In this proximal or application position, the folded edge protectors E are freed from their breaker assemblies 36 so that they can be secured to the load L when the strap is positioned and tensioned around the load L and edge protectors E. Following release of the edge protectors E, the shuttles return to their home or outboard positions.
[0052] Contact of the contact arms 56 with the load L is timed with the strapping machine 10 such that the edge protectors E are pushed from the breaker assemblies 36 as the strap S is drawn around the load L and retracted (to pull the strap S from the strap chute) and as the strap S is tensioned around the load L. The overall timing of the strapping machine 10 and application of the edge protectors E can be carried out using a controller or control system 92 that monitors and controls the function of the machine 10 . In this manner, the edge protectors E are captured by the strap S against the load L and are held in place by the strap S as and in conjunction with tensioning and sealing of the strap S.
[0053] It will be appreciated by those skilled in the art that the relative directional terms such as upper, lower, rearward, forward and the like are for explanatory purposes only and are not intended to limit the scope of the disclosure.
[0054] All patents referred to in the present disclosure, are incorporated herein by reference in their entirety, whether or not specifically done so within the text of this disclosure.
[0055] In the present disclosure, the words “a” or “an” are to be taken to include both the singular and the plural. Conversely, any reference to plural items shall, where appropriate, include the singular.
[0056] From the foregoing it will be observed that numerous modifications and variations can be effectuated without departing from the true spirit and scope of the novel concepts of the present disclosure. It is to be understood that no limitation with respect to the specific embodiments illustrated is intended or should be inferred. The disclosure is intended to cover all such modifications as fall within the scope of the claims. | A device forms and applies an edge protector to a corner of a load as strap is positioned and tensioned around the load, to position the edge protector between the strap and the load. The device includes a shuttle movable between a home position away from the load and an application position near the load. The shuttle includes a breaker assembly having a fixed portion and a movable portion. The movable portion is movable between a position in which it is generally planar with the fixed portion and another position in which it is transverse to the fixed portion. The breaker assembly includes a shoe that defines a receiving region between the shoe and the fixed and movable portions. The shuttle includes a load contact portion. Movement of the shuttle from the home position moves the movable portion from the first to the second position to fold the edge protector. Further movement of the shuttle and contact of the load contact portion with the load discharges the edge protector for receipt on the load as the strap is positioned and tensioned around the load. | 1 |
[0001] This application is a divisional of U.S. application Ser. No. 09/678,141, filed Oct. 04, 2000, herein incorporated by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to the use of fungal mycelium as a biopesticide. More particularly, the invention relates to the control and destruction of insects, including carpenter ants, fire ants, termites, flies, beetles, cockroaches and other pests, using fungal mycelia as both attractant and infectious agent.
[0004] 2. Description of the Related Art
[0005] The use of chemical pesticides is the cause of many secondary environmental problems aside from the death of the targeted pest. Poisoning of soil and underlying aquifers may occur, along with pollution of surface waters as a result of runoff. Increases in cancer, allergies, immune disorders, neurological diseases and even death in agricultural workers and consumers have been attributable to the use of pesticides. Chemical pesticides are increasingly regulated and even banned as a health risk to citizens. Communities are increasingly in need of natural solutions to pest problems.
[0006] Compounding these problems, many pest type or vermin insects have developed a broad spectrum of resistance to chemical pesticides, resulting in few commercially available pesticides that are effective without thorough and repeated applications. In addition to being largely ineffective and difficult and costly to apply, chemical pesticides present the further disadvantage of detrimental effects on non-target species, resulting in secondary pest outbreaks. It is believed that widespread use of broad-spectrum insecticides often destroys or greatly hampers the natural enemies of pest species, and pest species reinfest the area faster than non-target species, thereby allowing and encouraging further pest outbreaks. There is therefore a particular need for natural alternatives.
[0007] Biological control agents have been tried with varying results. Bacteria such as Bacillus thuringiensis are used with some success as a spray on plants susceptible to infestation with certain insects. Fungal control agents are another promising group of insect pathogens suitable for use as biopesticides for the control of insects. However, limited availability, cost and reliability have hampered the development of such fungal control agents. Host range and specificity has been a problem as well as an advantage; a fungal pathogen that is virulent and pathogenic to one insect species may be ineffective against other species, even those of the same genus. However, some success has been demonstrated.
[0008] The typical lifecycle of a pathogenic fungi control agent involves adhesions of the spore(s) to the host insect cuticle, spore germination and penetration of the cuticle prior to growth in the hemocoel, death, saprophytic feeding and hyphal reemergence and sporulation. For example, U.S. Pat. No. 4,925,663 (1990) to Stimac discloses Beauveria bassiana used to control fire ants (Solenopsis). Rice, mycelia and spores (conidia) mixture may be applied to fire ants or used as a bait and carried down into the nest, thereby introducing spores. U.S. Pat. No. 4,942,030 (1990) to Osborne discloses control of whiteflies and other pests with Paecilomyces fumosoroseus Apopka spore conidia formulations. The Paecilomyces fungus is also useful for control of Diptera, Hymenoptera, Lepidoptera, Bemisia, Dialeurodes, Thrips, Spodoptera (beet army worm), Leptinotarsa (Colorado potato beetle), Lymantria (Gypsy moth), Tetranychus, Frankliniella, Echinothrips, Planococcus (Citrus mealybug) and Phenaococcus (Solanum mealybug). U.S. Pat. No. 5,165,929 (1992) to Howell discloses use of Rhizopus nigricans and other fungus in the order Mucorales as a fungal ant killer. U.S. Pat. No. 5,413,784 (1995) to Wright et al. discloses compositions and processes directed to the use of Beauveria bassiana to control boll weevils, sweet potato whiteflies and cotton fleahoppers. U.S. Pat. No. 5,683,689 (1997) to Stimac et al. discloses conidial control of cockroaches, carpenter ants, and pharaoh ants using strains of Beauveria bassiana grown on rice. U.S. Pat. No. 5,728,573 (1998) to Sugiura et al. discloses germinated fungi and rested spore termiticides of entomogenous fungus such as Beauveria brongniartii, Beauveria bassiana, Beauveria amorpha, Metarhizium anisopliae and Verticillium lecanii for use against insects such as termites, cockroaches, ants, pill wood lice, sow bugs, large centipedes, and shield centipedes. U.S. Pat. No. 5,989,898 (1999) to Jin et al. is directed to packaged fungal conidia, particularly Metarhizium and Beauveria. The scientific journal literature also discusses similar uses of conidial preparations.
[0009] One disadvantage to such approaches is that the fungal lifecycle may be particularly sensitive to and dependent upon conditions of humidity, moisture and free water, particularly during the stages of germination, penetration of the cuticle prior to growth, and hyphal reemergence and sporulation after death of the insect.
[0010] Another continuing problem with existing techniques has been inconsistent bait acceptance. Baits are often bypassed and left uneaten. Such may be a particular problem with insects such as termites, as opposed to house ants and cockroaches, because it is usually not possible to remove competing food sources for termites. Attractants and feeding stimulants have sometimes increased the consistency of bait acceptance, but such increases cost and complexity, and there remains a continuing need for improved baits with improved bait acceptance.
[0011] A particular disadvantage with conidial fungal insect preparations becomes apparent from U.S. Pat. No. 5,595,746 (1997) to Milner et al. for termite control. Metarhizium anisopliae conidia are disclosed and claimed as a termite repellant in uninfested areas and as a termite control method in infested areas. The difficulties of utilizing conidia or conidia/mycelium as a bait and/or contact insecticide are readily apparent when considering that conidia are effective as an insect repellant to termites and are repellant in varying degrees to most or all targeted insect pests. A repellant, of course, does not facilitate use as a bait or contact insecticide. This may be a factor in explaining why fungal insecticides have all too often proven more effective in the laboratory, where conidia may be unavoidable in the testing chamber or even directly applied to insects, than in the field.
[0012] U.S. Pat. No. 4,363,798 (1982) to D'Orazio is for termite baits utilizing brown rot fungus as an attractant and toxicant boron compounds in mixtures effectively sufficient to kill termites without creating bait shyness. Brown-rot inoculated wood is ground and mixed with cellulosic binder and boron compounds. Such an approach has the disadvantage of utilizing toxic boron compounds. In addition, the cultured mycelium must be further processed.
[0013] There is, therefore, a continuing need for enhancing the effectiveness of entomopathogenic (capable of causing insect disease) fungal products and methods. There is also a need for enhancing the attractiveness of such fungal pesticides to insects. There is also a need for improved packaging, shipping and delivery methods.
[0014] In view of the foregoing disadvantages inherent in the known types of fungal biocontrol agents, the present invention provides improved fungal biocontrol agents and methods of using such agents.
SUMMARY OF THE INVENTION
[0015] The present invention offers an environmentally benign approach to insect control by attracting the insects who ingest latent preconidial mycelium (which may be fresh, dried or freeze-dried) which then infects the host. The preconidial mycelium is both the attractant and the pathogenic agent. The infected insects carrying the fungal hyphae become a vector back to the central colony, further dispersing the fungal pathogen. Mycelium is grown in pure culture using standard fermentation techniques for in vitro propagation. The fermented mycelia is diluted and transferred into a sterilized grain or a mixture of sterilized grains. Once inoculated, the fermented mycelia matures to a state prior to conidia formation. The preconidial mycelium may be utilized as is or may be arrested in its development through flash chilling (or by other means such as air-drying or refrigeration) and packaged in spoilage-proof or sealed packages. The end-user facilitates opening the package and placing the exposed mycelia-grain contents in the vicinity of recent pest activity.
[0016] The present invention thus provides improved products and methods wherein the fungal mycelium acts as bait and attractant and as an ingested or food insecticide, palatable enough that insects will readily consume it even in the presence of competing food sources, with high recruitment of other insects among social insects that exhibit such behavior. This results in multiple visits to a highly attractive pathogenic bait, thereby providing effective individual insect and/or colony inoculation.
[0017] The present invention further provides these and other advantages with improved control of insect pests using fungal insecticidal compositions (mycopesticides) having strong attractant properties and placing these attractant mycopesticides in or around an object or area to be protected. The present invention also provides insecticidal baits which use, as a toxicant, relatively innocuous, naturally occurring materials as the active agent, so as to control insects without undue effect on the ecology. Finally, by actively avoiding the use of conidia, the time and expense of raising conidial stage mycelium and/or separating conidia is avoided.
[0018] Still further objects and advantages of the present invention will become more apparent from the following detailed description and appended claims.
[0019] Before explaining the disclosed embodiments of the present invention in detail, it is to be understood that the invention is not limited in its application to the details of the particular products and methods illustrated, since the invention is capable of other embodiments. Also, the terminology used herein is for the purpose of description and not of limitation.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0020] The present invention provides improved mycopesticides (fungal mycelia utilized as insect biopesticides). The attractiveness of fungal mycelia to many species is well known. Black Angus cows have been observed running uphill (a rare event) to reach spent Oyster mushroom mycelium on straw. Cultured mycelia such as Morel mycelium is considered a delicacy when added to human foods; gourmet mushrooms themselves are a form of mycelium fruitbody. Indeed, the attractiveness of mycelial scents is to a great degree responsible for the fresh and refreshing scent of a forest after a rain, a result of the mushroom mycelia responding to the humid conditions with rapid growth. Mycelium is also known to be highly attractive to insects. Certain ants, termites and wood-boring beetles are known to cultivate and raise fungal mycelium as an exclusive food source (“ambrosia fungi”) and mycelium is a preferred food source of many insect species. As discussed above, brown rot mycelium (the mycelial stage of a wood-rotting type of fungus that produces polypore mushrooms) has been used as an attractant for termites.
[0021] However, for insect control typical use of fungal pathogens has involved use of either conidia (spores) or a mixture of conidia and mycelium as a “contact insecticide” control agent. Such conidial contact insecticides suffer two major disadvantages: 1) conidia and conidia/mycelium preparations are to some degree unattractive or even repellant to insects; and 2) such conidia preparations are highly dependent on free water or humid conditions for gestation and infestation during the typical life cycle of an insect fungal control agent. Furthermore, conidia have been found to be more effective against “stressed” insects and/or insect populations than against healthy insects and populations. For these and other reasons, conidia of entomopathogenic fungi have often been much more effective under laboratory conditions than in the field.
[0022] Noting that conidia have been utilized as a repellant for termites, further investigation of the preconidial and conidial stages were undertaken. The preconidial stage is the vegetative stage of the fungus, prior to the formation of structures leading to the release of air-borne spores (which is distinguished from fragmentation of hyphae which can become airborne if dried). Those skilled in the art will recognize that mycelia or mycelial hyphal fragments may form structures such as arthrospores (a preconidial structure imbedded within the mycelia) and such should be considered a “preconidial mycelium” as discussed elsewhere. It was found that the “fragrance signature” of the mycelium is a strong attractant to insects, but only prior to conidia formation. After conidia formulation, the conidia/mycelium was found to be repellant to insects such as carpenter ants. The odor was found to be similarly pleasing to humans when preconidial and repellant when post-conidial. It was noted such fragrance signatures are “washed away” or lost when mycelium is grown via liquid fermentation. It was also noted liquid fermentation utilizing a typical fermentor with bubbled air mixing will promote conidia formation, with such conidia production being even further promoted by the common commercial practice of utilizing bubbled oxygen.
[0023] It was further found that fungal control agents are much more effective when preconidial mycopesticidal mycelium is ingested by the targeted insect as compared to conidia or post-conidial mycelium/conidia offered to targeted insects for the purpose of infection by contact. Whereas conidia have little or no effect by ingestion or vapor, preconidial mycelium has proven to be highly effective by ingestion, the mycelial hyphae already being in a state of active growth when ingested. Furthermore, whereas conidial preparations are more dependent upon humidity in the insect environments, a preconidial mycopesticidal mycelium which is eaten by an insect is dependent upon humidity only in the immediate vicinity of the mycelium, the humidity of the mycelium of course being much more easily controlled than in the wider general insect environment.
[0024] It has further been found that the preconidial stage can be maintained provided carbon dioxide (CO 2 ) levels are maintained at an elevated level. The CO 2 levels preferably range from 2,000-200,000 ppm, more preferably in the range of 10,000-50,000+ ppm. Once exposed to fresh air, the mycelium can produce conidia in just a few days. By preventing conidial formation, the mycelium continues to accumulate mycelial biomass (sans conidia). Even after maturation, the mycopesticidal mycelium may be maintained in a preconidial state via elevated carbon dioxide levels. This prevention of conidia formation is an active component in this technology, as conidia formation is actively avoided.
[0025] Mycopesticidal mycelium is grown in pure culture using standard fermentation techniques well established for in vitro propagation. The fermented mycelia is diluted and transferred into a sterilized grain or a mixture of sterilized grains (rice, wheat, rye, oat, millet, sorghum, corn, barley, etc. The grain is pressure steam-sterilized at 1 kg/cm 2 (15 psi) for several hours. The master broth is transferred aseptically manually or by using peristaltic pumps into the sterilized grain. Growth mediums containing sawdust, sugar cane, corn cobs, cardboard, paper or other substances containing cellulose may be utilized for cellulose loving insects such as termites if desired. A variety of containers are used for incubation, including high-density polyethylene and polypropylene bags, glass and polypropylene jars, metal containers, etc.). Use of such containers provides a convenient method of maintaining high CO 2 levels, as the growing mycelium gives off carbon dioxide. CO 2 levels will rise to acceptable levels for use in the present invention even if filter patches, disks or materials are utilized to allow some gas exchange. Alternatively, grow rooms may be maintained at high CO 2 levels. Further information on such culture techniques may be found in the applicant's books, Growing Gourmet and Medicinal Mushrooms (1993, 2000) and The Mushroom Cultivator (1983) (with J. Chilton), and in standard microbiology manuals.
[0026] Once inoculated, the mycelia on grain matures to a state prior to conidia formation and may be utilized fresh or metabolically arrested or developmentally arrested through flash chilling (freeze-drying), drying, refrigeration or by other means. It will be understood that such metabolic arresting of development may encompass either a slowing of metabolism and development (such as refrigeration) or a total suspension or shutdown of metabolism (freeze-drying, air-drying and cryogenic suspension). When freeze-drying, drying or other known methods of arresting development are utilized, it is essential that freeze-drying or other methods occur at an early stage in the life cycle of these fungi before the repellant spores are produced. The mycelium-impregnated grain media may then be fragmented and packed in appropriate containers for commerce. Fresh mycelium may be shipped in growing containers such as jars or spawn bags, which allows easy maintenance of a high carbon dioxide atmosphere and maintenance of sterile conditions during shipping. It is preferable that the mycelium be utilized or processed while vigorous, before it “over-matures” and becomes less viable for lack of new food to digest and accumulation of waste products.
[0027] When the freeze-dried or dried mycelium is reactivated via rehydration, the mycelium is preferably allowed to slowly rehydrate through controlled absorption of atmospheric humidity, with the result that the mycelium “wakes up” and wicks into the air. This is a totally different response from immersion, which often results in bacterial contamination and souring, as the freeze-dried mycelium suffers when immersed in water. Such rehydration and reactivation may be carried out on a large scale through high humidity atmosphere, or may be accomplished by an end user through use of wet materials such as sponges, wicking materials and/or other evaporative materials or by atmospheric absorption of humidity from a remote water reservoir. Such end user rehydration may be carried out in any suitable container or a bait box if desired. Warming is suitable for reactivation of refrigerated materials; it is preferred that the mycelium not be refrigerated for extended lengths of time.
[0028] Novel features of the invention include the use of a vector of parasitization that relies on hyphal fragments, not spores or conidia; the use of a single mycelium as both attractant fungus and pathogen; the use of high levels of CO 2 to grow and maintain preconidial mycelium; and the preferred use of various methods to arrest development at the preconidial stage to facilitate growth, packaging, shipping and convenient application by an end user. More than one fungus can be used to create a matrix of characteristics to increase usefulness as a natural pesticide.
[0029] In general, preferred mycopesticidal species as pathogens are somewhat slow-acting (that is, not immediately fatal), so as to avoid bait shyness and to avoid learning effects in social insects before individuals have distributed mycelium to other members of the colony. In many applications it may be preferable to utilize a mixture or matrix of several species of entomopathogenic fungus with different characteristics, maturation and growth rates, preferred conditions, virulence and pathogenicity, time to insect death, etc., while in other applications a single species may be preferred. Similarly, with reference to a single species, a mixture of strains or a single strain may be utilized. Those skilled in the art will recognize that such characteristics can be selected for utilizing known techniques and bioassays. The mycopesticides disclosed herein may also be optionally enhanced by the use of other baits, attractants, arrestants, feeding stimulants, sex pheromones, aggregating pheromones, trail pheromones, etc.
[0030] There are numerous entomogenous and entomopathogenic fungal species known. Those skilled in the art will recognize that the above preconidial fungi methods and products may be favorably applied to all such insecticidal fungal species, and it is the intent of the inventor that the invention be understood to cover such. Suitable entomopathogenic fungi include Metarhizium, Beauveria, Paecilomyces, Hirsutella, Verticillium and other fungi imperfecti, the Entomophthoracae and other Phycomycetes, and sexually reproducing fungi such as Cordyceps and other Ascomycetes.
[0031] By way of example, but not of limitation, preferred mycopesticides include Metarhizium anisopliae (“green muscarine” for pests such as carpenter ants, including Camponotus modoc, C. vicinus, C. ferrugineus, C. floridanus, C. pennsylvanicus, C. herculeanus, C. varigatus and C. vicinus , fire ants ( Solenopsis invicta and Solenopsis richteri ), termites, including Coptotermes, Reticulitermes, Cryptotermes, Incisitermes, Macrotermes and Odontotermes, pasture scarabs such as Adoryphorus couloni , spittle bug Mahanarva posticata , corn earworm Helicoverpa zea , tobacco hornworm Manduco sexta , sugar cane froghopper, pill wood lice, sow bugs, large centipedes, shield centipedes, wheat cockchafer, beetle grubs, greenhouse pests such as Coleoptera and Lepidoptera, etc.); Metarhizium flaviride (grasshoppers and locusts); Beauveria bassiana (“white muscarine” for termites including Formosan termites, carpenter ants, fire ants, pharaoh ants, cockroaches, whiteflies, thrips, aphids, mealybugs, boll weevils, sweet potato whiteflies, cotton fleahoppers, European and Asiatic corn borers and larvae of other Lepidoptera, codling moth, chinch bug, soft-bodied insects in the orders Homoptero and Coleoptera, Heteroptera, etc.); Beauveria brongniartii (white grubs and cockchafers, Hoplochelis marginalis, Melolontha melontha ); Paecilomyces fumosoroseus (whiteflies, thrips, aphids, spider mites, mealybugs, beet army worm, Colorado potato beetle, Gypsy moth, etc.); Verticillium lecanii (greenhouse pests, whiteflies and aphids); Hirsutella citriformis (rice brown planthopper); Hirsutella thompsoni (citrus rust mite); and the wide variety of Cordyceps for baiting and killing pests such as beetles, flies, cockroaches, earwigs ( Forficula auricularia ), carpenter ants and various other insect pests, including Cordyceps variabilis , including imperfect forms (fly larvae, Xylophagidae family of the Diptera order), Cordyceps facis and C. subsessilis , (beetle larvae in the coleopteran family, Scarabaeidae), Cordyceps myrmecophila (ants); Cordyceps sphecocephala (wasps), Cordyceps entomorrhiza (beetle larvae), Cordyceps gracilis (larvae of beetles and moths), Cordyceps militaris, Cordyceps washingtonensis, Cordyceps melolanthae (beetles and beetle grubs), Cordyceps ravenelii (beetle grubs), Cordyceps unilateralis (ants, carpenter ants, bees and wasps) and Cordyceps clavulata (scale insects).
[0032] With regard to the sexually reproducing Cordyceps, preconidial or pre-sporulation refers to the pre-fruiting state. The term “preconidial” has a somewhat different meaning than with most other entomopathogenic fungi, as Cordyceps is a “fungi perfecti” or mushroom fungi, whereas the other non-mushroom fungi referred to herein are the more primitive “fungi imperfecti.” Some or all Cordyceps fungi are believed to be anamorphic or dimorphic and have conidial stages within the imperfect fungal genera including Beauveria, Metarhizium, Paecilomyces, Hirsutella, Verticillium, Aspergillus, Akanthomyces, Desmidiospora, Hymenostilbe, Mariannaea, Nomuraea, Paraisaria, Tolypocladium, Spicaria (=Isaria) and Botrytis. For example, C. subsessillis is the perfect form of Tolypocladium inflatum , an anamorph (imperfect) form which produces cyclosporin. Hodge et al., Tolypocladium inflatum is the anamorph of Cordyceps subsessilis. Mycologia 88(5): 715-719 (1996). Cordyceps militaris (Fr.) Lk. is also thought to be dimorphic, the conidial stage of which is believed to be a Cephalosporium. DNA studies are expected to better elucidate these relationships. As a further complexity, in addition to possible anamorphs and dimorphs, Cordyceps species also demonstrate nonsexual imperfect stages of development. As used herein, unless otherwise specified, preconidial Cordyceps refers to the pre-sporulation mycelial stage of the Cordyceps mushrooms, including any preconidial imperfect stages, but not any conidia bearing imperfect stages.
[0033] For initial experimentation, a Metarhizium anisopliae from naturally occurring sources and the carpenter ant were selected. M. anisopliae was obtained from a public culture collection and used without further selection for virulence and/or pathogenicity; a publicly available strain free of proprietary or patent restrictions on use was selected as offering a preferred source and a more demanding initial test than strains selected for specific pathogenicity. It will be understood, of course, that strains selected for specific characteristics and pathogenicity against specific insects will in general offer the best mode of practicing the invention. The carpenter ant offered several advantages: ants are typically more resistant to spores than termites and other insects, carpenter ants are a very destructive pest, the effect on other ant species could also be viewed, and the applicant enjoyed easy access to an experimental site as his residence was in danger of collapse due to long term structural infestation by carpenter ants.
EXAMPLE 1
[0034] [0034] Metarhizium anisopliae was grown in pure culture using standard fermentation techniques and diluted and aseptically transferred to grain (rice) which had been pressure steam-sterilized at 1 kg/cm 2 (15 psi). The fermented mycelia matured to a state prior to conidia formation and the fungus colonized grain was offered at the site of debris piles caused by carpenter ants at the 1,100-1,200 sq. ft. house of the applicant's residence located in Shelton, Wash., U.S.A. Approximately 10-20 grams of preconidial mycelium of Metarhizium anisopliae , grown on autoclaved rice and having been incubated for two weeks, was presented at the location of debris piles next to the interior face of an exterior wall within the house. The non-sporulating mycelium was presented on a dollhouse dinner dish and left exposed to the air. Later that night, the applicants' daughter urgently awoke the applicant when she observed carpenter ants feasting en masse on the non-sporulating mycelium of the presented Metarhizium. The applicant and his family observed approximately a dozen carpenter ants ingesting mycelium and retreating into the wall, carrying the infectious mycelium with them. In a week's time, the carpenter ant colony became inactive, killing the nest of ants, and no evidence of carpenter ant activity was observed henceforth, saving the structure from further structural damage. Months later, the ecological niche once occupied by the carpenter ants was taken over by common household Sugar and Honey ants which were unaffected by the Metarhizium anisopliae.
EXAMPLE 2
[0035] Cultivate strains of Metarhizium, Beauveria and Cordyceps on grain as above under high CO 2 conditions to produce preconidial mycelium. Freeze-dry and rehydrate. Apply as bait and pathogen at locations infested by insects such as carpenter ants, termites, beetles, flies, fire ants, cockroaches and other insect pests and vermin.
EXAMPLE 3
[0036] Drill one or more holes into a termite colony mound or tree mound. Insert entomopathogenic preconidial mycopesticidal mycelium into the holes. Cover the holes to prevent entry of marauding ants.
[0037] No limitations with respect to the specific embodiments disclosed herein is intended or should be inferred. While preferred embodiments of the present invention have been shown and described, it will be apparent to those skilled in the art that many changes and modifications may be made without departing from the invention in its broader aspects. The appended claims are therefore intended to cover all such changes and modifications as fall within the true spirit and scope of the invention. | The present invention utilizes the non-sporulating mycelial stage of insect-specific parasitic fungi. The fungus can be present on grain, attracting the pest, and also infecting it through digestion. More than one fungus can be used in combination. The matrix of fungi can be dried or freeze-dried, packaged and reactivated for use as an effective bioinsecticide. | 0 |
CROSS-REFERENCES TO RELATED APPLICATIONS
[0001] This application claims priority from U.S. Application No. 62/020803, filed Jul. 3, 2014, the contents of which is fully incorporated by reference herein in its entirety.
BACKGROUND
[0002] Coffee makers are prevalent in many environments because of society's affection for the beverage, and thus many industries endeavor to offer their customers or patrons coffee as a way to make the experience more enjoyable. From automobile service stations to bookstores, there are few places where a customer cannot get a cup of coffee these days. One such place that patrons can expect a cup of hot coffee is during commercial airplane flights of medium to large distances. Passengers have come to expect this service on commercial flights, and airline manufacturers have developed special coffee brewing machines that meet the specific requirements and limitations of electrical appliances on aircraft.
[0003] All coffee brewing apparatus include some form of water heating element to raise the temperature of the water to a level where the oils and extracts of the coffee beans can be released. Water is pumped through a tubing with a resistive heating element that heats the water as it flows through the tubing. The resistive heating element is typically a coiled wire, similar to the element in an electric toaster, that heats up when electricity is run through it. In a resistive element like this, the coil is embedded in a plaster to make it more rugged. The heating element serves multiple purposes, namely to initially raise the temperature of the supply water to brewing temperature, and then when the coffee is made, the heating element keeps the coffee warm.
[0004] The resistive heating element may be sandwiched between a warming plate and an aluminum water tube. The resistive heating element presses directly against the underside of the warming plate, and white, heat-conductive materials such as grease make sure the heat transfers efficiently. The coffee maker's power switch turns power to the heating element on and off, and to keep the heating element from overheating there are sensors and fuses. In coffee makers, sensors detect if the coil is getting too hot and, if so, cut off the electrical current. When the coil cools down, the sensor turns the current back on. By cycling on and off like this, coffee brewers keep the coil at an even temperature. Similarly, fuses simply cut the power if the temperature reaches a certain level. Fuses are a safety measure in the event that the main sensor fails. Coffee makers also typically employ a one-way valve. The one-way valve lets cold water into the aluminum tube, but forces the bubbles of boiling water to flow up the brew tube.
[0005] The present invention is directed to a flow-through type water heater for a beverage maker, and more particularly to a flow-through water heater for an aircraft galley appliance for making beverage, the appliance having three-phase power capability and a removable baffle core. Most flow-through heating assemblies use a single phase power source to energize the heating element. Examples of such heating assemblies include plasma-sprayed circuit flow-through heaters from Watlow Electric Manufacturing Company of St. Louis, Mo. These heaters receive a flow of water from a water supply and heat the water to a temperature that is appropriate for brewing coffees, teas, espressos, and the like. However, there are several characteristics of such heating units that make them unsuitable for use in aircraft. First, aircraft power systems utilize a three-phase power that cannot be used with the aforementioned single phase heaters. Second, the core of the prior art heating units are fixed, which makes it challenging to determine if deposits are affecting the performance of the heating core. That is, traditional heater assemblies are welded together into a single piece, so the core and end fittings can not be removed. Thus, the inner passage way of the heater that the water flows through cannot be well monitored for hard water scale buildup. In addition, the current baffles are made from stainless steel, which is much heavier than the PEEK plastic used to fabricate the removable baffle core of the present invention. Third, such cores are typically made of a solid metal, adding weight to the beverage maker that is undesirable to aircraft components. Fourth, these cores lack the capability to effectively monitor the temperature of the water inside the core, which can lead to safety concerns as well as inefficiencies in the heating operation.
SUMMARY OF THE INVENTION
[0006] The present invention is designed to overcome these shortcomings and provide a three-phase heating unit for an aircraft beverage maker that includes a removable light-weight baffle core that can be easily removed and inspected to determine if maintenance is required. In a preferred embodiment, the heating unit includes integrated resistance temperature detectors (RTDs) that allow the actual heater temperature to be monitored directly, thereby avoiding an over-temperature condition, and incorporates fast-response temperature control. The heating unit of the present invention uses a custom circuit for three-phase power to manage the unique power requirements of an aircraft while providing efficient power management.
[0007] Other features and advantages of the present invention will become more apparent from the following detailed description of the preferred embodiments in conjunction with the accompanying drawings, which illustrate, by way of example, the operation of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] FIG. 1 is an illustration of an assembled heater unit;
[0009] FIG. 2 is an illustration of the components of the heater unit of FIG. 1 ; and
[0010] FIG. 3 is a circuit diagram for a three-phase power supply used on an aircraft.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0011] The present invention comprises enhancements to prior art plasma-sprayed circuit flow-through heaters to make such heaters suitable for aircraft beverage maker applications. The enhancements include: 1) a high-performance, light weight plastic baffle core; 2) removable end fittings and baffle core, which allows for inspection of the core to check for hard water scale buildup inside the heater and enables maintenance and cleaning; 3) integrated RTDs, which allows the actual heater temperature to be monitored directly, thus avoiding an over-temperature situation and enabling fast-response temperature control in operation; and 4) a custom-designed circuit that incorporates three-phase power (essential for operation on aircraft) and dry steam production capability (particularly for espresso beverages) aboard aircraft.
[0012] The present invention is designed to be used in aircraft beverage makers with rapid in-line water heating and/or controlled steam production. The traditional heater design for non-aircraft use incorporates a single-phase electrical circuit. However, modern aircraft use a 400 Hz three-phase power supply to comply with FAA regulations. Thus, a multi-phase circuit must be incorporated into the heater. The heater of the present invention includes a plasma-sprayed circuit applied to a stainless steel substrate tube. Integrated resistance temperature detectors, or “RTD”s, are incorporated into the heater circuit that enables direct monitoring of the heater temperature. This not only provides for better temperature control of the heater circuit, but allows for improved safety as well.
[0013] FIG. 1 illustrates a fully assembled heating unit 10 of the present invention, with a three-way electrical conduit 12 that couple the heating unit 10 to a power supply (not shown). A steel tube body 14 houses a plastic baffle core 16 , and end fittings 18 , 20 are threaded or otherwise removably attached to allow access to the core 16 . A pair of O-rings 22 or washers are disposed between the end fittings 18 , 20 and the housing body 14 . At the end of the housing are three resettable temperature sensors 24 a, 24 b, 24 c, one for each phase of the input power. By monitoring and regulating each phase of the power, the present invention provides a far more accurate evaluation of the temperature of the core 16 , which in turn provides a measure of the water temperature and system performance. The three way electrical conduit 12 includes one jack 26 for each phase of the electrical power from the power supply, establishing a three-phase power system to convey the voltage to the heating unit 10 in three phases.
[0014] The removable end fittings 18 , 20 of the housing 14 preferably incorporate machined screw threads 28 that screw into tapped holes 30 on each end of the baffle core 16 . The end fittings 18 , 20 also have grooves on a mating surface that allow for seating and sealing of the end fittings when the unit 10 is assembled. The ability to quickly and easily disassemble the heater 10 also allows for flexibility with various end fittings for functional efficiency and enables easier cleaning and maintenance.
[0015] FIG. 2 illustrates an exploded view of the present invention of FIG. 1 , where the housing 14 is separated from the removable end pieces 18 , 20 and the plastic baffle core 16 is exposed. Each fitting 18 , 20 inserts into the core 16 , and water is heated by the resistive heater 32 inside the housing 14 as it is circulated around the core 16 from one end to the other. Each end piece 18 , 20 includes a stem 38 that fits into fitted holes 30 at the opposite ends of the baffle core 16 . The inlet end piece 18 includes a port 40 for receiving a water stream, and the outlet end piece 20 includes a port 42 for the water to exit the heating unit 10 . A washer 22 is preferably incorporated into each end piece 18 , 20 to resist leakage at the junctures with the housing 14 . The core 16 may be made of plastic, such as PEEK, to reduce the weight of the core and thereby reduce the weight of the heating unit 10 . The pitch of the threads 28 on the baffle core 16 may be selected so as to allow the residence of the water in the heating unit 10 to coincide with the heating characteristics of the resistive heating element 32 to efficiently heat the water therein.
[0016] FIG. 3 illustrates the plasma sprayed circuit 50 for the flow-through heater 10 of the present invention as incorporated into a brew heater. The power supply (not shown) is a 115 volt, three-phase power each having 805 watt maximum, for an 2415 watt total single zone at an operating temperature of 195° F. The wye configuration is shown in FIG. 3 , including phase C (blue) 52 , phase B (yellow) 54 , and phase A (red) 56 . The ground or heater return 58 is shown as well (white). The housing 14 is preferably 155 mm, although other sizes are possible, and the wires can be selected to be approximately 12 inches in length. The RTDs 24 (1kΩ, Class 1B) are attached at the outlet end of the housing as shown in FIG. 1 . In an alternate embodiment, the phases are each 533 watts for a total wattage of 1600 watts at an operating temperature of 300° F., which is used when the heater operates as both a water heater and a steam generator.
[0017] The three-phase heating unit for an aircraft beverage maker of the present invention incorporates a removable light-weight, easily removed baffle core allowing inspection of possible scale buildup in the heater. In a preferred embodiment, the heating unit includes integrated resistance temperature detectors (RTDs) that allow the actual heater temperature to be monitored directly, thereby avoiding an over-temperature condition and fast response temperature control. The heating unit of the present invention uses a custom circuit for three-phase power to manage the unique power requirements of an aircraft while providing efficient power management.
[0018] It will be apparent to those of ordinary skill in the art from the foregoing that while certain presently known preferred embodiments of the invention have been illustrated and described, various modifications can be made without departing from the spirit and scope of the invention. Accordingly, it is not intended that the invention be limited, except as by the appended claims. | A water heater for an aircraft beverage brewing apparatus includes a three way electrical conduit for conducting electrical power in three separate phases. The heater has a housing with a fluid inlet port at a first removable end piece and a fluid outlet port at a second removable end piece. The hollow cylindrical core incorporates a heating element wound around the core, and the housing includes three resettable temperature sensors at the outlet, each of the three resettable temperature sensors connected to a separate phase of power from the three way electrical conduit. | 5 |
This is a continuation of application Ser. No. 285,200, filed Dec. 16, 1988 now abandoned.
BACKGROUND OF THE INVENTION
The present invention relates to an insulated gate field effect transistor (hereinafter abbreviated to IGFET), and more particularly to an IC using a complementary type IGFET's (hereinafter abbreviated to CMOS) or to an IC using a bipolar and a CMOS (hereinafter abbreviated to BiCMOS).
The CMOS and the BiCMOS have been widely used in IC's, because the former has a low power consumption characteristic and the latter has a good high frequency and a low power consumption characteristics. Both IC's employ an N-channel type IGFET formed in a P-type substrate region, that is, a P-well, and a P-channel type IGFET formed in an N-type substrate region, and these N-type and P-type IGFET's are separated from each other by interposing an isolation region therebetween. The isolation region is made of a thick silicon oxide layer formed by thermal oxidation of a silicon substrate under a high temperature during a long time. In this case, at portions of the channel region of the IGFET abutted against the thick silicon oxide layer, a designed threshold voltage cannot be obtained, because impurities in both end portions of the channel region in the channel width direction abutted against the thick field silicon oxide layer migrate into the thick field silicon oxide layer and the impurity concentration at the end portions fall unfavorably to a low level. Particularly, borons are more apt to migrate, and the degree of the change in the boron concentration at the end portions of the channel region is largely deviated by the process conditions. Therefore, the problem is more serious in an N-channel type IGFET formed in a P-well doped with borons as the impurity. Consequently, in a prior art, a precise control of the characteristics of the IGFET or the IC using the IGFET is impossible.
SUMMARY OF THE INVENTION
Accordingly, it is an object of the present invention to provide an IGFET in which the adverse effect from the field silicon oxide layer is eliminated, and a precise control for the characteristics can be realized.
According to a feature of the present invention, there is provided an IGFET which comprises a silicon substrate having a major surface, a transistor region formed in the substrate, a field silicon oxide layer formed by thermally converting silicon in the substrate so as to be embedded inwardly in the substrate at its major surface, the field oxide layer having a sizeable thickness and surrounding substantially the transistor region, source and drain regions of the transistor formed in the transistor region, a channel region of the transistor positioned in the transistor region between the source and drain regions, the channel region having first, second, third and fourth edge lines, the first and second edge lines being abutted against the source and drain regions, respectively, the third and fourth edge lines facing the field oxide layer, respectively, a gate insulating film of the transistor formed on the channel region, first and second intermediate oxide layers formed between and abutted against the field oxide layer and the third and fourth edge lines of the channel region, respectively, each of the first and second intermediate oxide layers having a thickness thinner than the field oxide layer and thicker than the gate insulating film and having a belt-like or a rectangular plan shape, and a gate electrode of the transistor formed on the gate insulating film and extending on the first and second intermediate oxide layers and on the field oxide layer. The channel region may be of P conductivity type, and the transistor may be a N-channel type transistor. Generally, the surface of the transistor forming region of the substrate and the upper surface of the field oxide layer are substantially co-planar with each other. Each of the first and second intermediate oxide layers may extend with a constant width along both sides of the source and drain regions, respectively. Or else, the first and second intermediate oxide layers may be continuously formed such that they constitute a ring-like plan shape with a constant width surrounding the periphery of the IGFET region of the substrate attached to and provided between the periphery and the field oxide layer. The IGFET can be manufactured by forming selectively the field oxide layer by a heat treatment under an oxidizing atmosphere at a portion of a silicon substrate outside a transistor forming region including a channel forming region of the substrate, and thereafter forming a silicon oxide layer as the intermediate oxide layer at a portion of the substrate abutted against the field oxide layer and against the channel forming region.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1A is a plan view showing an IGFET in a prior art, and FIG. 1B is a cross-sectional view taken along line B--B' in FIG. 1A as viewed in the direction of arrows;
FIG. 2A is a plan view showing a first embodiment of the present invention, and FIGS. 2B, 2C and 2D are cross-sectional views taken along lines B--B', C--C' and D D' in FIG. 2A as viewed in the direction of arrows, respectively;
FIG. 3 to FIG. 14 are drawings showing process steps for manufacturing the first embodiment, in sequence; FIGS. 3 to 7 and 11 to 14 are cross-sectional views; FIG. 8A is a plan view; FIG. 8B is a cross-sectional view taken along lines B--B' in FIG. 8A as viewed in the direction of arrows; and FIGS. 9 and 10 are cross-sectional views showing process steps as viewed in the same direction as FIG. 8B; and
FIG. 15 to FIG. 17 are drawings showing schematically process steps for manufacturing a second embodiment of the present invention; and FIG. 15 is a cross-sectional view and FIGS. 16 and 17 are plan-views.
DESCRIPTION OF A PRIOR ART
Referring to FIGS. 1A and 1B, an N-channel type IGFET of a CMOS in a prior art is disclosed. A silicon substrate is constituted by a P-type silicon body 1 and a silicon epitaxial layer 2 formed on the silicon body. In the silicon epitaxial layer 2, a P-type impurity region, that is, a P-well 15 is formed by doping borons. The P-well region 15, in which the N-channel type IGFET is provided, is surrounded by a thick field silicon oxide layer 5 and a P + -type channel stopper region 4 provided under the layer 5. A P + -type buried layer 3 is positioned between the P-type silicon body 1 and the P-well region 15, and N-type source and drain regions 10, 11 are formed. On a channel region 12 between the N-type source and drain regions 10, 11, a silicon gate electrode 7 is formed via a gate insulating film 6 of 20 nm (nanometers) (200 Å) thickness. When the surface impurity (boron) concentration of the P-well region 15 is 2×10 16 cm -3 , the center portion 14, that is, the major portion of the channel region 12 has also the surface impurity concentration of 2×10 16 cm -3 and the threshold voltage thereof becomes, for example, 0.8 volts. Therefore, the IC is designed as the threshold voltage of the N-channel type IGFET to be 0.8 volts with a predetermined width W 1 , for example, of 20 μm (micrometers). However, at the end portions 13 of the channel region 12 in the channel width direction contacted to the thick field silicon oxide layer 5, the impurity (boron) concentration at the upper surface thereof is inevitably decreased, for example, to 5 to 10×10 15 cm -3 during the process steps for forming the silicon oxide layer 5. Therefore, the threshold voltage at these portions becomes from 0 to 0.4 volts. The degree of the change of the boron concentrations at the end portions 13 is largely deviated by the process conditions. Further, if the upper surface 5' of the field silicon oxide layer 5 is to be substantially flat with the major surface 2' of the epitaxial layer 2, that is, of the substrate, in which the IGFET is formed, or with the upper surface of the gate insulating film 6 as shown in FIG. 1B, twice the thermal oxidation process steps are necessary during the long time for forming the field silicon oxide layer 5. In this case, the problem is more serious.
DETAILED DESCRIPTION OF EMBODIMENTS
Referring to FIGS. 2A to 2D, a first embodiment of the present invention will be explained. In FIGS. 2A to 2D, the same components as those in FIGS. 1A and FIG. 1B are indicated by the same reference numerals. According to the present invention, on the unfavorable end portions 13 of the channel region 12, stripe type or belt-like or rectangular plan shaped intermediate silicon oxide layers 18 are formed. Each of the intermediate layers 18 has the width W 3 of 0.8 μm and the thickness of 400 nm (nanometers) (4000 Å) and is embedded into the silicon epitaxial layer 2 from the major surface 2'. By the layers 18, the threshold voltage at the portions 13 becomes such a sufficiently high level that an operation as IGFET is not conducted. That is, the end portions 13 do not operate as a part of the channel region under the normal signal voltage which is applied to gate electrode 7, and the threshold voltage, of the IGFET is defined only by the center or major portion 14 with the constant width W 2 , for example, of 20 μm. Consequently, a control of characteristics of the IGFET or of the CMOS using the IGFET can be possible. If the thickness of the intermediate silicon oxide layer 18 were to be far thicker, an unfavorable region same as the region 13 is newly formed inside the intermediate layer 18 at the center portion 14, and if the thickness was to be far thinner, the surface of the region 13 would conduct unfavorably as a part of the channel region. Practically, the thickness of the intermediate silicon oxide layer 18 favorably ranges from 200 nm (nanometers) to 600 nm (2000 Å to 6000 Å). On the other hand, the intermediate layer 18 must cover the region 13, and the integration density of the device must be considered. Therefore, the width W 3 of the intermediate layer 18 ranging from 0.4 μm to 1.5 μm is favorable.
Referring to FIGS. 3 to 14, manufacturing process steps for forming the structure shown in FIGS. 2A, 2B is explained.
At first, P + -type regions 4', 3' and an N + -type region 8' are selectively formed in the surface of the silicon body 1 (FIG. 3). Next, an epitaxial layer 2 is formed entirely, and the P-well region 15 is formed in the epitaxial layer by introducing borons therein. The deposited epitaxial silicon layer contains N-type impurities. Therefore, the regions of the epitaxial layer except the P-well regions are N-type epitaxial regions, and a P-channel IGFET is formed in the N-type epitaxial region. During the formation of the epitaxial layer, impurities in the P + - and N + -type regions 4', 3' and 8' are diffused upwardly into the epitaxial layer so that the P + -type channel stopper region 4, the P + -type buried region 3 and the N + -type buried region 8 are formed, respectively. Then, a thin silicon oxide film 31 is entirely formed on the surface of the epitaxial layer including the P-well region, and silicon nitride films 32 are selectively formed on the silicon oxide film 31 (FIG. 4). Next, a first oxidation is conducted to form a first thick silicon oxide layer 33 of 1.2 μm thickness using the silicon nitride films 32 as a mask under oxidizing atmosphere (O 2 or steam) of 5 atm (5×1.33×10 5 Pascal) at 950° C. during 2 hours. The first thick oxide layer 33 is partially embedded in the epitaxial silicon layer but does not reach to the P + - and N + -type regions 4, 3, 8 (FIG. 5). Next, the thick silicon oxide layer 33 is removed by using the silicon nitride films 32 as a mask so that a groove 34 is formed in the epitaxial silicon layer (FIG. 6). Thereafter, if necessary, another silicon nitride film may be entirely deposited and may be subjected to an anisotropic etching to remain at upper sides of the groove to enforce the silicon nitride film 32 for a subsequent second oxidation. Next, the second oxidation is conducted to form a second thick silicon oxide layer, that is, the thick field silicon oxide layer 5 by using the silicon nitride films 32 as a mask under oxidizing atmosphere (O 2 or steam) of 5 atm (5×1.33×10 5 Pascal) at 950° C. during 2 hours. The thick field silicon oxide layer 5 has the thickness of 1.2 μm with the upper surface 5' which is substantially co-planar with the surface 2' of the N-channel and P-channel forming regions. Further, field silicon oxide layer 5 reaches the P + -type channel stopper region 4 and surrounds the transistor forming regions, respectively (FIG. 7). The first and second oxidations (FIGS. 5 and 7) are conducted under the high pressure atmosphere (5 atm), and therefore, a relatively low temperature such as 950° C. may be used. Consequently, the P + -type channel stopper regions 3 are not diffused up to the upper surface of the epitaxial silicon layer along the silicon oxide layer 5 by the oxidations, as shown in FIG. 7. Next, as shown in FIGS. 8A and 8B, a photoresist film 35 is formed on the silicon nitride films 32 to expose the end sections 32' of the films 32.
In FIG. 8A, the Y direction is a channel width direction, and the X direction is a channel length direction. FIGS. 3 to 7 mentioned above are cross-sectional views at the channel length direction of N-channel and P-channel IGFET's. FIG. 8B and subsequent FIGS. 9 and 10 are cross-sectional views at the channel width direction of the N-channel IGFET. However, the same process steps are conducted in the P-channel IGFET. Subsequent FIGS. 11 to 14 are cross-sectional views at the channel length direction of the N-channel and P-channel IGFET's.
After the process step shown in FIG. 8, the exposed end sections 32' of the silicon nitride film 32 are etched away by using the photoresist film 35 as a mask (FIG. 9). Next, after removing the photeresist film 35, the belt-like silicon oxide layers 18 of the present invention are formed by using the remaining silicon nitride films 32 as a mask through an oxidation. The oxidation iε conducted under oxidizing atmosphere (O 2 or steam) of 5 atm (5×1.33×10 5 Pascal) at 950° C. during a short time of 1 hour. Owing to the short heat-treatment time, any unfavorable region same as the region 13 is not newly formed incide the silicon oxide layers 18 by the oxidation (FIG. 10). After removing the silicon nitride films 32 and the thin silicon oxide film 31, a silicon oxide film of 20 nm (200 Å) thickness is newly formed thermally. The film 6, 46 are used as gate insulating films at the parts under the gate electrodes and above the channel regions of the respective IGFET's (FIG. 11). Next, a polycrystalline silicon film 37 doped with phosphorus is deposited (FIG. 12). Next, silicon gate electrodes 7, 47 are formed by patterning the polycrystalline silicon film 37. N + -type source and drain regions 10, 11 are formed by ion implantation of phosphorus through the film 6 by using the gate electrode 7 as a mask, and P + -type source and drain regions 40, 41 are formed by ion implantation of boron through the film 46 by using the gate electrode 47 as a mask (FIG. 13). Next, an inter-ply insulating layer 51 is entirely formed, and aluminum electrode wirings 52 are connected to respective source and drain regions 10, 11, 40, 41 through contact holes 54 provided in the layer 51 and also aluminum electrode wirings 53 are connected to respective gate electrodes 7, 47 through contact holes 55 provided in the layer 51 to constitute a CMOS by the N-channel and P-channel IGFET's (FIG. 14).
By the method mentioned above, the upper surface of the field silicon oxide layer and the upper surface of the transistor forming silicon regions or the surface of the gate insulating films becomd substantially co-planar, that is, keep substantially the same height as each other, and therefore, the electrode wirings can be safely formed without breaking. However, the method necessitates two steps of oxidations (first and second oxidations) having the total time of 4 hours. Therefore, at the end portions of the channel region, boron concentration is unfavorably decreased. When unevenness between the surface of the field silicon oxide layer and that of the transistor forming silicon region is not so important, the field silicon oxide layer may be formed by one oxidation step. That is, in the process step shown in FIG. 5, the silicon oxide layer 33 is grown thicker so as to reach to the P + -type channel stopper region by prolonging the heat treatment time more than 2 hours, and the thicker silicon oxide layer by this process step is used as a field silicon oxide layer as it is. In this case, the problem of reducing boron concentration mentioned above is also produced. However, in view of the deviation and the amount of the reduction of the boron concentration, the problem in the method using two steps of oxidations shown in FIGS. 5 to 7 is more serious than the method using one step of oxidation for forming the field silicon oxide layer.
Referring to FIGS. 15 to 17, a method of manufacturing a second embodiment of the present invention will be explained. In FIGS. 15 to 17, the same components as those in drawings on the first embodiment are indicated by the same reference numerals.
A process step shown in FIG. 15 replaces the process step shown in FIG. 8 of the first embodiment. A silicon oxide film of 200 nm (2000 Å) is deposited by a CVD method, and a photoresist film 61 having the same pattern as the silicon nitride film 32 is formed on the CVD silicon oxide film above the silicon nitride film pattern 32. The CVD silicon oxide film is selectively etched away by using the photoresist pattern 61 as a mask. Further, the side etching is conducted on the silicon oxide film to form a reduced silicon oxide film pattern 60. The side etching process is conducted by immersing the substrate into a mixture solution of ammonium fluoride and hydrofluoric acid at a temperature of 22° C. during 4 minutes. Next, the photo resist film 61 is removed to expose a ring plan shaped end section of the silicon nitride film 32. Then, the exposed section of the silicon nitride film 32 is removed by using the reduced silicon oxide film 60 as a mask to exposed, via the thin silicon oxide film 31, a ring-shaped peripheral section 63 of the transistor forming region (FIG. 16). Next, by conducting an oxidation under the same conditions as the formation of the intermediate silicon oxide film 18 of the first embodiment, an intermediate silicon oxide layer 18' of the present invention having a ring plan shape with constant width, surrounding the IGFET including the source and drain regions 10, 11 and the channel region 12 and positioned between the IGFET and the thick field silicon oxide layer 5, is formed at the exposed peripheral section 63 (FIG. 17). The other components and process steps in the second embodiment are the same as in the first embodiment. | An insulated gate field effect transistor surrounded by a field silicon oxide layer which is at least partially embedded in a silicon substrate, is disclosed. A pair of silicon oxide layers thinner than the field silicon oxide layer and thicker than the gate insulating film are formed on both end portions of the channel region in the channel width direction, and the gate electrode is formed on the gate insulating film and extends on the pair of silicon oxide layers and on the field silicon oxide layer. | 8 |
This application claims benefit of Serial No. 20085369, filed 23 Dec. 2008 in Norway and which application is incorporated herein by reference. To the extent appropriate, a claim of priority is made to the above disclosed application.
BACKGROUND
Traditionally, huge amounts of information have required carefully cataloguing by a manual process in order to make it retrievable. The information is accessed by means of the manually added metadata.
As the Internet emerged, the initial mode of access was via directories that manually classify pages and sites on the Internet. These directories, such as Yahoo (www.yahoo.com) and the Open Directory Project (www.dmoz.org), still exist, but as the content volume grows faster than the capacity of manually classifying content, these directories are replaced or complemented with search-based information access patterns based on information retrieval methods.
Web directories have been generalized to portals. A portal presents information from a variety of sources, including typical non-Internet content, e.g. relational databases, applications, all within a consistent framework for the developer, look and feel for the consumer, and a unified security model across all sub-systems exposed as single sign-on to the information consumer and with corresponding content entitlement. Enterprise portals are commonly used to integrate a range of internal and external enterprise systems and data repositories.
A page in the portal is composed of several portlets, where a portlet represents the information from a single source. The developer states rules for which portlets are to appear on what page and where on the page they are to appear. The presentation can also be targeted to presentation devices, e.g. the limited screen estate on hand-held devices. Several big software companies provide portal products for the system integration. (For more information, see http://www-128.ibm.com/developerworks/ibm/library/i-portletintro/)
When an information consumer accesses information, the query is more or less explicit. The consumer can spell out a query if a suitable device is at hand. On a mobile device with limited textual input, it is desired to reduce the burden to spell out long queries. The context of the user as information is sought contributes implicitly to the query. For example, the query can be implicitly extended and directed to appropriate content depending on whether the user is at home or at work. The position of the consumer can give clues to what geospatial content is relevant.
The integration of search in a portal framework may simply choose to use a single portlet for the search. A more advanced integration makes separate portlets for the search box, the result list, and each of the navigators.
The presentation of query feedback (spelling suggestions, definitions, etc), the result list, and navigators in a portal framework is subject to rules specified by the developer. The size, position, and order are defined manually in advance based on assumptions and generalizations, optimizing the consumer experience for the least work required by the developer.
Discussion of the Problem
A portal aims to be the central point for any information requirement. By nature, it has to care for a wide range of information needs, for example high-level content aggregation and overviews, lower level knowledge investigation, specific fact finding, and retrieving a specific document the user has in mind.
Generally, the portal designer anticipates a pattern of use cases and defines a common layout across all use cases. At best, a few use cases have been identified that are central to the enterprise, and separate user interfaces have been geared towards these scenarios. Each of these tailor-made interfaces requires a significant amount of investment in identifying, developing, and testing the application logic and the usability of the presentation.
Thus, the user interfaces are based on crisp rules on what information components (portlets) are included, where they are positioned, and the presentation size. The rules are typically based only on user attributes, e.g. access rights, interest group, office location, and possibly on the device type. For example, a huge or client specific portlet may only be viewed on devices with sufficient screen estate. In general, it is hard and expensive to define one presentation layout that covers all information needs, and general layouts give unsatisfactory usability.
When screen estate is limited, it is hard to make correct a priori selections of portlets. The user may easily find it very hard to access the desired information as the correct elements for the given context are not included on e.g. a small hand-held device.
On large screens, however, portals tend to suffer from information overload. The portal designer incorporates a lot of content in order to increase the likelihood of presence of some appropriate content, and the content consumer experiences information overload. The consumer has to scan pages that are visually complex: there are many components of different structures and the pages may span several screens on the device. This cognitive distillation of the alternative information components is a stress factor for humans.
FIG. 6 is an example of an information presentation that suffers from information overflow. A user carrying out a task will need considerable time to digest the information in order to build a mental model of the structure of the presentation and the information within it. In many tasks involving search, users are not prepared to operate in such a mode. They expect the required information at most a few clicks away and within a few seconds. The presentation in FIG. 6 specifically suffers from too many content components (screen elements) and that several of the content components stretch beyond the current view.
Specifically in search systems, navigators are used to refine or otherwise manipulate search results in a user-friendly manner. However, on any result screen there is only space for a few navigators. While the available set of meta-data is very large, the choice of the best navigators is often limited, static and suboptimal. Navigator selection is either static or based on hard-coded rules applied at query time, with the risk of including irrelevant and excluding relevant navigators.
Individual navigators are often polluted by noisy elements. Low probability values are presented throughout navigators where the elements are ranked by value (e.g. with hierarchical/tree-like navigators) and at the end where the elements are ranked by probability/frequency. Such elements do not offer a likely query refinement for the end-user and should be removed (or grouped in an “other” option) in order to make the most efficient use of the presentation space. For example, there is no point in showing a drill-down option that includes 97% of the result set, even though it is the most prominent value within the current result set. Likewise, a drill-down option that includes 1% of the result set is most likely not interesting when there are three options that each account for more than 20% of the result set.
Both the physical exclusion and the information overload reduces the usability and the effectiveness of portals, resulting in reduced turnover in an e-commerce setting, customers leaving the site and reduced stickiness, reduced productivity of employees, etc.
The cost of improving the usability for specific use cases by extending the layout rules is prohibitive with current systems. Moreover, the portal frameworks are not geared towards the cooperative information coordination between portlets. The idea of independent, reusable information components is good for the portal designer but tend to contradict the ease of information consumption unless there is a common cognitive model behind the portal (and the portlets). Simply including many information views (portlets), there is no guarantee that these are orthogonal views of the content in question, and the portal designer has no support from the portal framework to judge (and define rules) to present the content most effectively on the given screen real estate.
As systems for information access, search and retrieval are becoming more sophisticated with search engines that not only search the content and present a straightforward search result to the user, but also analyze, evaluate and rank the data and moreover are able to create navigation tools offering these for a user, and hence allow for improved discovery for instance of deep and hidden structures in the information content. However, the manner of presenting the results of search and search-derived applications adheres to traditional modes of presentation that does not support user cognition and the presentation of information in a degree that matches the evolving sophistication of systems for search, access and retrieval, or advanced search engines which have been or are being developed for powering such systems. Hence there is a need for optimizing the presentation of information in a user-centric context and particularly improving the presentation for a user.
SUMMARY OF THE INVENTION
The present invention concerns a method for composing and presenting information in a user context, wherein the information comprises content of documents accessed and retrieved in an information search, and wherein information shall be presented for the user on a man-machine interface in the form of a visual or graphic display of a given shape and area.
Particularly the present invention discloses a method for optimizing the screen real estate for an information consumer. The presentation space is reduced by removing irrelevant facets of the information in context and reordering elements such that the most likely elements are positioned in the areas of highest visual impact. Overall, the presentation of the information in context is more compact and less confusing than alternative systems, providing the information consumer with an appropriate high-level overview.
A first object of the present invention is thus to optimize the presentation of information.
A second object of the present invention is to determine the information measure of the retrieved information or content in such a manner that it reflects the information as perceived by human being presented with the content.
Finally, it is also an object of the present invention to take into account various user- and content-related constraints when an optimum content presentation is determined.
The above-mentioned object as well as further features and advantages are realized with a method which is characterized by steps for
a) determining a user context in which the information is required,
b) selecting a set of content sources,
c) populating a set of content components by retrieving and refining content components from the set of content sources,
d) computing component information in the content components by means of an information measure that reflects the information as perceived by human cognition,
e) determining and composing an optimum presentation of said content components subject to one or more of human cognition constraints, user context constraints, presentation constraints and content constraints, and
f) presenting said optimum presentation for the user.
Additional features and advantage of the present invention will be apparent from the appended dependent claims.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention shall be better understood from the following discussion of the general background of the invention, and the necessary conditions for its realization, as well as the disclosure of the method in detail and read in conjunction with the appended drawing figures, of which
FIG. 1 shows an example of information overflow, as mentioned above
FIG. 2 a typical precision vs. recall graph,
FIG. 3 document level result set navigators,
FIG. 4 contextual navigation for the query “soccer”,
FIG. 5 human information of choice as number of symbols—mapping traditional information to human-centric information,
FIG. 6 grouping noisy entries into a new “other” entry,
FIG. 7 (“Less is more”) a set of alternative choices of equal probability,
FIG. 8 schematically the process flow for an optimized information access.
FIG. 9 five example input navigators with ranking, and
FIG. 10 five example navigators transformed for human cognition.
DETAILED DESCRIPTION
Huge amounts of valuable business information are stored in enterprise systems and repositories. Business intelligence (BI) tools provide mechanisms and graphical user interfaces to this information in portal-like software products.
Information retrieval has traditionally involved the end user to formulate a query using Boolean operators—either using a query language or via graphical user interface. Execution of the query provides a search result that is a set of matching documents. This result set has generally been a classical crisp set of which a particular document is either a member or not a member.
Throughout this discussion the term “document” will be used to denote for any searchable object, and it could hence mean for instance a textual document, a document represented in XML, HTML, SGML, or an office format, a database object such as record, table, view, or query, or a multimedia object.
The search quality of the search system is quantified in precision and recall. Both measures assume a certain set of documents, P, is the appropriate result for a given query. The recall is the fraction of P returned in the result set R, i.e. |R∩|P/|P|. The precision is the fraction of R that is relevant, i.e. |R∩P|/|R|. Typical search systems have precision-recall curves showing a trade-off between precision and recall, as shown in FIG. 2 . Great precision is only achieved with poor recall and vice versa. The search system is tuned to offer acceptable precision and recall.
However, with huge content volumes where many documents share the same keywords, the result sets become too large to be efficiently presented to a human user. More recently, information retrieval systems calculate a relevance score as a function of the quality of the match between the query and the document, as well as including a priori probabilities that the document is valid for any query (e.g. page rank from Google). The search result is presented ranked according to this relevance score, showing the details of the documents with the highest relevance scores first, usually in hyperlinked pages of 10-20 documents. The concepts of recall and precision are not as clear-cut as for the crisp result sets above, but they still apply. Recall refers to getting relevant documents included in the search result and preferably on the top of the first result page. Precision involves not having irrelevant documents on the first result page.
The user interacts with an information retrieval system (a search engine) by analyzing the search result, viewing result documents, and reformulating the query. The search result is often too general, as the user does not generally know the extent of the collection of documents in the system and thus does not make the query specific enough (i.e. having poor precision). A common query reformulation is to make a query refinement, i.e. selecting a subset of the original search result set in order to improve the precision.
Very recently, information retrieval systems have included the concept of result set navigation (for instance as disclosed in Endeca U.S. Pat. Nos. 7,035,864, 7,062,483, and as used with the enterprise search system ESP™ of the present applicant Fast Search & Transfer AS). A document is associated with multiple attributes (e.g. price, weight, keywords) where each attribute has none, one, or in general multiple values. The attribute value distributions are presented as a frequency histogram either sorted on frequency or value. A navigator is a graphical user interface object that presents the frequency histogram for a given attribute, allowing the user to analyze the result set as well as select an attribute-value pair as a query refinement in a single click. The refinement is instantly executed, and the new result set is presented together with new navigators on the new result set. For example, a search for “skiing” may include a “Country” navigator on the “Country” document attribute (metadata). This navigator contains a value “Norway” suggesting that there is a substantial number of documents in the result set for “skiing” that are associated Norway. When the user selects the “Norway” option in the navigator, the system presents the subset of the “skiing” result set that is further limited to documents associated with Norway.
FIG. 3 shows how the query 301 gives a result set 302 together with navigators on document-level metadata 303 - 305 . In the example, a search 301 for surname “Thorsen” and first name “Torstein” allows the user to refine the first name among those in the result set 304 and to constrain the search to a part of the country 303 . For each of the refinements, the size of the result set if the refinement was to be applied is shown.
Navigation includes many concepts of data mining. Traditional data mining is on a static data set. With navigation, data mining is employed on a dynamic per-query result set. Each document attribute represents a dimension/facet in terms of data mining terminology.
Formally, given a query Q, a navigator N on the attribute a having values {v} across a set of documents D has N(Q,a,v) instances of value v. The set of values for attribute a in document d is d(a).
N ( Q,a,v )=|{ d in D:Q matches d, v in d ( a )}|
Both the attribute values v and the document hit count N(Q,a,v) are presented, typically sorted either on the values or document hit count.
Navigation is the application of result set aggregation in the context of a query where a result set summary is presented to the user as well as a query modifier that is incorporated in the query when the user selects a particular object in the summary. The presentation is a view of the result set along an attribute dimension and may include a quality indicator in addition to the attribute value, where the quality usually is the number of documents for a given attribute value or attribute value range.
The ideas below incorporate both aggregation in the general case and specifically the application to navigation. The aggregation can be presented without necessarily linking it to query refinements, or it may be the basis for statistical analysis without even being presented. Also, the information retrieval system may choose to automatically select such query refinements based on an analysis of the query, the result set, and the navigators/aggregations associated with the result set.
The document-global attributes (metadata) are either explicit in the document or structured database records or automatically discovered attributes in the unstructured content of a document using techniques from the field of information extraction. In hierarchical structured content (e.g. from XML), sub-document elements can be explicitly associated with attributes. Automatically extracted information can be associated at the global document level and at the contextual (sub-document) level, e.g. at sentence elements. The sub-document elements can be explicit in the content (e.g. paragraphs in HTML) or automatically detected (e.g. sentence detection). The distinction between attributes and elements is with respect to the visible content flow: the content of elements is visible whereas the attributes are invisible metadata on the elements. For example, the content of sentence elements is visible including entity sub-elements (e.g. person names), but the sentiment attribute on a sentence element should not interfere with the content flow, e.g. phrase search across sentences. Likewise, an entity element contains the original content while an attribute contains the normalized version of the content that is used for search and analysis. For example, the text “yesterday” is wrapped in a date entity with an attribute containing the concrete date value normalized to the ISO 8601 standard as derived from the context.
The present applicant has recently introduced a method for contextual navigation (Contextual Insight™) on sub-document elements, e.g. paragraphs and sentences as described in e.g. International published application No. WO 2006/121338, assigned to Fast Search & Transfer AS. Entities are extracted from e.g. sentences and marked up as sub-elements of the sentence elements or as attributes on the sentence elements. The search system allows e.g. specific sentences to be selected by a query and navigation on the sentence sub-elements/attributes. For example, a query may select sentences containing “Bill Clinton” in a “person_name” sub-element and present a navigator on the “date” sub-element of those sentences. Such navigators are found to be much more relevant than equivalent document-level navigators on entities extracted from unstructured natural language content.
FIG. 4 shows an example of contextual navigation and particularly aggregations of persons associated with the query “soccer” at the document 401 , paragraph 402 , and sentence level 403 , clearly showing semantically more correct aggregations at the paragraph and sentence contexts than at the document level.
Sometimes a user will request specify a detailed query, and the result set will have too specific (or none) documents (i.e. poor recall). Some search systems allow the user to simply increase the recall, e.g. by enabling lemmatization or stemming that enables matching of alternative surface forms, i.e. matching different tenses of verbs, singular/plural of nouns, etc. Other recall enhancing measures are enabling synonymy, going from a phrase search to an “all words” search, and going from an “all words” search to an “n of m” (or “any”) search. Spell checking may work either way, improving recall or precision.
In order to scale for high-volume applications, search solutions have developed from software libraries handling all aspects of the search linked into a single application running on one machine, to distributed search engine solutions where multiple, sometime thousands, machines are executing the queries received from external clients. This development allows the search engine to run in a separate environment and to distribute the problem in an optimal manner without having external constraints imposed by the application.
The basis for performance, scalability, and fault-tolerance is the partitioning of the searchable documents into partitions handled on separate machines, and the replication of these partitions on other machines. In the search engine, the query is analyzed and then dispatched to some or all the partitions, the results from each partition are merged, and the final result set is subject to post processing before being passed on to the search client. Performance and fault-tolerance is increased by replicating the data on new machines. The search engines scales for more content by adding new partitions.
Now the constructive realization and the central features of the method of the present invention shall be discussed in greater detail with main emphasis on embodiments of the access and presentation method based on using result set aggregations in the form of navigators and ranking in order to provide an optimum presentation.
Formally, a navigator n contains a set of |n| unique entries. An entry has a value i and has a probability n_i. The probability of an entry n_i is defined as the fraction of the documents in the current context (search result set) that has the value i for the facet used for the navigator n.
According to traditional information theory, the information in a navigator n is the entropy
H ( n )=−sum — i n — i log n — i
where n_i denotes the probability of value i in the navigator. To rank navigators based on this entropy alone is ineffective on a search result page; a navigator where each document in the result set has a unique value will have the highest entropy. Such a navigator occupies a huge presentation space and is practically useless for a human end-user. On the other hand, a single drill-down option offers very little information, and in particular, if all documents contains the entry (it has probability one), it has no value for drilling down.
Research shows that a human mentally maximally comprehends about 7 items in a given cognitive task. In cognitive psychology, George A. Miller coined the concept “The magical number seven, plus or minus two” in 1956, suggesting the channel capacity for human cognitive tasks is limited to 5-9 choices or around 2.8 bits of information.
The document model can contain many facets by which one may want to narrow the search via navigators. With limited computational resources (CPU, disk bandwidth, and network bandwidth) and screen real estate (both on desktops and on mobile devices) the challenge is to select the appropriate set of facets to evaluate and present to the end-user. Different queries will in general have different optimal presentation layouts, where the most useful navigators are positioned in the most visible locations on the screen real estate.
In the simplest form, the ideas of the present invention are applied to a set of navigators on a search result page. The traditional information is calculated in all navigators as per the definition above. This information measure is mapped through a bell-shaped function such that navigators with too little or too much information are degraded in the overall ranking of the navigators in a particular search result page. The presentation scheme can include as many navigators as fits on the page, given the transformed ranking, or the scheme can employ a threshold such that only high-quality navigators are included.
FIG. 5 shows an example of such a bell-shaped function mapping the traditional information measure to the human-centric information measure. The bell-shaped function is centered around 7 items (2.8 bits) with a width of approximately 2 items. The function is used to transform the traditional information measure of a navigator to a new rank value that better reflects the channel capacity of humans.
The present invention also teaches the targeting of a navigator for the presentation to a human search user. A navigator that contains more than 9 items can have some dominant entries that have information around 2-3 bits followed by several entries with low probability. These unlikely drill-down candidates at the tail of the navigator (assuming entries are ranked in high to low probability order) can be put in a new entry in the navigator named e.g. “Other”. Starting at the tail (lowest probability), the probability of the last entry is added to the “Other” bin and removed from the navigator. This procedure repeats until the traditional information measure is reduced to reach the criteria for human information consumption, e.g. less than 3 bits. In some cases, it may not be desirable to present the “Other” entry, in which case only the remaining original entries are presented.
FIG. 6 shows the probability profile of the entries in a typical navigator. The entries with the lowest probabilities are grouped into a new “Other” entry. When the user selects the “Other” entry, the query is narrowed to include the values contained in the “Other” entry, as for traditional navigation. Alternatively, the query is narrowed to exclude the values listed together with the “Other” entry. Overall, this scheme teaches how to reduce the noise, as perceived by humans, in navigators on a search result page.
The present invention includes a scheme for selecting the navigation entries by means of a threshold on the probability of the entry. For example, only entries with more than 10% probability are to be included. The remaining entries are grouped into an “other” bin, and the overall information of the new navigator is used for content component ranking and positioning.
Ranking navigators after targeting them for human cognition, some navigators will be targeted such that they are ranked higher, while some navigators will not be possible to target to the desired information range and thus remain at the tail of the navigator ranking. The present invention teaches that navigator ranking and further navigator properties as described below are used in the presentation system such that visual effectiveness is optimized subject to constraints such as device output capabilities, including graphical display and audio output, input capabilities, and bandwidth, etc.
Traditionally, hierarchical navigators are presented fully expanded, i.e. all leaf nodes are visible. In general, such a navigator will produce information overload for a human search user. The present invention also teaches the targeting of hierarchical navigators for human information. For example, where a branch contains 20 direct child options (with roughly same probability), only the branch is presented without any descendants—the probabilities of all descendants are accumulated into the probability of the branch. The screen estate is better used for branches that better discriminate the document space per area of screen estate. The principle above of inserting an “Other” entry in a navigator can be applied to each branch node in a hierarchical navigator. An alternative is to put all noise entries into a top-level “Other” entry or to remove them entirely, using the current algorithm for identifying noise entries. After grouping noisy entries, branches may be collapsed such that the information is lowered. Collapsing a branch may suddenly reduce the information too much, below e.g. 2 bits. The brute force approach is to try all combinations of branch collapsing and select the configuration that achieves the optimal information measure around 3 bits. In practice, more efficient optimization can be achieved with e.g. the principles of dynamic programming.
FIG. 7 shows a fully expanded hierarchical navigator 701 (on the right). It has too much information for a human to consume on the time scale that a user interacts with a search result page. Collapsing the least likely and noisy branches of the navigator 701 provides the transformed navigator 702 (in the center) which has sufficient information to make it interesting while not too much to make it difficult to comprehend. The navigator 702 can be further collapsed into navigator 703 (on the left) making it trivial and of no use, containing a single entry. The x-axis of the figure represents traditional information content. The figure also shows the human information receptivity peaking in the neighborhood for navigator 702 and having fairly low values for navigators 701 and 703 .
In the special case where a parent node contains only one child, the parent and the child can be merged into one node in order to save screen real estate. In particular, this approach saves one level of indentation space in the presentation.
The present invention further includes a scheme for selecting navigation entries (choices) by the means of optimizing the information density in a navigator (as well as in a composite presentation of content components, a “meta-navigator”). Each entry (choice) in a particular navigator usually consumes the same screen estate, typically presented as a line within that content component. As more noisy entries (with low probability) are included, the information density, i.e. information per entry, will drop. For all possible groupings of the lowest probability entries, the information density will reach a maximum value which will select the grouping level and the corresponding information density will be used as a navigator rank value.
The present invention also includes a scheme for using the information density as above relative to the information density from the same number of equiprobable entries providing the maximum information in that many entries. The examples show that selecting the peak in this measure as a basis for selecting the grouping level is a robust heuristic. The information density from this grouping level is used for content component ranking and presentation.
The formal definition of information density for a navigator n with |n| entries such that all entries with probability lower than the |n|−1′th entry (entries are sorted on descending n_i) are grouped into the kith entry (the “Other” bucket) is
h ( n )=−sum — i n — i log n — i/|n|
The information density factor is the ratio of the actual information density to the maximum possibly information density for the given |n|. The maximum information density is achieved with |n| equiprobable entries having the information log |n|. Thus, the information density factor is
f ( n )=−sum — i n — i log n — i/|n| log | n |
In summary, the present method searches for an N that, when transforming the navigator n to another navigator n(N) containing N entries (N<|n|) by aggregating noisy elements into a new entry (“Other”), maximizes the information density factor of the transformed navigator f(n(N)) and uses the information density of the transformed navigator h(n(N)) as the rank value for the transformed navigator.
Generally, only one of the original navigator n or the transformed navigator n(N) will be included in the overall ranking of navigators. However, both may be included in the overall navigator ranking but with the risk wasting screen estate and causing information overload. The variants of navigator ranking in the present invention can be normalized such that the best transformation alternative, from e.g. simple probability threshold, information density factor, etc, all compete for the presentation to the user. In general, the highest ranked transformation will exclude the other transformations of the same navigator.
The presentation of a navigator may for example take the form of a tag cloud (http://en.wikipedia.org/wiki/Tag_cloud). A tag cloud, unlike traditional navigators, is not presented as an explicit sequence. Rather, the entry probability is represented as the font size and boldness (as well as color, etc) of the value of the entry. The methods of the present invention still applies—the noisy entries are aggregated into a new “Other” entry that is presented in the cloud, thus making the information in the tag cloud more accessible to a human user.
The method of information density can be applied to hierarchical navigators. For each N, the method picks the graph configuration with the highest information density. The N with the highest information density factor is found, and the corresponding information density is used for ranking the hierarchical navigator among all other navigators.
FIG. 8 shows the processing of the search results, via aggregation and building navigators, to the presentation to the end user. The processing can be feed-forward, i.e. a presentation is made to a user in a given context, the user provides input which modifies the context, the search executes in a given context providing a result set of documents, aggregation and navigation is performed according to parameters in or derived from the context, and the rendering processes present the result of the user interaction to the user. In this scenario, the aggregation and building of navigators has cues from the context as to what criteria to use for navigator transformation and ranking. The rendering process uses essentially the navigator ranking for selecting the best presentation.
FIG. 8 also shows the integrated processing of search, aggregation, and rendering. Rather than optimizing locally in aggregation on the navigators returned from the search, there may be global optimization across aggregation and rendering. Rendering may e.g. use different font size on the navigators which will enter the information density measure. Above, average information per entry was used as a criterion, assuming fixed font size for presentation, but for variable sized navigators, e.g. tag clouds, a more appropriate measure is the information per screen area. The overall size of a tag cloud is determined by both the aggregation and the rendering, thus requiring tightly coupled optimization. For audio output, e.g. in mobile search, the corresponding measure would be information per unit of time. The interaction between aggregation of navigators and rendering will find optimal multi-modal rendering of the search result on e.g. screen and audio.
FIG. 9 shows some example country navigators as returned from different queries to the search engine, i.e. sorted in descending probability (hit count) order. Navigator 901 shows a handful of relevant entries followed by a number of noisy elements. Navigator 902 shows that about half the documents hit “USA” and about half many other countries. Navigator 903 has many entries with approximately the same probability (hit count) followed by a few noisy entries. Navigators 904 and 905 have 7 and 15, respectively, equiprobable entries. All these navigators except navigator 904 would be classified as noisy and far from optimal being presented as is to the human user. The traditional information in these navigators is shown as a navigator rank order in 906 . The same facet would not compete against itself in such a rank order, but this rank order serves to compare the ranking as if navigators were appearing from different facets in the same search result.
FIG. 10 shows the example country navigators after being transformed to maximal information density. In navigator 1001 , the entries in navigator 901 from “Germany” onwards are grouped into “Other” yielding a navigator with 6 entries, down from 15 in navigator 901 . In navigator 1002 , all entries in navigator 902 except “USA” are put into “Other”, yielding a navigator with two roughly equally likely entries having an information measure of approximately 1.0 and information density of 0.5 as navigator 1002 occupies two lines. Transforming navigator 903 yields navigator 1003 —the current method yields 10 entries with the grouping in “Other” starting where the fall-off in probability starts in navigator 903 . The equiprobable navigators 904 and 905 are transformed into navigators 1004 and 1005 , respectively. Navigator 1004 is identical to navigator 904 while navigator 1005 is cut down to 5 entries.
Ten entries in navigator 1003 are on the high side given the limits suggested by Miller, as mentioned above. The information densities in the transformed navigators are shown in the navigator ranking 1006 . Navigator 1003 achieves a low score as it has a low information density due to relatively many entries. It is likely that there will exist better and more valuable navigators for that particular search result set than navigator 1003 . Navigators 904 / 1004 and 905 have maximum information for their respective number of entries, but neither achieves the top ranking. Navigators 904 / 1004 looses to navigators with less entries, thus achieving higher information density. Navigator 1005 is ranked down due to imbalanced probabilities.
Traditionally, the document hit list has claimed the dominant presentation space for a search result. Navigators tend to be presented at the sides of a major area reserved for the hit list. Based on usage data, including click-through data in the search engine and web server (browse) statistics, a-priori probabilities, reasoning within the search engine, publishing logic (e.g. promotions), probabilities can be assigned to each document presented in the hit list, and the information can be calculated. The hit list can be ranked among the navigators, allowing particularly valuable navigators for this search to take some or all of the presentation space traditionally reserved for the hit list.
The search hit list and the navigators are all content components in a portal framework. The methods of the present invention can be applied to all such content components where query-specific, conditional, or a priori probabilities can be assigned to the content. These content components can be thus be ranked and assigned appropriate presentation space subject to the rendering constraints—as imposed by the device, the user (for example being visually impaired), available rendering modalities, the context, etc.
Examples of Applications
Mobile search: The presentation method according to the present invention will provide a optimum exploitation of the rather small screens of mobile devices and also take into account that the input capabilities whether via keyboard or display usually are limited and often has to be undertaken in a manner “peculiar” to mobile devices. Moreover, search and presentation on mobile device could also exploit possibilities for audio output and input.
Shopping including e-commerce: A general problem here is aligning sales with inventory. For instance in an e-commerce setting it is desirable to tailor the search experience in such a manner that the number of clicks the user has to go through between entering a query and finding an item to buy, is minimized This is thought to be conducive for optimizing the conversion rate of a site, i.e. the proportion of customers to the site that actually ends up making a purchase from the site. The minimization can be achieved by providing logic in the presentation such that an aggregation, for instance a navigator in the presentation, makes sense relative to the query and enables customers to quickly narrow in on an item offered for sale. The general idea is that the method of the present invention can be optimized in such a manner that a customer hangs on to the site if the presentation creates an overall impression of the effectiveness of a purchase process. Classified advertisements: Generally navigators are the main user interface, but the method of presentation according to the present invention is of course not limited to aggregations such as navigators, but when the latter are used for classified advertisement the presentation should be optimized so as to provide a high quality response. News search: News presented as text are highly dynamic and queries might be quite wide-ranging, so an optimum presentation method will be highly desirable. Media search and search in rich content: Here the information is of course not limited to text, but may comprise images, video and audio and an optimum presentation should be able to integrate search results so as to present the user with choices from different types of sources, and yet offering the user a clearly set out and easy to follow view of the search results. Business Intelligence: A presentation is optimized taking into account that business intelligence (BI) reports usually are static, predefined and directed to a rather narrow group of users.
Conclusions
The method according to the present invention offers a number of advantages not provided in the prior art. This includes i.a. the following:
Ranking of navigators based on user data and the information content of navigators. Automated algorithms that shall improve discovery via navigators. Optimal navigators for each query even if the latter is unpredictable. An improved and more discriminatory use of the screen or display estate. Screen clutter that is never or seldom used can be removed or re-used by applying tools for improved discovery. User behaviour can be fed back in a loop to improve screen or display utilization usage.
In addition the method according to the present invention could apply parameters for automatic choice and placement of content components, including navigators on the screen and generally applied to follow the rule that the highest valued navigator shall be given the most prominent place in the presentation.
As persons skilled in the art readily will understand, the method according to the present invention offer a number of possibilities with regard to further developments of accessing and presenting information in a human-centric context. For instance it should be possible to profile data with metadata summaries at global and contextual level. Dynamic programming could be applied for optimizing screen usage and it would be possible to provide human information navigators.
Another highly interesting prospect is the possibility of aggregating hierarchical alternatives in the form of hierarchical navigators. Only the alternative that matches the overall aggregation is used.
However, as persons skilled in the art also may understand, some of the perspective and outlooks mentioned here would fall outside the scope of the present invention. Finally, it should be noted that the exemplary embodiments thereof given hereinabove have their main emphasis on content components comprising aggregation in the form of navigators, but the presentation could just as well include other content components, such as for instance search query feedback and aggregation of scopes. | In a method for composing and presenting information in a user context, the information shall be presented for the user on a man-machine interface in the form of a visual or graphic display. The method comprises steps for determining a user context in which the information is required, selecting a set of content sources, and the content components are retrieved from the content sources. The information in selected content components are computed using an information measure that reflects the information as perceived by human cognition, and an optimum presentation of the selected content components are determined and presented for the user. | 6 |
CROSS-REFERENCE TO RELATED APPLICATION
This application is a continuation-in-part of copending application Ser. No. 214,250, filed Dec. 8, 1980.
BACKGROUND OF THE INVENTION
The present invention relates to a supporting grid system for suspended ceilings and, more particularly, to an improvement in the construction of the ceiling tile supporting members which coact to define the suspended ceiling supporting network.
The use of suspended ceilings in building construction is well known. One mode of construction provides a metal framework with longitudinal runners and lateral cross members or runners disposed at right-angles thereto and fitted together in a lattice or grid network to thereby define plurality of modular openings. The framework is supported by hangers from overhead structure and functions to support ceiling tiles or panels, fluorescent light fixtures, ventilation fixtures, and the like.
The runners and cross runners are usually of inverted T-shape with a pair of horizontally disposed flanges on opposite sides of a central upstanding, vertically disposed web section. The flanges are relatively wide in order to support the ceiling tiles while permitting sufficient clearance or tolerance between the edges of the tiles and the web sections. Architects frequently object to the appearance presented by such exposed flanges, and seek alternatives.
Various prior constructions have been proposed in an attempt to present a pleasing, thin outline for the exposed portions of the suspended ceiling tiles. One such construction incorporates a relatively wide tile supporting flange but attempts to hide the same from view by employing L-shaped lips extending below the tile supporting flange and directed inwardly toward the upstanding web of the inverted T main runner or cross runner. In this construction, rabbet-edged ceiling tiles are employed to rest on the flange and depend downwardly therefrom, substantially flush with the L-shaped lip.
Another known construction, also employing rabbet-edged tiles, provides extruded metal runners and cross runners; each having inverted U-shaped tile supporting flanges, with the metal thicknesses of the legs thereof serving as the exposed outline for the suspended ceiling.
SUMMARY OF THE INVENTION
The foregoing problems of prior art constructions, as well as others not specifically mentioned, are overcome according to the teachings of the present invention which provides a framework or grid for suspended ceilings wherein the tile supporting flanges of the main runners and the cross runners are relatively thin in width to provide an aesthetically pleasing appearance: while, at the same time, functioning to firmly and uniformly support the ceiling tiles in such a manner that the same are automatically centered within the modular opening. The use of standard-sized, straight-edged tiles is permitted, if desired, without any need to provide sufficient clearance to avoid lateral shifting and possible fall-through of the tiles. Further, the structure of the present invention precludes the necessity of, and saves the added cost of, providing additional structure to hide from view the wide flanges of prior constructions.
The invention also incorporates in the main runners and/or the cross runners relatively simple and inexpensive structure to permit lighting fixtures and the like to be easily and effectively hung therefrom, without the need for providing specially designed, costly adapters as typified by prior art constructions.
It is a further feature of this invention to provide an efficient and effective arrangement for splicing or joining main runners in abutting end to end relationship, and for securely locking the cross runners to each other in intersecting relation to the main runners.
More specifically, the main runners and the cross a pair of resilient webs depending downwardly and outwardly from an upper tubular bulb portion to a horizontally disposed, reduced-width, tile supporting flange portion at the lower extremity of each web. The flange portions are resiliently biased in an outward direction by the webs such that supporting forces are exerted on the ceiling tiles to thereby automatically center the same and uniformly support the same in their assembled position. In this manner, thin-line, exposed flanges are observable to present a pleasing appearance without any sacrifice in the tile supporting requirements of the flanges. The interior space between the webs may be prepainted with the same color as the exposed flanges or with a contrasting color. In either case, from an observer's point of view an aesthetically pleasing grid network is presented.
The interior walls of the webs may be provided with screw-fastener guide means to permit easy installation of lighting fixtures and the like. Such guide means may preferably comprise a plurality of relatively short curved recesses in the interior facing walls of each of the webs and extending downwardly and outwardly therewith to provide a composite tubular opening sufficient to receive and guide the screw-fastener into position.
A clip member engageable with the runner members is provided to underlie the areas of interconnection of the runner members and the cross members to thereby give the appearance of an uninterrupted recess in the cross members. The clip includes a flat portion, an inverted, upwardly extending substantially U-shaped portion in the flat portion, and an upwardly extending arm at each of the outer ends of the flat portion. The arms include inwardly directed gripping means to engage the outer edge of the legs of a runner member, and the U-shaped portion engages the inner surfaces of the legs of the runner members.
Other characterizing features and advantages of the present invention will become apparent as the detailed description thereof proceeds.
BRIEF DESCRIPTION OF THE DRAWINGS
For a fuller understanding of the invention reference should now be made to the following detailed description thereof taken in conjunction with the accompanying drawings, wherein:
FIG. 1 is an enlarged side elevational view of a main runner section constructed in accordance with the invention, with parts thereof broken away for ease of illustration;
FIG. 2 is an end elevational view of the runner looking in the direction of line 2--2 of FIG. 1;
FIG. 3 is a side elevational view, with parts thereof broken away, depicting a splice or connection between two main runners, each of which is characterized by the runner depicted in FIG. 1;
FIG. 4 is a cross-sectional view taken substantially along line 4--4 of FIG. 3;
FIG. 5 is an enlarged side elevational view of a cross runner constructed in accordance with the invention, with parts thereof broken away for ease of illustration;
FIG. 6 is an end elevational view of the cross runner looking in the direction of line 6--6 of FIG. 5;
FIG. 7 is a partial fragmentary view of the main runner of FIG. 1 depicting one of a plurality of spaced slots in the webs thereof for receipt of adjacent cross runner
FIG. 8 is a fragmentary elevational view of adjacent cross runners in operative engagement with each other and with their intersecting main runner;
FIG. 9 is a cross-sectional view taken along line 9--9 of FIG. 8;
FIG. 10 is a fragmentary side elevational view of a main runner or a cross runner depicting the application thereto of means for guiding fixture-holding fasteners;
FIG. 11 is a vertical cross-sectional view of one of the main runners or one of the cross runners depicting the manner in which a fixture is affixed thereto;
FIG. 12 is a fragmentary view of the assembled adjacent cross runner sections depicting the application of a clip means for blocking from view the coupling structure which locks each of such cross runners together:
FIG. 13 is a bottom fragmentary view looking in the direction of line 13--13 of FIG. 12:
FIG. 14 is a fragmentary cross-sectional view of one of the main runners or cross runners depicting support of a standard size square-edged ceiling tile and a slightly modified flange construction;
FIG. 15 is a view similar to FIG. 14 but depicting optional support of a rabbet-edged ceiling tile;
FIG. 16 is a fragmentary cross-sectional view of the assembled adjacent cross runner sections depicting the application of an alternative structure for a clip means for blocking from view the coupling structure which locks each of the cross runners together;
FIG. 17 is a bottom fragmentary view looking in the direction of line 17--17 of FIG. 16;
FIG. 18 is a fragmentary side view, partially in section, looking in the direction of line 18--18 of FIG. 16.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to the drawings in detail and, more particularly, to FIGS. 1-4, a main supporting runner, generally depicted at 10, is formed to provide an upper tubular reinforcing bulb 12 of substantially circular cross-section (although other cross-sectional shapes would suffice), a pair of resilient webs 14 depending downwardly and outwardly from bulb 12 in substantial inverted V fashion, and horizontally disposed tile supporting flanges 16 integrally connecting to the lower extremities of each of webs 14 and extending outwardly therefrom. Main runner 10 can be fabricated from any single piece of any suitable material, such as thin gauge steel; however, the same is preferably rolled, folded and stamped from soft steel or the like. Alternatively, other well known methods of fabrication may be employed. The webs are inherently spring biased with a "memory" that causes them to normally maintain their spread apart position and, as such, they will offer an outward biasing force in response to inward movements.
At their opposite longitudinal ends each web 14 is integrally provided with suitable splicing or clip means to permit adjacent main runners to be rigidly joined in abutting and aligned relationship, while effectively preventing any relative twisting therebetween. To this end, one pair of web ends 18 are provided with suitable locking projection tabs or stabs 20 slightly pressed from the plane of its respective web in one lateral direction and projecting outwardly therefrom to define an upper edge surface 22, a reduced length lower surface 24, and a forward edge surface 26 upwardly and outwardly directed from lower edge surface 24 to upper surface 22 via an outwardly curved guiding edge surface 28. An elongated central reinforcing rib 30 is pressed slightly out of the plane of stab 20 in said one lateral direction and contains at its end adjacent outer edge surface 26 a laterally curved, planar edged locking element 32 protruding from the plane of stab 20 in an opposite lateral direction to thereby define an abutment or stop 34.
Each stab 20 further includes a tongue 35 pressed out of the plane thereof in one lateral direction leaving an abutment edge 36 that is substantially aligned with the projecting leading edge surfaces of the stab and is spaced inwardly of stop 34.
The opposite pair of web ends 38 are each provided with similar locking projection tabs or stabs 20a, except that the same (including projecting edge surfaces 22a, 22a, 26a and 28a reinforcing rib 30a, locking element 32a, stop 34a and tongue 35a) are slightly offset in lateral directions that are opposite to that of their corresponding structure on web ends 18. As depicted in FIGS. 3 and 4, the arrangement is such that when adjacent main runner sections are brought together, the stabs on one pair of web ends 18 are guided through the tongues on the other pair of web ends 38 whereby the abutments 34 snap into locking engagement with the abutment edges 36a and the stabs on the other pair of web ends 38 are guided through the tongues on the other pair of web ends 18 whereby the abutments 34a snap into locking engagement with the abutment edges 36, thereby providing a main runner splice.
Referring to FIGS. 5 and 6, the cross runners, generally depicted at 40, are provided with a reinforcing tubular bulb 42, a pair of resilient webs 44 and horizontally disposed tile supporting flanges 46 which are all formed in a manner similar to that of main runner 10; therefore, no further description of these elements is deemed necessary. At opposite longitudinal ends thereof each of the webs 44 are provided with suitable locking connectors, generally designated at 48, 48a, which, respectively project outwardly from their respective ends and are formed integral therewith. It should be noted that connectors 48, 48a at opposite ends of each cross runner 40 are slightly offset from the plane of their respective webs 44 in opposite lateral directions and are provided with substantially hook-shaped tabs defined by a leading curved edge 50, 50a; a flat bottom edge 52, 52a; and a web-gripping edge 53, 53a which, respectively, connects edges 50, 50a to edges 52, 52a. It should be noted that edges 53, 53a are inclined to follow the inclination angles of each of the main runner webs 14, as will become apparent hereinbelow. Each connector 48, 48a further includes transverse through openings 54, 54a located adjacent their respective curved edges 50, 50a. Also provided are catches 56, 56a aligned with and inwardly spaced from their respective openings 54, 54a. Catches 56 at one end of cross runners 40 may be suitably pressed out of the plane of each of the connectors 48 in one lateral direction, whereas catches 56a at the other end of cross runners 40 may be suitably pressed out of the plane of each of the connectors 48a in the opposite lateral direction. Such lateral offsetting of the catches 56, 56a provide the same with curved abutment edges 58, 58a, respectively.
Turning to FIGS. 7-9, each main runner web 14 is provided with a plurality of longitudinally spaced cross runner slots 60 (only one of which being illustrated); the slots on one web being disposed for alignment with their corresponding slots on the other web. Each slot 60 is formed with a pair of curved side edges 62, a flat upper edge 64 and a notched lower edge 66 to thereby define substantially the profile of an inverted bottle. The spacing between top edge 64 and the bottom of lower edge 66 substantially corresponds to the vertical extent of the leading curved edges 50, 50a of the connectors 48, 48a.
Adjacent cross runners 40 may be rigidly coupled to each other through slot 60 in locking engagement therewith to define the intersecting grid structure for supporting the ceiling tiles. Alternatively, only one cross runner may be locked through the slot 60, if desired or required. More specifically, as adjacent cross runners are joined together through slots 60 adjacent aligned connectors 48, 48a on each are snap-locked together by engagement of openings 54, 54a with their respective abutment edges 58a, 58 of catches 56a, 56, respectively, as clearly indicated in FIG. 9.
As the curved leading edges 50 and the curved leading edges 50a of their respective connectors are brought into contact with their respective slots 60 the same are engaged by the side edges 62 which cause connectors to compress to the width of the bottom notch 66. When each connector edge surface 53, 53a passes through both aligned slots, the connectors are free to expand to their normal position with the top edges 52, 52a thereof resting on slot side edges 62 above notch 66 and with edge surfaces 53, 53a gripping their respective main runner webs along a surface of the webs on each side of slot edges 62 adjacent notch 66. In this manner, opposite pull through of the cross runners is prevented unless the webs are deliberately compressed to permit the connectors to pass through notch 66 of the slot. Thus, the relationship between the connectors and the slots is such as to permit automatic straight-through insertion without the necessity of any manual squeezing of the cross runner webs. In their assembled position the cross runner flanges 46 are maintained substantially coplanar or flush with the main runner flanges 16 by means of an offset or relieved portion 68 on the ends of cross runner flanges 46.
As illustrated in FIG. 7, each main runner web 14 may be provided with a plurality of longitudinally spaced openings 70. Suitable hangers H may pass through selected openings 70 for suspending the main runners from overhead support structure, as is conventional.
It should be apparent, from the structure of the present invention as thus far described, that the tile supporting flanges on the main runners and the cross runners are substantially narrower (in a lateral sense) than would be required in constructions employing conventional inverted T-shaped members. Whereas in a conventional inverted T construction the flanges on each side of the web must be sized to permit sufficient tolerance within the modular grid for adequate support of the tile, the flanges of the present invention need only be of a size sufficient for the actual support of the tile and not any larger to provide for such tolerances as typified by prior art constructions. It should be understood that the spring action of the resilient webs, on the main runners and the cross runners, provides or permits automatic centering and support of the tiles without any need for greater flange widths. Moreover, no additional structure is required to hide the actual supporting flanges from view to give the appearance of a narrower grid network. Further, in the event of slight tile shrinkage due to fire or other sources of high heat, the resilient webs will expand to permit the flanges to move outwardly for continued tile support.
It is a further feature of the present invention to provide a simple and effective means for permitting lighting fixtures and the like to be supported from either the main runners or the cross runners without any need for special adaptors or the like.
Prior to a discussion of such means as depicted in FIGS. 10 and 11 and to such other features or arrangements as depicted in FIGS. 14 and 15, it should be noted that these Figures depict main runner and/or cross runner structure. Therefore, generic designation shall be employed to indicate various parts of such structure that are clearly common to both main runners and cross runners.
Thus, turning to FIGS. 10 and 11, the web W of either a main runner or a cross runner may be provided with a plurality of adjacent recesses or serrations 72. Each recess 72 is preferably formed integral with its respective web and pressed out of the inner surfaces thereof adjacent the bulb portion B to extend downwardly and outwardly therefrom to a point between the upper and lower extremities of the webs. Recesses 72 on each web W are disposed for alignment with corresponding recesses on the opposite web to thereby define composite channels or tubular openings for guiding and receiving suitable fasteners or metal screws 74. As depicted in FIG. 11, the arrangement is such that a fixture or a support S for a partition head channel or the like may be brought into engagement with ceiling tiles T and affixed to runner bulbs B by means of the sheet metal screw or the like 74 which is guided through the composite openings defined by the facing recesses 72 and secured through the bulb portion B.
As depicted in FIGS. 12 and 13, the present invention further contemplates the employment of a suitable means to maintain the thin-line, exposed grid appearance in the locations where the cross runners intersect the main runners. To this end, a clip, generally designated at 76, is provided to substantially span the gap between the flanges 46 of adjacent connected cross runners 40. More specifically, clip 76 is fabricated of a suitable resilient, spring-like material and has a pair of upwardly and outwardly directed snap fingers 78 connecting to a pair of substantially planar horizontally disposed sections 80 which, in turn, connect to an upwardly directed and centrally located substantially inverted U-shaped portion 82 extending upwardly into the space between main runner webs 14. The arrangement is such that spring fingers 78 removably snap onto the outer edges of main runner flanges 16 to permit clip 76 to bridge the space between adjacent connecting cross runners 40 whereby the connecting or coupling structure thereof is hidden from view. Thus, the continuity of the outline of the grid network is preserved as normally seen from an observer's point of view. Inverted U-shaped portion 82 functions to simulate the appearance of the shadow space formed between the inner surfaces of oppositely inclined main runner webs 14.
As noted earlier, the exposed surfaces of flanges 16 and 46 may be prepainted or coated prior to forming with a color contrasting to that of the space between their respective webs 14 and 44. In which case, the main runners and the cross runners would have their flanges folded in such a manner as to reverse the surfaces thereof to enable one color to appear between the webs and the contrasting color exposed on the flanges. This folding arrangement has been disclosed throughout the drawings but is highlighted at F in FIG. 15. However, if it were desired to expose the same colors between the webs and on the exposed portions of the flanges, then the flanges could be folded opposite to the folds of FIG. 15 as depicted at F' in FIG. 14.
FIG. 15 also illustrates the optional employment of rabbet-edged ceiling tiles T' for support by the main runner flanges and the cross runner flanges.
Another embodiment of a clip structure suitable for use in connection with the present invention is shown in FIGS. 16, 17, and 18. The clip member 76 there shown is somewhat similar to the clip member illustrated in FIGS. 12 and 13, except that the former includes a differently configured, upwardly directed, centrally located substantially inverted U-shaped portion 82. In this embodiment U-shaped portion 82 has a greater width than the corresponding portion of the earlier embodiment, and it is adapted to contact the inner surfaces of the webs 14 to thereby define a minimum separation angle for the webs. This particular feature is advantageous in situations where the webs do not diverge outwardly sufficiently because of a loss of spring in reinforcing bulb 12 of runner member 10, and the combination of the U-shaped portion 82 with the upwardly and outwardly directed snap fingers 78 defines a pair of spaced openings to receive supporting flanges 16 of webs 14 and thereby space them at a predetermined distance. As in the embodiment of FIGS. 12 and 13, each of planar, horizontally disposed sections 80 interconnects one of snap fingers 78 with U-shaped portion 82.
As best seen in FIG. 17, when clip 76 is in position on runner 10, it preferably is in alignment with the longitudinal axis of cross runner 40, which also has an upwardly directed recess defined by cross runner flanges 46. The recesses provided in the runner and cross members are for decorative purposes in that they provide a contrasting linear element which adds to the visual appeal of the grid structure. The discontinuity in the cross member recess at the point where the cross members intersect the runner members is masked by providing clip 76 of a generally dark color to correspond with the color in the longitudinal recesses. When so colored, clip 76 appears from a distance to be a part of the recess and renders the appearance of the cross member recess essentially continuous. In addition to serving to impart visual continuity to the cross member recess, clip 76 preferably also is of such a width as to define a minimum spacing between the webs of the adjacent cross runner members. Thus clip 76 establishes the minimum lateral spacing between tile supporting flanges 16 of runner member 10 and between tile supporting flanges 46 of cross runners 40 and thereby maintains a consistent and uniform spacing therebetween to provide a more visually appealing grid structure.
Referring now to FIG. 18, snap fingers 78 each include an inwardly recessed portion in the side edges thereof in order to provide a space to accommodate inwardly directed wrinkles which may develop in the course of the manufacture of the cross members adjacent the intersection of the web members and the outwardly directed flanges. Preferably, the recessed portions define inwardly bowed areas and are positioned between the upper and lower edges of fingers 78.
Although preferred embodiments of the present invention have been disclosed and described in detail, changes will obviously occur to those skilled in the art. It is, therefore, intended that the present invention is to be limited only by the scope of the appended claims. | A clip member is disclosed for underlying the areas of interconnection of main and cross runner members of a grid system for suspended ceilings. The runner members include downwardly opening recesses between their respective tile supporting flanges, and the clip member provides the appearance of an uninterrupted recess in the cross members at the areas of interconnection. | 4 |
[0001] This application is filed within one year of, and claims priority to Provisional Application Ser. No. 62/072,904, filed Oct. 30, 2014.
[0002] This application is a continuation-in-part of application Ser. No. 13/603,081, filed Sep. 4, 2012; status: Now Pending—hereinafter referred to as the “parent” application.
BACKGROUND OF THE INVENTION
[0003] 1. Field of the Invention
[0004] This invention relates generally to skin care appliances and, more specifically, to a Handheld Motorized Facial Brush Having Three Floating Heads.
[0005] 2. Description of Related Art
[0006] Facial massage, cleansing, treatment and exfoliation devices have become widely available for home use. Despite their wide variety, there remains to be a multi-headed brush/massage device for preparing a man's face for shaving. Some relevant examples of prior devices are described below.
[0007] Glucksman, et al., U.S. Pat. No. 7,270,641 for “Apparatus for Abrading Hair and Exfoliating Skin” describes a handheld device having three rotating disks. Each disk is configured with a covering of hook-and-loop fastener material for engaging abrasive pads. The pads are designed for removing hair and abrading the skin. The Glucksman device has individually “floating” heads that are permanently attached to the drive housing. The disks are not removeable from the housing/drive mechanism, nor do they float as an assembly on a single drive shaft. Furthermore, Glucksman would not work with brush or sponge applicators, because neither is functional with the hook-and-loop fastener attachment system.
[0008] Podolsky, U.S. Pat. No. 5,725,483 for “Massaging Device” is a motorized device having three rotating/translating balls for the application of shaving cream. The Podolsky device, however, does not suggest the use of brushes or sponges, nor does it include interchangeable and/or floating treatment heads.
[0009] Tsang, U.S. Pat. No. 6,032,313 for “Household Applicance ./. .” describes a motorized brush having concentric rotating brush rings, or side-by-side translating brushes. While the heads are detachable, they do not float as a single assembly, nor are each heads rotating separate from one another.
[0010] DeLuca et al., U.S. Pat. No. 5,103,809 for “Massaging Device” that has a plurality of rotating massage fingers dispersed around a stationary massage head, or stationary fingers dispersed around a rotating massage head. While the head is interchangeable, it does not float as an assembly. Furthermore, the “massage fingers” are not detachable from the massage head. There is further no suggestion of using bristle brushes or sponges in place of the elongate massage fingers.
SUMMARY OF THE INVENTION
[0011] In light of the aforementioned problems associated with the prior devices, it is an object of the present invention to provide a Handheld Motorized Facial Brush Having Three Floating Heads. The motorized device should be able to generate rotational, oscillating or vibrating motion at a plurality of micro-treatment heads. The microheads should be interchangeable, and be selectable from a group including bristle brushes, sponge applicator, silicone massage finger/element, among others. The device should have a detachable three-headed treatment head assembly that interlocks to the main handle housing by twist-lock or other mechanism. The treatment head assembly should have an option of being pivotally attached to the handle housing in order to allow it to closely follow the contours of the user's face. Finally, the device should have internal batteries that are rechargable.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] The objects and features of the present invention, which are believed to be novel, are set forth with particularity in the appended claims. The present invention, both as to its organization and manner of operation, together with further objects and advantages, may best be understood by reference to the following description, taken in connection with the accompanying drawings, of which:
[0013] FIG. 1 is a front perspective view of a preferred embodiment of the handheld motorized facial brush having floating heads of the present invention;
[0014] FIG. 2 is a rear perspective view of the device of FIG. 1 ;
[0015] FIG. 3A is rear perspective view, FIG. 3B is a cutaway side view, and FIG. 3C is a front perspective view of the device of FIGS. 1 and 2 ;
[0016] FIG. 4 is a perspective view of the treatment head base of FIG. 3 ;
[0017] FIG. 5 is a cutaway side view of the motor and battery components of the device of FIGS. 1 and 2 ;
[0018] FIG. 6 is a perspective view of a conventional rotary shaver head assembly; and
[0019] FIGS. 7A-7B are perspective views of preferred embodiments of the members of the group of microheads attachable to the device of FIG. 1 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0020] The following description is provided to enable any person skilled in the art to make and use the invention and sets forth the best modes contemplated by the inventor of carrying out his invention. Various modifications, however, will remain readily apparent to those skilled in the art, since the generic principles of the present invention have been defined herein specifically to provide a Handheld Motorized Facial Brush Having Three Floating Heads.
[0021] The present invention can best be understood by initial consideration of FIG. 1 . 1 FIG. 1 is a front perspective view of a preferred embodiment of the handheld motorized facial brush having floating heads 10 of the present invention. While it is entitled “brush,” it must be understood that the device 10 can comprise a plurality of brushes as shown, but also sponges, silicone massaging elements, and other treatment elements. 1 As used throughout this disclosure, element numbers enclosed in square brackets [ ] indicates that the referenced element is not shown in the instant drawing figure, but rather is displayed elsewhere in another drawing figure.
[0022] The device 10 has two main parts or assemblies: the main housing 12 , within which the power supply and drive motor are housed (and the controllers/displays therefor), and the treatment head assembly 14 , which receives rotational input from the drive motor (not shown) through the motor drive interface 16 extending from the main housing 12 .
[0023] The main housing 12 preferably has a charging socket at its tip 18 to charge the internal batteries. Control switch 20 allows the user to turn on and off the operating features of the device 10 . The device 10 may provide rotational output at the treatment head assembly 14 , as well as oscillating motion, and simple vibration of the assembly 14 (or some combination of these features, depending on user selection by the control switch 20 ). The indicator lights 22 provide the user with a display indicating the operating mode of the device, and perhaps the battery/charging status.
[0024] The treatment head assembly 14 receives rotational or oscillating input from the motor drive interface 16 . Gearing within the treatment head base 22 transfers the mechanical input from the interface 16 and splits it into the three microheads 24 shown, so that the microheads 24 rotate in direction “M” (or oscillate, etc.). The treatment head base 22 remains stationary while the microheads 24 move, however, the interface 16 may allow for the treatment head assembly 14 to pivot or float relative to the main housing 12 , in order that the microheads 24 can more adequately follow the contours of the user's face. The structure facilitating the pivoting/floating will be selected from one of the designs disclosed in the Parent Application—the disclosures therein being incorporated herein by reference. FIG. 2 provides additional detail regarding this novel device 10 .
[0025] FIG. 2 is a rear perspective view of the device 10 of FIG. 1 . Here, sponge microheads 24 A have been installed on the base 22 . Sponges 24 A may be preferred where a less aggressive massage/conditioning experience is desired. A pivot subassembly 26 (from the Parent Application) extends from the top of the housing through the shoulder face 28 . The pivot subassembly 26 will permit the base 22 to tilt/float in direction “P,” when the device 10 has the integrated pivot assembly 26 (an optional feature). The electrical socket 13 is preferably provided at the tip 18 of the main housing 12 . FIG. 3 provides additional detail regarding the features of this invention.
[0026] FIG. 3 are perspective and cutaway side views of the treatment head assembly 22 of the device [ 10 ] of FIGS. 1 and 2 . In this depiction, brush microheads 24 B have been attached to the base 22 of the assembly 14 . The pivot assembly 26 extends from the rear housing 30 B and terminates in interlock sleeve 32 . The interlock sleeve 32 is cooperatively designed to be attachable to a corresponding structure extending from the shoulder face [ 28 ] of the main housing [ 12 ]. A twist-lock and twist-unlock design has been found to be suitable for this structure, however other designs that do not permit rotation between the housing [ 12 ] and the treatment head assembly 14 are also likely to be acceptable.
[0027] The interlock sleeve 32 may have interlock slots 34 formed therein (to interact with structure on the housing [ 12 ]. Drive shaft 36 is centered within the interlock sleeve 32 . The drive shaft 36 engages the motor drive interface [ 16 ] such that motion of the motor drive (not shown) will also drive the shaft 36 to cause the microheads [ 24 ] to rotate/oscillate/vibrate.
[0028] The microheads 24 B extend from the front housing 30 A, and are comprised of a plurality of bristle elements 40 extending from a microhead base 38 . Whether the microheads are sponge, silicone or other structure, they all have the same microhead base 38 (at least as it applies to their engagement with the drive mechanism described in FIG. 4 .
[0029] FIG. 4 is a perspective view of the treatment head base 22 of FIG. 3 . The front housing 30 A has a plurality of microhead receptacles 42 formed in it. Each receptacle 42 has a recessed micro face 46 , which is sized to accept the microhead base [ 38 ] within it. Centered on each face 46 is a microdrive socket 44 . The microdrive sockets 44 all rotate/oscillate/vibrate “M” in response to the input from the drive system [ 49 ] of FIG. 5 .
[0030] FIG. 5 is a cutaway side view of the motor and battery components of the device of FIGS. 1 and 2 . These components collectively make up the drive subsystem 49 . An electric drive motor 48 is mechanically connected to drive gear assembly 50 which translates the rotational output of the motor 48 shaft into rotation/oscillation/vibration in the appropriate magnitude and speed. The resultant mechanical motion is tranferred to the treatment head assembly through the motor drive interface [ 16 ] (within the interlock sleeve 32 ).
[0031] Control switch 20 activates the different operational modes of the drive motor 48 . The internal batteries 52 power the motor 48 . The batteries 52 are recharged by charging probe 54 , which extends through the electrical socket [ 13 ] at the tip [ 18 ] of the main housing [ 12 ].
[0032] FIG. 6 is a perspective view of a conventional rotary shaver head assembly 60 , that is provided in order to highlight an essential structural distinction between the prior art devices and the facial treatment device [ 10 ] of the present invention. For safety reasons, the rotating cutter blades 64 are each covered by a stationary face element 62 . The face elements 62 are formed with perforations (slots or holes) through them so that the cutter blades 64 do not actually come in contact with the user's skin as they rotate or oscillate (which would of course cut the user's skin). While the user's hair is intended to protrude through the perforations, the face elements 62 are not activated to move by the shaver motor. FIGS. 7A-7C illuminate the contrast between these stationary face elements 62 and the moving face elements of Applicant's claimed design.
[0033] FIGS. 7A-7B are perspective views of preferred embodiments of the members of the group of microheads attachable to the device [ 10 ] of FIG. 1 . The bristle brush microheads 24 each define a face 25 composed of the ends of the brush bristles (for cleansing and massaging the skin). The sponge microheads 24 A each define a face 25 A composed of the sponge material (for applying lotions or creams to the skin). The silicone microheads 24 B each define a face 25 B that is coated with a silicone material (for smoothing and massaging the skin). Unlike the faces 62 of the shaver head assembly 60 , each of these faces 25 , 25 A, 25 B are driven to move by the internal drive motor [ 48 ]. The motion of the microheads 24 , 24 A, 24 B is synchronous rotation, oscillation or vibration (very small incremental movements) that allow the user to massage/cleanse/treat their skin.
[0034] Those skilled in the art will appreciate that various adaptations and modifications of the just-described preferred embodiment can be configured without departing from the scope and spirit of the invention. Therefore, it is to be understood that, within the scope of the appended claims, the invention may be practiced other than as specifically described herein. | A Handheld Motorized Facial Brush Having Three Floating Heads. The motorized device can generate rotational, oscillating or vibrating motion at a plurality of micro-treatment heads. The microheads are interchangeable and selectable from a group including bristle brushes, sponge applicator, silicone massage finger/element, among others. The device has a detachable three-headed treatment head assembly that interlocks to the main handle housing by twist-lock or other mechanism. The treatment head assembly may have the option of being pivotally attached to the handle housing in order to allow it to closely follow the contours of the user's face. Finally, the device has internal batteries that are rechargable. | 0 |
BACKGROUND OF THE INVENTION
U.S. Pat. No. 4,029,549 discloses and claims a steroid conversion process for making 9α-hydroxy-3-ketobisnorchol-4-en-22-oic acid (9α-OH BN acid). The process can be conducted using a mutant of a variety of steroid degrading microorganisms. The mutation process to prepare the mutants is disclosed in the patent. Specifically exemplified is the use of Mycobacterium fortuitum NRRL B-8119.
U.S. Pat. No. 4,035,236 discloses and claims a process for preparing 9α-hydroxyandrostenedione (9α-OH AD). This compound is also produced by the process as disclosed in U.S. Pat. No. 4,029,549.
The presence of additional compounds in the fermentation beers disclosed in the above patents was previously recognized, but the identity of the compounds was not known prior to the date of the subject invention. These additional compounds were subsequently shown by advanced identification techniques to be useful steroid intermediates as disclosed herein. Of these compounds, 9α-OH testosterone is a known compound, whereas the others are novel.
BRIEF SUMMARY OF THE INVENTION
9α-OH testosterone, 9α-OH BN alcohol and 9α-OH BN acid methyl ester are produced in a fermentation process using the microorganism Mycobacterium fortuitum NRRL B-8119. This organism is disclosed and characterized in U.S. Pat. No. 4,029,549. In addition to the characteristics given in said patent, this microorganism is further characterized by its ability to accumulate the compounds disclosed herein under fermentation conditions, also as disclosed herein. Other mutants of Mycobacterium, as well as mutants from the genera of microorganisms disclosed in U.S. Pat. No. 4,029,549, can be used in the subject invention. Examples of suitable steroid substrates are sitosterol, cholesterol, stigmasterol, campesterol, and like steroids with 17-alkyl side chains of from 8 to 10 carbon atoms, inclusive. These steroid substrates can be in either the pure or crude form.
DETAILED DESCRIPTION OF THE INVENTION
The microorganisms which can be used to produce the compounds of the subject invention are the same as disclosed in U.S. Pat. No. 4,029,549. The microorganism specifically exemplified is Mycobacterium fortuitum, NRRL B-8119. A subculture of this microorganism is freely available from the depository at the Northern Regional Research Laboratory, U.S. Department of Agriculture, Peoria, Ill., U.S.A., by request made thereto. It should be understood that the availability of the culture does not constitute a license to practice the subject invention in derogation of patent rights granted with the subject instrument by governmental action.
The transformation process of the subject invention is also as disclosed in U.S. Pat. No. 4,029,549.
Also, the procedure for the preparation of Mycobacterium fortuitum NRRL B-8119 is as disclosed in U.S. Pat. No. 4,029,549. This process can also be used to prepare mutants of other genera of microorganisms as disclosed in U.S. Pat. No. 4,029,549 and herein.
The isolation of the products of the subject invention from the fermentation broth is accomplished by first removing the major products of the sterol conversions, i.e., 9α-OH AD and 9α-OH BN acid. These major products are recovered from the fermentation beer by first extracting the fermentation beer with a water-immiscible organic solvent for steroids. Suitable solvents are methylene chloride (preferred), chloroform, carbon tetrachloride, ethylene chloride, trichloroethylene, ether, amyl acetate, benzene and the like.
Alternatively, the fermentation liquor and cells can be first separated by conventional methods, e.g., filtration or centrifugation, and then separately extracted with suitable solvents. The cells can be extracted with either water-miscible or water-immiscible solvents. The fermentation liquor, freed of cells, can be extracted with water-immiscible solvents.
The extract from the fermentation beer is dried. The resulting solids are taken up in chloroform and sufficient methanol is added to precipitate residual sterols which are then filtered off. The filtrate is dried and the residue dissolved in hot acetone. Upon cooling and subsequent addition of cyclohexane most of the 9α-OH AD is precipitated and recovered by filtration. The filtrate is then dried and the residue dissolved in chloroform and extracted with a saturated sodium bicarbonate solution to remove 9α-OH BN acid. The individual components remaining in the chloroform after the bicarbonate extraction are separated by chromatography on a silica gel column, eluting with chloroform-methanol (98:2).
The first compound to elute is the methyl ester of 9α-OH BN acid. The second compound to elute is residual 9α-OH AD which remains soluble in the acetone-cyclohexane solution described above. The third compound is 9α-OH BN alcohol. The next compound to elute from the column is 9α-OH testosterone.
The compounds of the subject invention are valuable as intermediates in the manufacture of steroids. For example, 9α-OH BN acid methyl ester can be converted to 9(11)-dehydro BN acid by treatment with N-bromoacetamide and sulfur dioxide in pyridine, as disclosed in British Pat. No. 869,815, followed by hydrolysis to generate the 22-carboxyl. 9(11)-Dehydro BN acid can be converted to 9(11)-dehydroprogesterone by, for example, the method described in Ber. 88: 883 (1955), and subsequently to 11β-hydroxyprogesterone as described in JACS 88: 3016 (1966). Treatment of 11β-hydroxyprogesterone with chromic acid yields 11-ketoprogesterone which is a known intermediate in the synthesis of cortisol acetate, a major and highly active cortical steroid [see, for example, Fieser and Fieser, Steroids, page 676, Reinhold (1959)].
9α-OH BN alcohol can be readily converted to 9α-OH BN acid by chromic acid oxidation, then to 9α-OH BN acid methyl ester by treatment with diazomethane and subsequently to 11-ketoprogesterone as described above.
9α-Hydroxy-11-unsubstituted steroids of the androstane series can also easily be dehydrated to the valuable 9(11)-dehydro steroids in accordance with methods known in the art, e.g., with thionyl chloride in the presence of pyridine. The 9(11)-dehydro compounds thus obtained are known intermediates in the production of highly active compounds. For example, the 9(11)-dehydro steroids can be converted to the corresponding 9α-halo-11β-hydroxy compounds in accordance with procedures known in the art, e.g., U.S. Pat. No. 2,852,511 for the preparation of 9α-halo-hydrocortisone. Also, 9α-hydroxy compounds of the androstane series are useful as antiandrogenic, antiestrogenic and antifertility agents.
The following examples are illustrative of the process and products of the subject invention but are not to be construed as limiting. All percentages are by weight and all solvent mixture proportions are by volume unless otherwise noted.
EXAMPLE 1--Preparation of Mutant M. fortuitum NRRL B-8119 From M. fortuitum ATCC 6842.
(a) Nitrosoguanidine Mutagenesis
Cells of M. fortuitum ATCC 6842 are grown at 28° C. in the following sterile seed medium:
Nutrient Broth (Difco) 8 g/liter
Yeast Extract 1 g/liter
Sodium Propionate 0.5 g/liter
Distilled Water, q.s. 1 liter
The pH is adjusted to 7.0 with 1 N NaOH prior to sterilization at 121° C. for 20 minutes.
The cells are grown to a density of about 5× 10 8 per ml, pelleted by centrifugation, and then washed with an equal volume of sterile 0.1 M sodium citrate, pH 5.6. Washed cells are resuspended in the same volume of citrate buffer, a sample removed for titering (cell count), and nitrosoguanidine added to a final concentration of 50 μg/ml. The cell suspension is incubated at 37° C. in a water bath for 30 minutes, after which a sample is again removed for titering and the remainder centrifuged down and washed with an equal volume of sterile 0.1 M potassium phosphate, pH 7.0. Finally, the cells are resuspended in a sterile minimal salts medium, minus a carbon source, consisting of the following:
NH 4 NO 3 1.0 g/liter
K 2 HPO 4 0.25 g/liter
MgSO 4 .7H 2 O 0.25 g/liter
NaCl 0.005 g/liter
FeSO 4 .7H 2 O 0.001 g/liter
Distilled Water, q.s. 1 liter
The pH is adjusted to 7.0 with 1 N HCl prior to sterilization at 121° C. for 20 minutes. The cells are then plated out to select for mutants.
(b) Selection And Isolation Of Mutant M. fortuitum NRRL B-8119
Mutagenized cells, as described above, are diluted and spread onto plates containing a medium consisting of the following (modified from Fraser and Jerrel. 1963. J. Biol. Chem. 205: 291-295):
Glycerol 10.0 g/liter
K 2 HPO 4 0.5 g/liter
NH 4 Cl 1.5 g/liter
MgSO 4 .7H 2 O 0.5 g/liter
FeCl 3 .6H 2 O 0.05 g/liter
Distilled Water, q.s. 1 liter
Agar (15 g/liter) is added, and the medium is autoclaved at 121° C. for 30 minutes and then poured into sterile Petri plates.
Growth on this medium eliminates most nutritional auxotrophes produced by the mutagensis procedure, e.g. cultures that require vitamins, growth factors, etc. in order to grow on chemically defined medium are eliminated. After incubation at 28° C. for about 7 days, the resulting colonies are replicated to test plates suitable for selecting mutants and then back onto control plates containing the glycerol-based medium. The test plates are prepared as described by Peterson, G. E., H. L. Lewis and J. R. David. 1962. "Preparation of uniform dispersions of cholesterol and other water-insoluble carbon sources in agar media." J. Lipid Research 3: 275-276. The minimal salts medium in these plates is as described above in section (a) of Example 1. Agar (15 g/liter), and an appropriate carbon source (1.0 g/liter), such as sitosterol or androstenedione (AD), are added and the resulting suspension autoclaved for 30 minutes at 121° C. The sterile, hot mixture is then poured into a sterile blender vessel, blended for several minutes, and then poured into sterile Petri plates. Foaming tends to be a problem in this procedure but can be reduced by blending when the mixture is hot and by flaming the surface of the molten agar plates. In this manner uniform dispersions of water-insoluble carbon sources are obtained which facilitates the preparation of very homogenous but opaque agar plates.
Colonies which grew on the control plates, but not on test plates containing AD as the sole carbon source, are purified by streaking onto nutrient agar plates. After growth at 28° C., individual clones are picked from the nutrient agar plates with sterile toothpicks and retested by inoculating gridded plates containing AD as the carbon source. Purified isolates which exhibit a phenotype different from the parental culture are then evaluated in shake flasks.
(c) Shake Flask Evaluation
Shake flasks (500 ml) contain 100 ml of biotransformation medium consisting of the following ingredients:
Glycerol 10.0 g/liter
K 2 HPO 4 0.5 g/liter
NH 4 Cl 1.5 g/liter
MgSO 4 .7H 2 O 0.5 g/liter
FeCl 3 .6H 2 O 0.05 g/liter
Distilled Water, q.s. 1 liter
Soyflour (1 g/liter) is blended into the medium and then sitosterol (10 g/liter) is also blended into the medium. After the flasks are autoclaved for 30 minutes at 121° C., they are cooled to 28° C. and then inoculated with 10 ml of seed growth prepared as follows:
The purified isolates from part (b) are grown on agar slants at 28° C. A loop of cells taken from a slant is used to inoculate at 500-ml flask containing 100 ml of sterile seed medium consisting of the following ingredients:
Nutrient Broth (Difco) 8 g/liter
Yeast Extract 1 g/liter
Glycerol 5 g/liter
Distilled Water, q.s. 1 liter
The pH is adjusted to 7.0 with 1 N NaOH prior to autoclaving the flasks at 121° C. for 20 minutes. The seed flasks are incubated at 28° C. for 72 hours.
As disclosed above, 10 ml of seed growth is then used to inoculate each 500-ml flask containing 100 ml of sterile transformation medium. The flasks are then incubated at 28° C. to 30° on a rotary shaker and sampled at various intervals. Ten ml samples are removed and extracted by shaking with 3 volumes of methylene chloride. Portions of the extracts are analyzed by thin layer chromatography (tlc) using silica gel and the solvent system described above, i.e., 2:3 (by volume) ethyl acetate-cyclohexane, and by gas-liquid chromatography. Evidence of the presence of 9α-OH AD confirms the selective degradation of sitosterol by the novel mutant produced from the parent M. fortuitum ATCC 6842.
EXAMPLE 2
To a medium consisting of 1.0 part of glycerol, 0.15 part of ammonium chloride, 0.05 part of magnesium sulfate heptahydrate, 0.05 part of dipotassium hydrogen phosphate, 0.005 part of ferric chloride hexahydrate, and 100 parts of distilled water is added 0.1 part of soyflour and 1.0 part of sitosterols, N.F. The resultant mixture is sterilized by heating 30 minutes at 121° C., whereupon it is cooled to 30° C. and then inoculated with 10 parts of a seed culture of the mutant Mycobacterium fortuitum NRRL B-8119, prepared as described in Example 1(c). The inoculated mixture is incubated at 30° C. for 336 hours with agitation to promote submerged growth. Following incubation, the mixture is extracted with methylene chloride. The extract is filtered through diatomaceous earth and the filtrate is vacuum distilled to dryness. The residue is taken up in 10% chloroform in methanol and then concentrated with nitrogen on a steam bath until crystals appear. The solution is then cooled to room temperature and filtered to remove the precipitated sitosterols. From the supernatant, on evaporation of solvent, good yields of 9α-OH testosterone, 9α-OH BN alcohol and 9α-OH BN acid methyl ester, as well as 9α-OH AD and 9α-OH BN acid are obtained.
EXAMPLE 3
By substituting cholesterol for sitosterol in Example 2 there are obtained the compounds produced in Example 2.
EXAMPLE 4
By substituting stigmasterol for sitosterol in Example 2 there are obtained the compounds produced in Example 2.
EXAMPLE 5
By substituting campesterol for sitosterol in Example 2 there are obtained the compounds produced in Example 2.
EXAMPLE 6
By adding a combination of any of the steroids in Examples 2-5, in addition to sitosterol, or in place of sitosterol, in Example 2 there are obtained the compounds produced in Example 2.
EXAMPLE 7
The products produced in Example 2 can be isolated as separate entities in the essentially pure form by the following procedure. The supernatant of Example 2, containing the products produced in the fermentation, is dried and the residue dissolved in hot acetone. Upon cooling and subsequent addition of cyclohexane most of the major product, 9α-OH AD, is precipitated and recovered by filtration. The filtrate is then dried and the residue dissolved in chloroform and extracted with a saturated sodium bicarbonate solution to remove 9α-OH BN acid. The individual components remaining in the chloroform after the bicarbonate extraction are separated by chromatography on a silica gel column, eluting with chloroform-methanol (98:2 v/v). Fractions containing the same component as determined by tlc are combined and further purified by liquid chromatography or preparative tlc followed by recrystallization, to give more 9α-OH AD plus the compounds of the subject invention.
The mass spectrum of the first eluted compound in its essentially pure form has a molecular ion at 374, and also exhibits intense ions at m/e 124, 136 and 137 confirming its close relationship to 9α-OH AD. The ir spectrum exhibits bands at 3540 and 3400 cm -1 (hydroxyl) and also at 1735 cm -1 and 1655 cm -1 suggesting the presence of two carbonyl groups. Comparison of the 1 H-nmr spectrum with that of 9α-OH BN acid shows that they are virtually identical except for an additional 3 proton peak at δ3.63 where a methyl ester would be expected. This compound is therefore identified as the methyl ester of 9α-OH BN acid, and confirmation of this is obtained from the 13 C-nmr spectrum which shows signals for 23 carbon atoms including four methyl groups (δ11.1, 17.0 19.8 and 5.13), two carbonyls (δ176.9 and 199.0), two olefinic carbons (δ126.7 and 168.6) and a quaternary carbon atom bearing oxygen (δ76.2).
The second eluted compound in its essentially pure form is residual 9α-OH AD which remains soluble in the acetone-cyclohexane solution described above.
The third component in its essentially pure form has a molecular weight of 346, the mass spectrum of which again exhibits the characteristic ions at m/e 124, 136 and 137. The presence of a hydroxyl group and an unsaturated carbonyl are deduced from infrared peaks at 3400 cm -1 and 1650 cm -1 and its evident from the doublet centered at δ1.05 in the 1 H-nmr spectrum that a side chain similar to that of 9α-OH BN acid and 9α-OH BN acid methyl ester is present at C-17. The 1 H-nmr spectrum in dimethyl sulfoxide-d 6 also indicates the presence of both a primary (δ4.18, t, J=5) and a tertiary (δ3.95) alcohol. Signals due to 22 carbon atoms are seen in the 13 C-nmr spectrum, including three methyl groups (δ11.1, 16.7 and 19.9), two olefinic carbons (δ126.6 and 169.4), one carbonyl (δ199.2) and two carbon atoms bearing hydroxyls (δ67.7, triplet and 76.3, singlet). On the basis of the above spectral evidence the structure 9α-hydroxy-3 -oxo-23,24-bisnorchol-4-en-22-ol (9α-OH BN alcohol) is assigned to this compound.
The mass spectrum of the next major eluted compound in its essentially pure form from this column shows a molecular ion at 304, and the usual intense ions at 124, 136 and 137. Given the evident close relationship to 9α-OH AD, and the fact that the 13 C-nmr spectrum showed 19 carbon atoms, only one of which was part of a carbonyl group (δ199.3), this compound is identified as 9α-OH testosterone, and the structural assignment is confirmed by comparison with an authentic sample.
EXAMPLE 8
By substituting a microorganism from the genera Arthrobacter, Bacillus, Brevibacterium, Corynebacterium, Microbacterium, Nocardia, Protaminobacter, Serratia, and Streptomyces, in Example 1 for Mycobacterium fortuitum ATCC 6842 there are obtained mutant microorganisms which are characterized by their ability to selectively degrade steroids having 17-alkyl side chains of from 8 to 10 carbon atoms, inclusive, and accumulate the products disclosed herein in the fermentation beer.
EXAMPLE 9
By substituting the mutants obtained in Example 8 for M. fortuitum NRRL B-8119 in Examples 2-7, there are obtained the products as disclosed herein.
EXAMPLE 10
By substituting a microorganism selected from the group consisting of Mycobacterium phlei, M. smegmatis, M. rhodochrous, M. mucosum, and M. butyricum for M. fortuitum ATCC 6842 in Example 1 there are obtained mutant microorganisms which are characterized by their ability to selectively degrade steroids having 17-alkyl side chains of from 8 to 10 carbon atoms, inclusive, and accumulate the products disclosed herein in the fermentation beer.
EXAMPLE 11
By substituting the mutants obtained in Example 10 for M. fortuitum NRRL B-8119 in Examples 2-7, there are obtained the products as disclosed herein.
The structural formulae for the novel compounds of the invention can be shown as follows:
9α-OH BN alcohol ##STR1##
9α-OH BN acid methyl ester ##STR2## | Valuable steroid intermediates, 9α-hydroxyandrost-4-ene-17β-ol-3-one (9α--OH testosterone), 9α-hydroxy-3-ketobisnorchol-4-en-22-ol (9α--OH BN alcohol) and 9α---hydroxy-3-ketobisnorchol-4-en-22-oic methyl ester (9α--OH BN acid methyl ester), prepared by microbiological conversion of steroids having 17-alkyl side chains of 8 to 10 carbons. | 2 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates, in general, to an arrowhead having expanding blades capable of being retracted or expanded by a gear mechanism, and, more particularly, to an arrowhead in which a rack gear formed on a shaft is engaged with pinion gears of expanding blades coupled to a main body, and thus a relative movement between the main body and the shaft causes the retraction or expansion of the expanding blades.
2. Description of the Related Art
Generally, an arrow is composed of a hollow arrow shaft, an arrowhead attached to a leading end of the arrow shaft, the nock of an arrow using which the arrow is fit in the string, and feathering for securing the flight stability of an arrow.
The arrowhead serves to pass through a target, so it should have excellent wear resistance and strength and it should have a structure enabling its flight to be stable, because upon hitting the target, the accumulated energy of an arrow is collected upon the arrowhead.
Generally, an arrowhead has a sharpened tip to improve penetration, but such a sharpened arrowhead is not practical for certain types of hunting. This is because it is difficult for the sharpened arrowhead to kill large game and thus gain control over the same. Thus, for this reason, a broad type arrowhead which has two to four sharp blades on its edge to induce profuse bleeding and the death of game may be used.
There is also disclosed a variety of arrowheads in which the blades are normally retracted inside the arrowhead and expand upon hitting a target because the blades of the broad type arrowhead affect the flight stability of an arrow.
Such blades having an expandable structure are referred to as expanding blades. A variety of conventional examples of arrowheads having such expanding blades are disclosed in U.S. Pat. No. 5,082,292 entitled “BROADHEAD WITH DEPLOYABLE CUTTING BLADES,” U.S. Pat. No. 5,066,021 entitled “ARROW SYSTEM,” U.S. Pat. No. 4,973,060 entitled “ARROHEAD WITH EXPANDABLE BLADES,” U.S. Pat. No. 6,669,586 entitled “EXPANDING BROADHEAD,” U.S. Pat. No. 6,258,000 entitled “PENETRATION ENHANCING AERODYNAMICALLY FAVORABLE ARROWHEAD,” U.S. Pat. No. 6,287,223 entitled “DULLING PREVENTION FOR SHARP CUTTING EDGE OF BLADE-OPENING ARROWHEAD BLADES WHEN IN A CLOSED IN-FLIGHT POSITION,” U.S. Pat. No. 8,062,155 entitled “ARROWHEAD HAVING BOTH FIXED AND MECHANICALLY EXPANDABLE BLADES,” and U.S. Pat. No. 6,200,237 entitled “SLIDING BODY EXPANDING BROADHEAD,” respectively.
All of the patent documents described above disclose an arrowhead having two to four expanding blades, in which, when an arrow hits a target, such as game, a plurality of expanding blades are expanded to enlarge and more deeply penetrate into the wound of the game, thereby enhancing the killing capability of the arrow.
However, such conventional expanding blades have a problem in that, when an arrow is flying after being shot, the expanding blades expand by themselves, thereby degrading the flight stability of the arrow and adversely affecting the hit rate and flight distance of the arrow.
Due to such a problem, in the case of an arrowhead having the conventional expanding blades, the plurality of expanding blades must be typically retracted and grouped together before an arrow is shot, and then be tied by a band or string which can be easily broken or slip off when the arrow hits the target.
In doing so, the expanding blades are maintained in a retracted state during flight of the arrow, but can be expanded by slipping-off of the band or string as soon as the arrow hits and penetrates into the target.
However, in such a manner in which the expanding blades should be retracted and then tied or bundled by the band and the like, there are inconveniences in that the retracted expanding blades must be bundled by the band and the like whenever an arrow is shot, and in turn the band must be always carried when hunting.
Therefore, there is a need to develop an arrowhead in which, during flight of an arrow, retracted expanding blades can be kept un-expanded to ensure the flight stability without using an additional means, and the expanding blades can automatically expand only when the arrow hits and penetrates into a target.
Documents of Related Art
U.S. Pat. No. 5,082,292 entitled “BROADHEAD WITH DEPLOYABLE CUTTING BLADES”; U.S. Pat. No. 5,066,021 entitled “ARROW SYSTEM”; U.S. Pat. No. 4,973,060 entitled “ARROHEAD WITH EXPANDABLE BLADES”; U.S. Pat. No. 6,669,586 entitled “EXPANDING BROADHEAD”; U.S. Pat. No. 6,258,000 entitled “PENETRATION ENHANCING AERODYNAMICALLY FAVORABLE ARROWHEAD”; U.S. Pat. No. 6,287,223 entitled “DULLING PREVENTION FOR SHARP CUTTING EDGE OF BLADE-OPENING ARROWHEAD BLADES WHEN IN A CLOSED IN-FLIGHT POSITION”; U.S. Pat. No. 8,062,155 entitled “ARROWHEAD HAVING BOTH FIXED AND MECHANICALLY EXPANDABLE BLADES”; and U.S. Pat. No. 6,200,237 entitled “SLIDING BODY EXPANDING BROADHEAD.”
SUMMARY OF THE INVENTION
Accordingly, an object of the present invention is intended to provide an arrowhead having expanding blades capable of being retracted or expanded as required, in which the expanding blades can be maintained in a retracted state without using an additional means to bundle up the expanding blades during flight of an arrow, and then can quickly and reliably expand only when the arrow hits a target.
In order to achieve the above object, according to one aspect of the present invention, there is provided an arrowhead having expanding blades controlled by a gear mechanism, including: a penetrating tip including a sharpened leading end and a screw thread formed on an inner peripheral surface thereof; a main body adapted to allow a lower end of the penetrating tip to be inserted therein, the main body including a body portion having a hollow portion therein and opened on upper and lower end sides thereof, a plurality of expanding blade coupling pieces formed on an outer surface of the body portion, and a plurality of expanding blade receiving grooves respectively formed on a surface of each of the plurality of expanding blade coupling pieces; a plurality of expanding blades respectively hingedly and rotatably coupled to each of the expanding blade coupling pieces, the plurality of expanding blades each including a blade formed on one side end thereof and a pinion gear portion formed on a lower end thereof; a shaft including a body portion, a front-end threaded portion formed on an upper end of the body portion to be coupled to the screw thread of the penetrating tip, a rear-end threaded portion formed on a lower end of the body portion to be coupled to an arrow shaft, a rack gear portion formed on an outer peripheral surface of the body portion to engage with the pinion gear portion, and a stopper formed to protrude from the outer peripheral surface below the rack gear portion; and a spring mounted and elastically supported between the stopper and the main body; wherein a relative movement between the rack gear portion and the pinion gear portion causes the retraction or expansion of the expanding blades.
In this case, the spring may be inserted onto the shaft such that a lower end of the spring is supported by the stopper, and an upper end of the spring is fixedly coupled on an inner diameter surface of the main body.
Preferably, the penetrating tip may include a tip portion provided with a tip edge and a cylindrical body portion having the screw thread formed on an inner peripheral surface thereof, and a shoulder may be defined between the tip portion and the cylindrical body portion.
Also, the main body may be opened on upper and lower ends thereof to communicate with the hollow portion therein, and an outer diameter of the main body is gradually reduced from the lower end to the upper end.
Also, the shape of the pinion gear portion may be overall that of an arc and may include streamline-shaped protrusions and streamline-shaped grooves alternately formed on a lower end thereof.
Furthermore, each of the expanding blades may include a spur formed on a front end thereof to be folded at a predetermined angle relative to the blade.
Additionally, the stopper may be formed to protrude in a circular shape from an outer peripheral surface of the body portion between the rear-end threaded portion and the rack gear portion such that the diameter of the stopper may be larger than the diameter of the body portion.
According to the present invention, the following effects may be obtained.
The plurality of expanding blades provided in the arrowhead is maintained in a retracted state without using an additional means to bundle the expanding blades during flight of an arrow and then expand only when the arrow hits a target, thereby providing excellent flight stability of the arrow and very excellent killing capability against a target.
Particularly, means or mechanisms for retracting or expanding the plurality of expanding blades in a timely manner have a simple structure, thereby easily assembling or manufacturing the arrowhead and also obtaining the trouble-free arrowhead.
BRIEF DESCRIPTION OF THE DRAWINGS
The above and other objects, features and other advantages of the present invention will be more clearly understood from the following detailed description when taken in conjunction with the accompanying drawings, in which:
FIG. 1 shows a perspective view of an arrowhead with expanding blades retracted according to the present invention;
FIG. 2 shows a perspective view of the arrowhead with the expanding blades expanded according to the present invention;
FIG. 3 shows an exploded perspective view of the arrowhead according to the present invention;
FIG. 4 shows a front view of the arrowhead according to the present invention;
FIG. 5 shows a plan view of the arrowhead of FIG. 4 ;
FIG. 6 shows a perspective view and a front sectional view of a penetrating tip according to the present invention;
FIG. 7 shows a perspective view, a front view, a plan view and a bottom view of a main body according to the present invention;
FIG. 8 shows a perspective view and a front view of an expanding blade according to the present invention;
FIG. 9 shows a perspective view of a spring according to the present invention; and
FIG. 10 shows a perspective view and a front view of a shaft according to the present invention.
DETAILED DESCRIPTION OF THE INVENTION
Reference will now be made in greater detail to the construction and operating principle of the invention, an example of which is illustrated in the accompanying drawings. Wherever possible, the same reference numerals will be used throughout the drawings and the description to refer to the same or like parts.
FIG. 1 shows a perspective view of an arrowhead with expanding blades retracted according to the present invention, FIG. 2 shows a perspective view of the arrowhead with the expanding blades expanded according to the present invention, FIG. 3 shows an exploded perspective view of the arrowhead according to the present invention, FIG. 4 shows a front view of the arrowhead according to the present invention, and FIG. 5 shows a plan view of the arrowhead of FIG. 4 .
An arrowhead 100 according to the present invention generally includes a penetrating tip 110 for penetrating into a target, a main body 120 having a hollow portion therein and adapted to allow the penetrating tip 110 and a shaft 150 as described below to be partially inserted therein, a plurality of expanding blades 130 rotatably mounted on the main body 120 , a spring 140 , and the shaft 150 extending through the main body 120 and threadably coupled to the penetrating tip 110 .
FIG. 1 shows a state of retraction of the plurality of expanding blades 130 , and, for convenience, illustrates in a transparent manner the main body 120 to aid the understanding of an inside structure thereof.
FIG. 6 shows a perspective view and a front sectional view of the penetrating tip according to the present invention. When an arrow hits a target, the penetrating tip 110 is adapted to penetrate into the skin and flesh of game as the target and has a sharpened leading end. The penetrating tip 110 has a tip portion 111 at its front end and a cylindrical body portion 112 at its rear end, and a boundary portion between the tip portion 111 and the cylindrical body portion 112 is provided with a shoulder 113 as shown.
The tip portion 111 has flat tip surfaces 111 a and tip edges 111 b formed by sharpened corners.
A cylindrical tip body 112 a of the body portion 112 has an inner peripheral surface provided with a screw thread 112 b to be coupled to a front-end threaded portion 152 of the shaft 150 as described below.
FIG. 7 shows a perspective view, a front view, a plan view and a bottom view of the main body according to the present invention. The main body 120 has a hollow portion 121 a vertically extending through and with openings at upper and lower end sides of a body portion 121 , and an outer surface of the body portion 121 is provided with a plurality of expanding blade coupling pieces 122 protruding from the outer surface.
The body portion 121 preferably has a truncated cone shape in which its outer diameter is generally gradually reduced from a lower end to an upper end, but it is not necessary to be limited to such a configuration.
Each of the expanding blade coupling pieces 122 has a hinge shaft coupling hole 122 a extending through side surfaces thereof, an expanding blade receiving groove 122 b elongatedly formed on the other surface in a longitudinal direction of the main body 120 as shown.
The whole or a portion of the expanding blade receiving groove 122 b is formed to communicate with the hollow portion 121 a inside the body portion 121 , thereby allowing a pinion gear portion 134 of the expanding blade 130 as described below to engage with a rack gear portion 154 of the shaft 150 as described below.
FIG. 8 shows a perspective view and a front view of an expanding blade according to the present invention. As shown, the expanding blade 130 of the invention generally includes a body portion 131 having a blade 132 formed on its one side end, a spur 133 formed in a folded or bended shape on an upper end of the body portion 131 , and the pinion gear portion 134 formed on a lower end of the body portion 131 . The body portion 131 is also provided with a hinge shaft coupling hole 131 a extending through a flat surface thereof.
The pinion gear portion 134 has a plurality of streamline-shaped protrusions 134 a and a plurality of streamline-shaped grooves 134 b alternately formed on a generally semicircular-shaped arc end thereof, and engages with the rack gear portion 154 of the shaft 150 as described below.
It is not necessary for the shape of gear teeth in the pinion gear portion 134 to be limited to the streamline-shaped curved surface, and this shape may be substituted for by any other shape as required. Accordingly, it should be appreciated by those skilled in the art that such a configuration may also fall within the spirit and scope of the invention.
FIG. 10 shows a perspective view and a front view of the shaft according to the present invention. The shaft 150 of the invention is coupled to the penetrating tip 110 at its upper end and to an arrow shaft (not shown) at its lower end. The shaft 150 generally includes a cylindrical body portion 151 , the front-end threaded portion 152 formed on a front end of the body portion 151 , a rear-end threaded portion 153 formed on a rear end of the body portion 151 , a stopper 155 protruding from an outer diameter surface of the body portion 151 , and the rack gear portion 154 formed on an outer peripheral surface of the body portion 154 located above the stopper 155 .
The front-end threaded portion 152 is coupled to the screw thread 112 b formed on the inner peripheral surface of the body portion 112 of the penetrating tip 110 , and the rear-end threaded portion 153 is threadably coupled and fixed to the front end of the arrow shaft (not shown) in which the arrowhead 100 is inserted.
On the rack gear portion 154 formed on the outer peripheral surface of the body portion 151 there are disposed in an alternating fashion a plurality of streamline-shaped protrusions 154 a and a plurality of streamline-shaped grooves 154 b . Reference numeral 151 a , which is indicated in the drawings but not described in detail herein, designates a groove with a predetermined length formed on an outer surface of an upper end of the body portion 151 .
Similar to the pinion gear portion 134 of the expanding blade 130 as described above, is not necessary for the shape of gear teeth constituting the rack gear portion 154 to be limited to such a streamline shape, and this shape may be substituted for by other shapes as required.
The stopper 155 formed on an outer surface of the body portion 151 between the rear-end threaded portion 153 and the rack gear portion 154 protrudes and has a diameter larger than the diameter of the body portion 151 .
An upper end of the spring 140 is fixed on an inner diameter portion of the main body 120 , or is caught and supported on an inner diameter surface of the main body 120 . The appearance of the spring 140 is shown in FIG. 9 .
The arrowhead 100 according to the present invention constituted of the components as described above is in a retracted state wherein the plurality of expanding blades 130 are retracted as shown in FIG. 1 , before the arrow is shot, which changes to an expanded state after the plurality of expanding blades 130 have rotated and expanded downwards as shown in FIG. 2 , when the arrow has been shot and hit a target.
In the retracted state as shown in FIG. 1 , the spring 140 is left in a compressed state, and the pinion gear portion 134 of each of the expanding blades 130 is engaged with an upper end of the rack gear portion 154 of the shaft 150 .
Then, when the arrow has been shot and hits the target, the penetrating tip 110 penetrates into the skin and flesh of game which is the target, during which the shaft 150 compresses the spring 140 against the main body 120 while moving forward relative to the main body 120 .
As the shaft 150 moves forward inside the main body 120 , the pinion gear portion 134 of each of the expanding blades 130 engaged with the upper end of the rack gear portion 154 is expanded by being rotated from up to down.
Namely, the rack gear portion 154 moves forward to rotate the pinion gear portion 134 , and as a result, the expanding blades 130 are rotated about hinge shafts (not shown).
According to the arrowhead of the present invention having the structure described above, the expanding blades 130 are always maintained in a state of engaging with the rack gear portion 154 . Therefore, the expanding blades 130 are stably maintained in the retracted state while the arrow is flying when no impact has been applied thereon, but on the other hand, the expanding blades 130 quickly and efficiently expand when they hit the target.
Therefore, an additional means for preventing the unexpected expansion of the expanding blades 130 during flight of the arrow is not required, and a hitting effect against the target is reliable such that ascendancy over the game can be quickly and efficiently gained in a short time.
In the embodiment shown, three expanding blades 130 are installed on the outer surface of the main body 120 at intervals of 120 degrees in a circumferential direction. However, it is not necessary to limit the configuration to that shown, and the number of the expanding blades 130 may be two or four or more as required.
In the above embodiment, an up-and-down rotation angle between the retracted state and the expanded state of the expanding blades 130 is preferably, but not limited to, between roughly 100 degrees to 120 degrees.
As set forth above, the present arrowhead has a plurality of expanding blades to more efficiently and reliably hit game which is the target, in which an operation of retracting or expanding the expanding blades can be reliably performed. Further the present arrowhead has a simple structure and excellent durability.
Although a preferred embodiment of the present invention has been described for illustrative purposes, those skilled in the art will appreciate that various modifications, additions and substitutions are possible, without departing from the scope and spirit of the invention as disclosed in the accompanying claims. | Disclosed is an arrowhead in which a plurality of expandable blades can be quickly and reliably retracted or expanded without using an additional means to bundle the expanding blades, thereby enhancing the penetrating capability or killing capability of an arrow. Particularly, a portion of a shaft forming the arrowhead is provided with a rack gear portion formed thereon and a lower end of each of the expanding blades is provided with a pinion gear portion, such that the rack gear portion and the pinion gear portion engage with each other and such a rack-pinion action controls the operation of retracting or expanding the expanding blades. | 5 |
INCORPORATION BY REFERENCE
The present application claims priority under 35 U.S.C. §119 to Japanese Patent Application No. 2010-043551 filed on Feb. 26, 2010. The content of the application is incorporated herein by reference in its entirety.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an isolator for cell culture (cultivation).
2. Description of Related Art
An isolator containing a working chamber under a sterile environment has been used (for example, see JP-T-2001-518816; the term “JP-T” as used herein means a published Japanese translation of a PCT patent application). In the isolator, a culturing work for culture, operation, observation, etc. of cells of human bodies, animals or plants or microorganisms is performed by a worker.
In some cases, an auxiliary work such as an opening work, a seal-breaking work, etc. of instruments for experiments and chemicals is performed in an isolator. Therefore, when this auxiliary work is performed, dust or dirt occurs in some cases. Therefore, when the auxiliary work is performed, dust or dirt occurs and invades into cells or the like, whereby a culturing work is adversely affected.
SUMMARY OF THE INVENTION
In order to attain the above object, according to the present invention, an isolator for cultivating cells, comprises: a working chamber having a plurality of gloves arranged side by side into which operator's hands are inserted to operate cells, the working chamber being sectioned into at least an operation area for operating the cells, and an auxiliary working area for opening a packaged auxiliary instrument used to operate the cells; a gas supply unit that supplies gas into the working chamber so that the gas flows downwardly from an upper side in the working chamber; and a gas flow control unit for controlling the flow of the downwardly flowing gas so that the gas flows from the operation area to the auxiliary working area around the gloves (particularly in the neighborhood of the gloves), wherein the gas flow control unit has an exhaust hole portion that has an opened area for passing the gas therethrough and is provided at a lower portion of at least the auxiliary working area, and through which the gas in the auxiliary working area is exhausted.
In the above isolator, the exhaust hole portion is provided to each of the operation area and the auxiliary working area, and the opened area of the exhaust hole portion at the auxiliary working area side is set to be larger in total opening area than the opened area of the exhaust hole portion at the operation area side.
The above isolator further comprises an air supply port that exhausts the gas from the exhaust hole portion and is disposed at the auxiliary working area side.
In the above isolator, the air supply port serves as an air supply port of an exhaust duct for exhausting the gas from the exhaust hole portion.
The above isolator further comprises an exhaust blower for exhausting the gas from the exhaust hole portion, wherein the air supply port serves as an air supply port of the exhaust blower, and the exhaust blower is provided below the lower portion of the auxiliary working area.
In the above isolator, the exhaust hole portion is provided to each of the operation area and the auxiliary working area, and the opening area of the opened area of the exhaust hole portion at the lower portion of the auxiliary working area is set to be equal to the opening area of the opened area of the exhaust hole portion at the operation area side.
In the above isolator, the exhaust hole portion comprises a belt-like member that extends in a width direction of the working chamber and has a plurality of holes formed therein.
The above isolator further comprises a cultivating chamber for cell culture that is disposed to be adjacent to the operation area.
According to the isolator of the present invention, contamination of dirt or dust into cells or the like can be prevented, and thus dirt or dust can be prevented from affecting the cultivation (culture) work such as the operation, etc. of cells or the like can be prevented.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a front view showing an isolator according to a first embodiment of the present invention;
FIG. 2 is a side cross-sectional view of the isolator;
FIG. 3 is a top view of the inside of a working chamber;
FIG. 4 is another top view of the inside of the working chamber;
FIG. 5 is a top view of the inside of a working chamber according to a second embodiment;
FIG. 6 is a top view of the inside of a working chamber according to a third embodiment;
FIG. 7 is a top view of the inside of a working chamber according to a fourth embodiment;
FIG. 8 is a top view of the inside of a working chamber according to a fifth embodiment;
FIG. 9 is a top view of the inside of a working chamber according to a sixth embodiment;
FIG. 10 is a side cross-sectional view of the isolator;
FIG. 11 is a top view of the inside of the working chamber;
FIG. 12 is another top view of the inside of the working chamber;
FIG. 13 is a front view showing an isolator according to a seventh embodiment;
FIG. 14 is a side cross-sectional view showing the isolator;
FIG. 15 is a top view showing the inside of the working chamber; and
FIG. 16 is another top view of the inside of the working chamber.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Preferred embodiments according to the present invention will be described hereunder with reference to the accompanying drawings.
First Embodiment
FIG. 1 is a front view showing an isolator according to a first embodiment of the present invention.
As shown in FIG. 1 , an isolator 10 has a glove box 11 whose inside is kept under sterile conditions, a frame 12 for supporting the glove box 11 from the lower side, an air supply blower 13 and an exhaustion blower 14 which are provided on the top surface of the glove box 11 , and a decontamination unit for decontaminating the inside of the glove box 11 with decontamination gas.
The inner space of the glove box 11 serves as a working chamber 16 in which works for biological derivative materials as targets such as a cell extraction work, a cell culturing work, etc. are performed. The glove box 11 has a box-shaped housing 17 which is opened at one surface thereof, and a transparent plate 18 which is formed of a rectangular glass or resin member and closes the opening of the housing 17 . The inside of the working chamber 16 is visually identified through the transparent plate 18 which is provided to the substantially overall front surface of the glove box 11 . The glove box 11 is designed in a rectangular shape which is longest in the width direction thereof.
The transparent plate 18 is provided with plural gloves 19 A, 19 B, 19 C, 19 D extending into the working chamber 16 , and a worker for operating and cultivating cells, etc. can perform works in the working chamber 16 by inserting his/her hands from the outside into the gloves 19 A, 19 B, 19 C, 19 D. Each of the gloves 19 A, 19 B, 19 C, 19 D is disposed at a lower position than the intermediate portion of the glove box 11 in height. In this embodiment, four gloves 19 A, 19 B, 19 C and 19 D are horizontally arranged substantially side by side on a line so as to be spaced from one another at a substantially equal interval. That is, in the glove box 11 , the four gloves 19 A, 19 B, 19 C and 19 D are arranged side by side laterally in the glove box 11 , and thus two workers can perform works at the same time by inserting their both hands into the gloves 19 A, 19 B, 19 C and 19 D. The glove box 11 contains an incubator 21 (cultivating chamber) for cultivating cells accommodated therein, a pass box 22 through which articles (samples) are inserted into and taken out from the working chamber 16 , a joint box 23 to which the incubator 21 is secured, and a centrifugal machine 20 .
The joint box 23 is provided to one side surface 24 A at one end side in the width direction of the glove box 11 , and has a joint box door 23 A for blocking a part of the one side surface 24 A so that the one side surface 24 A is freely opened or closed. The incubator 21 is freely detachably secured to the joint box 23 .
The incubator 21 is a box-shaped cultivating chamber in which an environment suitable for cultivating cells is formed. The incubator 21 is designed so that the temperature and CO 2 concentration in the incubator 21 can be adjusted, and it has a function of decontaminating the inside thereof. The incubator 21 is provided with a door 21 A for closing the inside of the incubator 21 so that the inside of the incubator 21 can be hermetically sealed. The incubator 21 is secured to the joint box 23 from the outside under the state that the door 21 A faces the joint box door 23 A. When the worker accesses the incubator 21 from the inside of the working chamber 16 , the worker opens the joint box door 23 A, opens the door 21 A and then extends his/her hand to insert or take out cells accommodated in petri dish or like into/from the incubator 21 . Furthermore, under the state that the incubator 21 is detached from the joint box 23 , the joint box door 23 A is closed, and the hermetic sealing state between the inside of the working chamber 16 and the outside of the working chamber 16 is kept.
The pass box 22 is a front chamber used when articles are inserted into or taken out from the glove box 11 . The pass box 22 has an external door 22 B provided to the front surface side of the glove box 11 so as to be freely openable and closable, and an internal door 22 B for closing a part of the side surface of the glove box 11 so that the part can be freely opened/closed. The pass box 22 is provided to the other side surface 24 B at the other end side in the width direction of the glove box 11 . Furthermore, the pass box 22 is connected to a decontamination unit 15 .
When an article is carried into the glove box 11 , the external door 22 A is opened, the article is put into the pass box 22 and then the external door 22 A is closed. Under this state, the article is decontaminated by the decontamination unit 15 . Thereafter, the internal door 22 B is opened by using the gloves 19 C and 19 D, and the article is taken out from the pass box 22 , whereby the article can be carried into the glove box 11 .
Articles which are to be carried into the glove box 11 by using the pass box 22 contain instruments, etc. used for cultivating works, and for example, an injector is used as an article. The instruments such as injectors, etc. are accommodated in packages which are managed under a sterile condition.
The glove box 11 is sectioned into an operation area 25 in which cultivating works such as cultivation, operation, observation, etc. of cells are performed, and an auxiliary working area 35 in which auxiliary works for the cultivating work are performed. An opening work for opening packages for instruments and chemicals used for the cultivating work, an operation of the centrifugal machine 20 , etc. are performed as the auxiliary works.
Specifically, the operation area 25 is one half side portion at one side of the glove box 11 at which the incubator 21 is disposed, and the auxiliary working area is the other half side portion at the other side of the glove box 11 at which the pass box 22 is disposed. The boundary portion S between the operation area 25 and the auxiliary working area 35 is located at the intermediate portion between the two gloves 19 B and 19 C at the center side as indicated by two-dotted chain line extending in the vertical direction of FIG. 1 . That is, the two gloves 19 A and 19 b at the incubator 21 side are used for the works to be performed in the operation area 25 , and the two gloves 19 C and 19 D at the pass box 22 side are used for the works to be performed in the auxiliary working area 35 . A worker may insert his/her right and left hands into the two gloves 19 B and 19 C at the center portion and perform a work over the operation area 25 and the auxiliary working area 35 by using both the right and left hands.
In this embodiment, the half side portion (the left side portion in FIG. 1 ) of the working chamber 16 at the incubator 21 side is used as the operation area 25 for performing the cultivating work such as the operation, etc. of cells, and thus the cells used in the cultivating work can be directly carried into the incubator 21 by using the gloves 19 A and 10 B, so that the workability can be enhanced. Furthermore, the other half side portion (the right side portion in FIG. 1 ) of the working chamber 16 at the pass box 22 side is used as the auxiliary working area 35 , and thus the instruments, etc. which are taken out from the bass box 22 can be opened and supplied to the operation area 25 by using the gloves 19 C and 19 D, so that the workability is enhanced.
The centrifugal machine 20 is used for a work of separating cells, etc., and disposed at the intermediate portion in the width direction of the glove box 11 . Therefore, the centrifugal machine 20 can be used from both the sides of the operation area 25 side and the auxiliary working area 35 side.
Furthermore, the operation area 25 of the glove box 11 is provided with a display 26 . The display 26 is provided so as to face the transparent plate 18 , and it can display a working procedure of the cultivating work, etc. to the worker.
FIG. 2 is a side cross-sectional view showing the isolator 10 .
As shown in FIGS. 1 and 2 , the air supply (air suction) blower 13 and the exhaust blower 14 are provided above the glove box 11 to be arranged in the front-and-rear direction. The air supply blower 13 is disposed at the front portion of the transparent plate 18 side, and the exhaust blower 14 is disposed at the rear portion of the transparent plate 18 side. An air supply blower catalysis 28 and an air supply valve 29 for adjusting an air supply (intake) amount are connected to the air supply blower 13 . An exhaust catalysis 31 for purifying exhaust gas discharged to the outside and an exhaust valve 30 for adjusting an exhaust gas amount are connected to the exhaust blower 14 .
The air supply blower 13 and the exhaust gas blower 14 are insulated from each other by a partition portion 32 extending in the vertical direction ( FIG. 2 ). An air supply chamber 33 extending substantially wholly in the width direction of the glove box 11 is disposed below the air supply blower 13 , and an air supply filter 34 for collecting dust in sucked gas (air or the like) is provided between the air supply chamber 33 and the working chamber 16 . Furthermore, an exhaust chamber 36 extending substantially wholly in the width direction of the glove box 11 is provided below the exhaust blower 14 , and an exhaust filter 37 for collecting dust in exhaust gas (air or the like) is provided between the exhaust chamber 36 and the working chamber 16 .
An inner wall plate 40 extending substantially wholly in the width direction of the inside of the glove box 11 is provided to partition the inside of the glove box 11 . A space is formed at the lower portion and back surface portion of the inside of the glove box 11 by the inner wall plate 40 . The inner wall plate 40 is formed as if one plate member is bent, and it is constructed to have a working plate 42 (lower surface) which is disposed to be spaced from the bottom surface of the housing 17 and constitutes the bottom surface portion of the working chamber 16 , a back surface plate 43 which is disposed to be spaced from the back surface 41 B of the housing 17 and constitutes the back surface of the working chamber 16 , and a partition plate 44 for connecting the upper end of the back surface plate 43 and the upper surface of the working chamber 16 .
The working plate 42 is provided substantially in parallel to the bottom surface 41 A, and an exhaust hole portion 45 extending in the width direction of the glove box 11 is formed in each of the front and rear edges of the working plate 42 . The back surface plate 43 is continuous with the rear edge of the working plate 42 and extends upwardly in parallel to the back surface 41 B. The partition plate 44 extends obliquely from the upper edge of the back surface plate 43 to the front surface side, and also is connected to the lower surface of the partition portion 32 . The space surrounded by the working plate 42 , the back surface plate 43 , the partition plate 44 , and the bottom surfaces 41 A and the back surface 41 B of the housing 17 functions as an exhaust gas passage 46 , and the exhaust gas from the working chamber 16 passes through the exhaust gas passage 46 and flows to the exhaust blower 14 side. The exhaust gas passage 46 has a lower duct 46 extending at the lower side of the working plate 42 and an upper duct 46 B (exhaust duct) which is continuous with the lower duct 46 A and extends upwardly between the back surface 41 B of the housing 17 and the back surface plate 43 . The lower end of the upper duct 46 B serves as an air supply port 46 C of the upper duct 46 B.
Air (gas) at the outside of the glove box 11 passes through the air supply catalyst 28 , invades into the air supply chamber 33 through the air supply valve 29 , prevails over the whole area of the air supply chamber 33 in the width direction, passes through the air supply filter 34 so that dust in the air (gas) is removed, and then flows into the working chamber 16 from the upper side. The air (gas) flowing into the working chamber 16 flows from the upper side to the lower side over the whole area of the working chamber 16 in the width direction, reaches the lower duct 46 A through the exhaust hole portions 45 of the front and rear edges of the working plate 42 , flows upwardly in the upper duct 46 B, passes through the exhaust gas filter 37 and then flows into the exhaust chamber 36 . The air (gas) flowing into the exhaust chamber 36 is sucked by the exhaust blower 14 , passed through the exhaust valve 30 and the exhaust catalyst 31 and then discharged to the outside.
FIGS. 3 and 4 are top views of the inside of the working chamber 16 . FIG. 3 shows a state that the joint box door 23 A is closed, and FIG. 4 shows a state that the joint box door 23 A is opened.
The joint box door 23 A has a hinge 23 B ( FIG. 1 ) at the lower edge thereof, and it is downwardly laid toward the working chamber 16 side around the hinge 23 B, whereby the opening state is set.
As shown in FIG. 3 , a substantially rectangular door mount recess portion 47 which is concaved downwardly is formed on the working plate 42 at the operation area 25 side. The door mount recess portion 47 is formed in conformity with the joint box door 24 A, and when the joint box door 23 A is set to the open state, the joint box door 23 A is mounted in the door mount recess portion 47 as shown in FIG. 4 . Under the state that the joint box door 23 A is mounted in the door mount recess portion 47 , the upper surface of the joint box door 23 A is coincident with the upper surface of the working plate 42 in height, and thus the joint box door 23 A serves as a part of the working plate 42 .
That is, when a cultivating work is performed, the joint box door 23 A is used under the open state, and functions as a working table. The cultivating work is mainly performed on the joint box door 23 A. As described above, the joint box door 23 A is downwardly laid to be set to the open state, and mounted in the door mount recess portion 47 . Therefore, the joint box door 23 A can be prevented from obstructing the display of the display 26 , and also the joint box door 23 A can be used as a working table.
A wall portion is provided between the door mount recess portion 47 and the lower duct 46 A, and thus the door mount recess portion 47 does not directly intercommunicate with the lower duct 46 A.
The centrifugal machine 20 is covered by an lid portion 20 A which is freely openable and closable, and located below the working plate 42 . The lid portion 20 A is provided so that the surface thereof is coincident with the surface of the working plate 42 and thus serves as a part of the working plate 42 . The end 47 A of the door mount recess portion 47 is located at the incubator 21 side with respect to the centrifugal machine 20 so that it does not disturb the arrangement of the centrifugal machine 20 .
The exhaust hole portions 45 extend in a belt-like arrangement in the width direction of the glove box 11 along the front and rear edges of the working plate 42 , and plural holes having substantially the same diameter are formed to penetrate through the working plate 42 and arranged to be spaced from one another at a substantially equal interval. The exhaust hole portions 45 are provided to the front and rear edges of the working plate 42 , and thus they are prevented from obstructing the cultivating work and the auxiliary work. Here, the exhaust hole portions 45 may be provided by directly forming holes in the working plate 42 or by providing punching metal or a mesh-like plate at the front and rear edge portions of the working plate 42 .
Furthermore, the upper duct 46 B and the lower duct 46 A are provided over the whole area in the width direction of the glove box 11 .
Each of the exhaust hole portion 45 is configured to have an operation area side exhaust hole portion 45 A provided in the operation area 25 (an exhaust hole portion at the operation area side), and an auxiliary working area side exhaust hole portion 45 B provided in the auxiliary working area 35 (an exhaust hole portion at the auxiliary working area side).
The operation area side exhaust hole portion 45 A is provided so that a part thereof is overlapped with the door mount recess portion 47 , and no hole is formed at the overlap portion thereof with the door mount recess portion 47 . Specifically, the operation area side exhaust hole portion 45 A at the rear edge side is provided only around (particularly, in the neighborhood) of the boundary portion S. In the operation area side exhaust hole portion 45 A at the front edge side, the operation area side exhaust hole portion 45 A is provided to be continuous from the boundary portion S to the incubator 21 side. However, in the operation area side exhaust hole portion 45 A, the number of holes located along the door mount recess portion 47 is set to be smaller than the number of holes located at the other portions.
Furthermore, the auxiliary working area side exhaust hole portions 45 B are provided to be continuous from the boundary portion S to the pass box 22 side ( FIG. 1 ) at both the front and rear edges.
That is, in the auxiliary working area side exhaust hole portions 45 B, a larger number of holes are formed than that in the operation area side exhaust hole portions 45 A. Therefore, in the exhaust hole portions 45 , the total opening space (the total area of the opening) of the holes in the auxiliary working area side exhaust hole portions 45 B is larger than the total opening space of the holes in the operation area side exhaust hole portions 45 A. Therefore, air (gas) more easily flows into the working chamber 16 at the auxiliary working area side exhaust hole portion 45 B side than that at the operation area side exhaust portion 45 A. Therefore, in the working chamber 16 , air (gas) flows from the operation area 25 side at the upstream side to the auxiliary working area 35 side at the downstream side. That is, air (gas) flow in the working chamber 16 is controlled by the exhaust hole portions 45 , and the exhaust hole portions 45 function as an air (gas) flow control unit.
Next, the air (gas) flow in the working chamber 16 will be described. In FIGS. 1 , 2 and 4 , the flow of air (gas) is represented by an arrow X.
As shown in FIG. 1 , fresh air is supplied from the air supply chamber 33 extending in the width direction into the whole area in the width direction of the working chamber 16 . This air flows downwardly as if it is attracted by the front and rear exhaust hole portions 45 .
As shown in FIG. 1 , the downwardly flowing air flow straightly downwardly in the auxiliary working area 35 , and flows into each of the front and rear auxiliary working area side exhaust hole portions 45 B. In the operation area 25 , most of the downwardly flowing air flows straightly downwardly to the neighborhood of the gloves 19 A, 19 B. Below the gloves 19 A, 19 B, the flow of the air is bent to the auxiliary working area 35 side around (particularly, in the neighborhood of the working plate 42 ) as if the air is attracted to the auxiliary working area side exhaust hole portions 45 B, and then the air flows into each of the auxiliary working area side exhaust hole portions 45 B. A part of the air flowing in the operation area 25 flows into the operation area side exhaust hole portions 45 A. Thereafter, the air flowing into the auxiliary working area side exhaust hole portions 45 B and the operation area side exhaust hole portions 45 A is passed through the lower duct 46 A and the upper duct 46 B and discharged from the exhaust blower 14 to the outside.
As described above, in the glove box 11 , the total opening area of the holes of the auxiliary working area side exhaust hole portions 45 B is set to be larger than the total opening area of the holes of the operation area side exhaust hole portion 45 A, whereby the air flows from the operation area 25 side to the auxiliary working area 35 side. Therefore, even when dust has already occurred when the auxiliary work is performed at the auxiliary working area 35 side, this dust is made to flow to the auxiliary working area side exhaust hole portions 45 B by the air flowing to the auxiliary working area 35 side. Accordingly, dust can be prevented from contaminating into the place at the operation area 25 side at which the cultivating work is performed.
Furthermore, in the operation area 25 , the air flowing downwardly to the neighborhood of the gloves 19 A and 19 B is attracted by the auxiliary working area side exhaust hole portions 45 B, and the air flow is bent to the auxiliary working area 35 side around the working plate 42 below the gloves 19 A, 19 B. Therefore, the air is made to flow from the upper side to the lower side while the air is supplied as uniformly as possible, and the air flow is bent to the auxiliary working area 35 side around the working plate 42 , thereby preventing contamination of dust.
Furthermore, two workers can simultaneously perform a work in the operation area 25 and the auxiliary working area 35 respectively while sharing the work by using the gloves 19 A, 19 B and the gloves 19 C, 19 D, respectively. Therefore, the working efficiency can be enhanced, and also even when a package for an instrument or the like is opened in the auxiliary working area 35 , dust caused by the package can be prevented from contaminating into the operation area 25 .
As described above, according to the first embodiment to which the present invention is applied, the air flowing from the upper side to the lower side in the operation area and the auxiliary working area 35 is controlled to flow from the operation area 25 side to the auxiliary working area 35 side around (particularly, in the neighborhood of) the gloves 19 A and 19 B by the auxiliary working area side exhaust hole portions 45 B of the exhaust hole portions 45 . Therefore, air (gas) can be made to flow from the operation area 25 side to the auxiliary working area 35 side while uniformly supplied into the working chamber 16 . Accordingly, dust caused by a package opened at the auxiliary working area 35 side is made to flow to the auxiliary working area side exhaust hole portions 45 B by the air (gas) stream from the operation area 25 side to the auxiliary working area 35 side, so that scattering of dirt and dust to the operation area 25 side can be prevented, and they can be prevented from affecting the cultivating work such as the operation, etc. of cells.
Furthermore, the air flow is controlled by the exhaust hole portions 45 provided to the working plate 42 in the operation area 25 and the auxiliary working area 35 . Therefore, the air (gas) flow can be controlled so that the air (gas) flows to the auxiliary working area 35 side around (particularly, in the neighborhood of) the working plate 42 , so that the air (gas) can be made to flow from the operation area 25 side to the auxiliary working area 35 side while the air (gas) is made to flow from the upper side to the lower side to uniformly supply the air (gas) into the working chamber 16 . Furthermore, the total opening area of the holes at the auxiliary working area 35 side is set to be larger than the total opening area of the holes at the operation area 25 side, whereby the air flow can be controlled. Accordingly, it is not required to provide any dedicated part for controlling the air flow, and the structure can be simplified.
Furthermore, the incubator 21 is provided at the operation area 25 side, and thus cells operated in the operation area 25 can be easily taken out from the operation area 25 and put into the incubator 21 . Therefore, the workability is excellent. Furthermore, contamination of dirt or dust into the incubator 21 can be prevented.
The first embodiment is a mere embodiment of the present invention, and thus the present invention is not limited to the first embodiment.
In the first embodiment, the inside of the working chamber 16 is sectioned into the operation area 25 and the auxiliary working area 35 . However, the present invention is not limited to this style, and the inside of the working chamber 16 may be sectioned into at least the operation area 25 and the auxiliary working area 35 . For example, a storage area for storing instruments, etc. may be provided adjacently to the auxiliary working area 35 . Furthermore, in the first embodiment, dirt and dust are caused by opening the packages. However, the present invention is not limited to this style. For example, dirt and dust may invade into the working area when the pass box 22 is opened. Still furthermore, in the first embodiment, the air supply port 46 C corresponds to the lower end of the upper duct 46 B connected to the exhaust blower 14 . However, the present invention is not limited to this style, and the air supply port may be an intercommunication port intercommunicating with a gas exhausting unit. For example, the air supply port may be an intercommunication port between the exhaust hole portion 45 and a duct connected to the exhaust unit such as an exhaust blower or the like provided to the outside of the isolator 10 .
The other detailed constructions may be arbitrarily changed.
Second Embodiment
A second embodiment to which the present invention is applied will be described with reference to FIG. 5 . In this embodiment, the same elements as the first embodiment are represented by the same reference numerals, and the description thereof is omitted.
The second embodiment is different from the first embodiment in that the door mount recess portion 47 of the first embodiment is not provided.
FIG. 5 is a top view of the inside of a working chamber 16 according to the second embodiment.
In the second embodiment, the joint box door (not shown) of the first embodiment is laterally (horizontally) opened, and thus it is turned to the display 26 side to be opened, so that the door mount recess portion 47 of the first embodiment is not provided to the working plate 42 . The working plate 42 has an operation area side working face 55 extending to the incubator 21 side. The operation area side working face 55 is formed to that the surface thereof is coincident with the surface of the working plate 42 in the auxiliary working area 35 , and no exhaust hole portion 45 is formed on the operation area side working face 55 . The end 55 A of the operation area side working face 55 is located at the incubator 21 side with respect to the centrifugal machine 20 . The cultivating work is mainly performed on the operation area side working face 55 .
The operation area side exhaust hole portion 45 A is provided only around (particularly, in the neighborhood of) the boundary portion S on the working plate 42 . Furthermore, the auxiliary working area side exhaust hole portion 45 B is continuously provided from the boundary portion S till the pass box 22 side ( FIG. 1 ).
As described above, the operation area side working face 55 having no exhaust hole portion 45 is provided in the operation area 25 , whereby the total opening area of the holes of the auxiliary working area side exhaust hole portions 45 B can be set to be relatively larger than the total opening area of the holes of the operation area side exhaust hole portions 45 A and thus the air flow can be controlled so that air flows form the operation area 25 to the auxiliary working area 35 .
Third Embodiment
A third embodiment to which the present invention is applied will be described hereunder with reference to FIG. 6 . In the third embodiment, the same constituent elements as the first embodiment are represented by the same reference numerals, and the description thereof is omitted.
The third embodiment is different from the first embodiment in that the area of the exhaust hole portion 145 varies continuously.
FIG. 6 is a top view showing the inside of the working chamber 16 according to the third embodiment.
In the third embodiment, a working plate 142 (lower surface) extending from the incubator 21 side to the pass box 22 side is provided in place of the working plate 42 of the first embodiment. In the third embodiment, the joint box door (not shown) shown with respect to the first embodiment is designed to be laterally opened, and the upper surface of the working plate 142 is formed to be flat over the whole surface thereof.
The exhaust hole portions 145 extends in the width direction of the glove box 11 along the front and rear edges of the working plate 142 respectively, and each of the exhaust hole portions 145 is formed in a belt-like shape so that the width thereof gradually increases from the incubator 21 side to the pass box 22 side. In plan view, each exhaust hole portion 145 is formed in a triangular shape to be tapered from the pass box 22 side to the incubator 21 side. That is, the total opening area of the holes of the auxiliary working area side exhaust hole portions 145 B formed at the auxiliary working area 35 side is set to be larger than the total opening area of the holes of the operation area side exhaust hole portions 145 A formed at the operation area 25 side.
As described above, by continuously varying the area of the exhaust hole portion 145 , the total opening area of the holes of the auxiliary working area side exhaust hole portions 145 B may be set to be larger than the total opening area of the holes of the operation area side exhaust hole portions 145 A, whereby air flow is controlled so that air flows from the operation area 25 to the auxiliary working area 35 .
Fourth Embodiment
A fourth embodiment to which the present invention is applied will be described with reference to FIG. 7 . In the fourth embodiment, the same constituent elements as the first embodiment are represented by the same reference numerals, and the description thereof is omitted.
In the fourth embodiment, the shape of an upper duct 146 continuous with the lower duct 46 A and the shape of the air supply port 146 C at the lower end of the upper duct 146 B are different from the shapes of the upper duct 46 and the air supply port 46 C of the first embodiment.
FIG. 7 is a top view of the inside of the working chamber 16 according to the fourth embodiment.
In the fourth embodiment, a working plate 242 (lower surface) extending from the incubator 21 side to the pass box 22 side is provided in place of the working plate 42 of the first embodiment. Furthermore, in the fourth embodiment, the joint box door (not shown) shown in FIG. 1 is designed to be laterally opened, and the upper surface of the working plate 242 is formed to be flat over the whole surface thereof.
Exhaust hole portions 245 extend over the whole length in the width direction of the glove box 11 along the front and rear edges of the working plate 242 respectively, and each of the exhaust hole portion 245 is formed in a belt-like shape to be uniform in width over the whole length thereof.
In the fourth embodiment, the upper duct 146 and the air supply port 146 C of the upper duct 146 B between the back surface 41 B of the housing 17 and the back surface plate 43 of the inner wall plate 40 ( FIG. 2 ) are designed to be gradually expanded in the depth direction of the glove box 11 from the incubator 21 side to the pass box 22 side. Therefore, air (gas) in the working chamber 16 easily flows to the pass box 22 side, and the air flows from the operation area 25 side to the auxiliary working area 35 side as indicated by arrows Y in FIG. 7 . As described above, the size of the upper duct 146 B is gradually increased while shifting from the operation area 25 side to the auxiliary working area 35 side, whereby air flow is controlled so that air (gas) flows to the auxiliary working area 35 side.
Fifth Embodiment
A fifth embodiment to which the present invention is applied will be described with reference to FIG. 8 .
In this fifth embodiment, the same constituent elements as the first embodiment are represented by the same reference numerals, and the description thereof is omitted.
In the fifth embodiment, the shape of the upper duct 246 B continuous with the lower duct 46 A and the shape of the air supply port 246 C at the lower end of the upper duct 246 are different from the shapes of the upper duct 46 B and the air supply port 46 C of the first embodiment.
FIG. 8 is a top view of the inside of the working chamber 16 according to the fifth embodiment.
In the fifth embodiment, the working plate 242 extending from the incubator 21 side to the pass box 22 side is provided in place of the working plate 42 of the first embodiment. Furthermore, in the fifth embodiment, the joint box door (not shown) described with reference to the first embodiment is designed to be laterally opened, and the upper surface of the working plate 242 is formed to be flat over the whole surface thereof.
The exhaust hole portions 245 extend over the whole length in the width direction of the glove box 11 along the front and rear edges of the working plate 242 respectively, and each of the exhaust hole portions 245 which is formed in a belt-like shape is formed to be uniform in width over the whole length thereof.
In the fifth embodiment, the upper duct 246 B and the air supply port 246 C thereof between the back surface 41 B of the housing 17 and the back surface plate 43 of the inner wall plate 40 ( FIG. 2 ) are formed only at the auxiliary working area 35 side. Accordingly, air (gas) in the working chamber 16 easily flows to the auxiliary working area 35 side, and air (gas) flows from the operation area 25 side to the auxiliary working area 35 side as indicated by arrows X in FIG. 8 . As described above, the exhaust passage 246 at the back surface 41 B side is disposed to be tilted to the auxiliary working area 35 side, whereby the air flow is controlled so that air (gas) flows to the auxiliary working area 35 side.
In the fifth embodiment, the upper duct 246 B is formed at only the auxiliary working area 35 side. However, the upper duct 246 B may be disposed to be tilted to the auxiliary working area 35 side, and a part of the upper duct 246 B may be provided in the operation area 25 .
Sixth Embodiment
A sixth embodiment to which the present invention is applied will be described with reference to FIGS. 9 to 12 . In the sixth embodiment, the same constituent elements as the first embodiment are represented by the same reference numerals, and the description thereof is omitted.
The sixth embodiment is different from the first embodiment in that the air supply blower 13 is provided at the operation area 25 side and the exhaust blower 14 is provided at the auxiliary working area 35 side.
FIG. 9 is a front view showing an isolator 100 according to the sixth embodiment. FIG. 10 is a side cross-sectional view of the isolator 100 . Specifically, FIG. 10 is a side cross-sectional view at the auxiliary working area 35 side.
The incubator 21 is provided to one end side of the glove box 11 through the joint box 23 , and the joint box 23 is provided with a laterally-opening type joint box door 123 A which is turned to the display 26 side and opened.
As shown in FIGS. 9 and 10 , the isolator 100 has the glove box 11 , and the air supply blower 13 and the exhaust blower 14 are separated from each other in the width direction of the glove box 11 by a partition member 132 provided at the intermediate portion in the width direction of the glove box 11 . The partition member 132 is located just above the boundary portion S.
An air supply chamber 133 and an air supply filter 134 which extend from one side in the width direction of the glove box 11 to the partition member 132 are connected to the air supply blower 13 . The air supply filter 134 is provided between the air supply chamber 133 and the working chamber 16 . Furthermore, an exhaust chamber 136 and an exhaust filter 137 which extend from the partition member 132 to the other end in the width direction of the glove box 11 are provided to the exhaust blower 14 . The exhaust filter 137 is provided between the exhaust chamber 136 and the working chamber 16 .
That is, in the isolator 100 , air (gas) is supplied from the air supply blower 13 at the upper side of the operation area 25 side into the working chamber 16 , and then discharged from the exhaust blower at the upper side of the auxiliary working area 35 to the outside.
Furthermore, the air supply filter 134 and the exhaust filter 137 are configured to be attachable/detachable to/from the front surface side of the isolator 100 . As described above, in the sixth embodiment, the air supply blower 13 and the exhaust blower 14 are arranged side by side in the width direction of the glove box 11 , and configured to be attachable/detachable to/from the front surface side of the isolator 100 , so that the maintenance performance is excellent.
As shown in FIG. 10 , an inner wall plate 140 which extends wholly in the width direction of the glove box 11 and partitions the inside of the glove box 11 is provided in the glove box 11 , and a space is formed at the lower portion and the back surface portion of the inside of the glove box 11 by the inner wall plate 140 . The inner wall plate 140 has a working plate 342 (lower surface) constituting the bottom surface portion of the working chamber 16 which is disposed to be spaced from the bottom surface 41 A of the housing 17 , a back surface plate 143 which is provided to be spaced from the back surface 41 B of the housing 17 and constitutes the back surface of the working chamber 16 , and a partition plate 144 for connecting the upper end of the back surface plate 143 and the upper surface of the working chamber 16 .
FIG. 11 is a top view of the inside of the working chamber 16 .
As shown in FIGS. 10 and 11 , the working plate 342 is provided substantially in parallel to the bottom surface 41 A, and the front and rear edges thereof are provided with exhaust hole portions 345 extending in the width direction of the glove box 11 . The back surface plate 143 is provided to be tilted to the auxiliary working area 35 side and continuous with the rear edge of the working plate 342 and extends upwardly in parallel to the back surface 41 B of the rear edge of the working plate 342 . The partition plate 144 obliquely extends from the upper edge of the back surface plate 143 to the front surface side, and is connected to the front edge of the upper surface of the working chamber 16 . The partition plate 144 is provided so as to cover the exhaust filter 137 from the lower side.
The space surrounded by the working plate 342 , the back surface plate 143 , the partition plate 144 , and the bottom surface 41 A and the back surface 41 B of the housing 17 functions as an exhaust passage 346 , and exhaust gas from the working chamber 16 passes through the exhaust passage 346 and flows into the exhaust blower 14 . The exhaust passage 346 has a lower duct 46 A passing below the working plate 342 , and an upper duct 346 B (exhaust duct) extending upwardly between the back surface 41 B of the housing 17 and the back surface plate 143 and intercommunicating with the exhaust filter 137 . The upper duct 346 B intercommunicates with the working chamber 16 through only the lower duct 46 A and the exhaust hole portions 345 . The lower end of the upper duct 346 serves as an air supply port 346 C of the upper duct 346 B.
The air supply filter 134 is not covered by the upper duct 346 B, and the air supply blower 13 is directly connected to the inside of the working chamber 16 through the air supply filter 134 .
In the sixth embodiment, the upper duct 346 B connected to the exhaust blower 14 and the air supply port 346 C at the lower end of the upper duct 346 B are provided to be tilted to the auxiliary working area 35 , and thus air (gas) in the working chamber 16 flows from the operation area 25 side to the auxiliary working area 35 side. That is, the air (gas) flow in the working chamber 16 is controlled on the basis of the position of the upper duct 346 , and the upper duct 346 B functions as an air (gas) flow control unit.
As shown in FIG. 11 , each exhaust hole portion 345 has plural holes of substantially the same diameter which are formed so as to be arranged at a substantially equal interval, and is designed in a belt-like shape having substantially the same width over the whole width of the working chamber 16 .
Each exhaust hole portion 345 has an operation side exhaust hole portion 345 A provided to the operation area 25 , and an auxiliary working side exhaust hole portion 345 B provided to the auxiliary working area 35 . Each exhaust hole portion 345 has substantially the same width over the whole width of the working chamber 16 , and thus the total opening area of the holes of the operation side exhaust hole portions 345 A is equal to the total opening area of the holes of the auxiliary working side exhaust hole portions 345 B. Here, the total opening area is equal between the operation side exhaust hole portions 345 A and the auxiliary working side exhaust hole portions 345 B are equal to each other, and this indicates that the total opening areas of the operation side exhaust hole portions 345 A and the auxiliary working side exhaust hole portions 345 B is equal to each other to the extent that the difference therebetween does not affect the air (gas) flow.
Next, the air (gas) flow in the working chamber 16 will be described with reference to FIGS. 9 to 11 . In FIGS. 9 to 11 , the air (gas) flow is represented by arrows X.
As shown in FIG. 9 , fresh air (gas) is supplied from the air supply chamber 133 through the air supply filter 134 to the upper side of the operation area 25 of the working chamber 16 by the air supply blower 13 , and this air (gas) downwardly flows as if it is attracted by the front and rear exhaust hole portions 345 as shown in FIG. 10 .
As shown in FIGS. 9 and 11 , the downwardly flowing air (gas) flows straightly downwardly to the neighborhood of the gloves 19 A, 19 B as if it is attracted to the operation side exhaust hole portions 345 A. The flow of a part of the air (gas) is bent to the auxiliary working area 35 side around (particularly, in the neighborhood of) the working plate 342 as it the air (gas) is attracted to the auxiliary working side exhaust hole portions 345 B below the gloves 19 A, 19 B, and then the air (gas) flows into the auxiliary working side exhaust hole portions 345 B. The residual air (gas) directly downwardly flows into the operation side exhaust hole portions 345 A. Thereafter, the air (gas) flowing into the auxiliary working side exhaust hole portions 345 B and the operation side exhaust hole portions 345 A is passed from the lower duct 46 A and the air supply port 346 C through the upper duct 346 B and then discharged from the exhaust blower 14 to the outside.
As described above, according to the sixth embodiment to which the present invention is applied, since the upper duct 346 B and the air supply port 346 C at the lower end of the upper duct 346 B of the exhaust passage 346 for exhausting air (gas) from the working chamber 16 are disposed to be tilted to the auxiliary working area 35 side, air (gas) flows to the upper duct 346 B side, and thus the air (gas) can be made to flow from the operation area 25 side to the auxiliary working area 35 side, thereby preventing dirt or dust from being scattered to the operation area 25 side.
Furthermore, the working plate 342 at the operation area 25 side is provided with the operation side exhaust hole portions 345 A whose total opening area is equal to that of the auxiliary working side exhaust hole portions 345 B, and thus air (gas) flows to the exhaust hole portions 345 of the operation area 25 and the auxiliary working area 35 . Therefore, an air (gas) stream flowing from the upper side to the lower side can be formed in the operation area 25 and the auxiliary working area 35 , and thus air (gas) can be uniformly supplied to both the operation area 25 and the auxiliary working area 35 . The air flow can be controlled with a simple structure that the upper duct 346 B is provided to the auxiliary working area 35 side, and thus air (gas) can be made to flow from the operation area 25 side to the auxiliary working area 35 side with a simple structure.
In the sixth embodiment, the exhaust hole portions 345 are provided over the whole width of the working chamber 16 . However, the present invention is not limited to this embodiment. The exhaust hole portions 345 may be provided to at least the auxiliary working area 35 of the working plate 342 . For example, as shown in FIG. 12 , an operation area side working face 155 on which no operation side exhaust hole portion 345 A is formed may be provided to the working plate 342 at the operation area 25 side. In this case, the air (gas) which is supplied by the air supply blower 13 and downwardly flows into the working chamber 16 is attracted to the upper duct 346 B disposed to be tilted to the auxiliary working area 35 side, and flows into the auxiliary working side exhaust hole portions 345 B as indicated by arrows X in FIG. 12 . Accordingly, the air (gas) can be made to flow from the operation area 25 side to the auxiliary working area 35 side, thereby preventing scattering of the dust to the operation area 25 side.
Furthermore, in the sixth embodiment, the joint box door 123 A is configured to be laterally opened. However, the present invention is not limited to this embodiment, and the joint box door 123 A may be configured to be downwardly laid to the working chamber 16 side as in the case of the first embodiment. In this case, a recess portion for mounting the joint box door 123 A may be provided to the working plate 342 , and the joint box door 123 A may be used as a working table.
Seventh Embodiment
A seventh embodiment to which the present invention is applied will be described with reference to FIGS. 13 to 16 . The same constituent elements as the first embodiment are represented by the same reference numerals, and the description thereof is omitted.
The seventh embodiment is different from the first embodiment in that the exhaust blower 14 is provided below the working chamber 16 .
FIG. 13 is a front view showing an isolator 200 according to the seventh embodiment. FIG. 14 is a side cross-sectional view showing the isolator 200 .
The incubator 21 is provided to one end side of the glove box 11 through the joint box 23 . The joint box 23 is provided with a joint box door 123 A which is designed to be turned to the display 26 side and opened laterally.
As shown in FIGS. 13 and 14 , the isolator 200 has the glove box 11 , the air supply blower 13 is disposed above the glove box 11 and the exhaust blower 14 is disposed below the glove box 11 .
The air supply blower 13 is connected to the working chamber 16 through an air supply chamber 233 and an air supply filter 234 . The air supply blower 13 , the air supply chamber 233 and the air supply filter 234 are disposed at one side in the width direction of the glove box 11 , and it is located at the side of the incubator 21 with respect to the boundary portion S.
Furthermore, the exhaust blower 14 is connected to the bottom surface 41 A of the housing 17 from the lower side through an exhaust chamber 236 and an exhaust filter 237 (air supply port). The exhaust blower 14 , the exhaust chamber 236 and the exhaust filter 237 are disposed at the other side in the width direction of the glove box 11 , and it is located at the side of the pass box 22 with respect to the boundary portion S.
That is, in the isolator 200 , air (gas) is supplied from the air supply blower 13 at the upper side of the operation area 25 into the working chamber 16 , and then discharged from the exhaust blower 14 at the lower side of the auxiliary working area 35 to the outside. Furthermore, the air supply filter 234 and the exhaust filter 237 are configured to be attachable/detachable to/from the front surface side of the isolator 200 , so that the maintenance performance is excellent.
As shown in FIG. 14 , a working plate 442 (lower surface) for partitioning the lower portion of the glove box 11 is provided in the glove box 11 . The working plate 442 is provided substantially in parallel to the bottom surface 41 A of the housing 17 so as to be spaced from the bottom surface 41 A of the housing 17 , and constitutes the bottom surface of the working chamber 16 .
FIG. 15 is a top view of the inside of the working chamber 16 .
As shown in FIGS. 14 and 15 , the working plate 442 is provided substantially in parallel to the bottom surface 41 A, and exhaust hole portions 445 extending in the width direction of the glove box 11 are provided to the front and rear edges of the working plate 442 , respectively. An exhaust passage 446 is formed below the working plate 442 , and it is formed by a space formed between the bottom surface 41 A and the working plate 442 . The exhaust passage 446 is connected to the exhaust blower 14 through the exhaust filter 237 provided at the auxiliary working area 35 side. That is, the exhaust filter 237 functions as an air supply port of the exhaust blower 14 in the glove box 11 .
As shown in FIG. 15 , each exhaust hole portion 445 is designed in a belt-like shape having substantially the same width over the whole width of the working chamber 16 , and plural holes having substantially the same diameter are formed in each exhaust hole portion 445 so as to be arranged at a substantially equal interval.
Each exhaust hole portion 445 comprises an operation area side exhaust hole portion 445 A provided in the operation area 25 , and an auxiliary working area side exhaust hole portion 445 B provided in the auxiliary working area 35 . Each exhaust hole portion 445 has substantially the same width over the whole width of the working chamber 16 , and thus the total opening area of the holes of the operation area side exhaust hole portion 445 A is equal to the total opening area of the holes of the auxiliary working area side exhaust hole portion 445 B. Here, the total opening area is equal between the operation area side exhaust hole portion 445 A and the auxiliary working area side exhaust hole portion 445 B, and this indicates that the total opening area is equal between the operation area side exhaust hole portion 445 A and the auxiliary working area side exhaust hole portion 445 B to the extent that the difference in total opening area therebetween does not affect the air (gas) flow of the working chamber 16 .
In the seventh embodiment, the exhaust blower 14 is provided at the auxiliary working area 35 side below the glove box 11 , and in connection with this structure, the exhaust filer 237 as the air supply port is connected to the exhaust passage 446 of the auxiliary working area 35 . Therefore, air (gas) in the working chamber 16 flows from the operation area 25 side to the auxiliary working area 35 side. That is, the air (gas) flow in the working chamber 16 is controlled on the basis of the position of the exhaust filter 237 , and thus the exhaust filter 237 functions as an air (gas) flow control unit.
Next, the air (gas) flow in the working chamber 16 will be described with reference to FIGS. 13 to 15 . In FIGS. 13 to 15 , the air (gas) flow is represented by arrows X.
As shown in FIG. 13 , refresh air (gas) is supplied from the air supply chamber 233 through the air supply filter 234 into the upper portion of the operation area 25 of the working chamber 16 . As shown in FIG. 14 , this air (gas) flows downwardly as if it is attracted by the front and rear exhaust hole portions 445 .
As shown in FIGS. 13 to 15 , the downwardly flowing air (gas) flows straightly downwardly to the neighborhood of the gloves 19 A, 19 B as if it is attracted by the operation area side exhaust hole portions 445 A. The flow of a part of the air (gas) is bent to the auxiliary working area 35 side around (particularly, in the neighborhood of) the working plate 442 as if the air (gas) is attracted by the auxiliary working area side exhaust hole portions 445 B located below the gloves 19 A, 19 B, and then the air flows into the auxiliary working area side exhaust hole portions 445 B. The residual air (gas) directly flows downwardly and then flows into the operation area side exhaust hole portions 445 A. Thereafter, the air (gas) flowing into the auxiliary working area side exhaust hole portions 445 B and the operation area side exhaust hole portions 445 A is passed through the exhaust passage 446 , the exhaust filter 237 and the exhaust chamber 236 and then discharged from the exhaust blower 14 .
As described above, according to the seventh embodiment to which the present invention is applied, air (gas) in the working chamber 16 flows to the exhaust filter 237 as the air supply port of the exhaust blower 14 provided below the working plate 442 at the auxiliary working area 35 side. Therefore, the air (gas) flow can be controlled on the basis of the arrangement position of the exhaust blower 14 so that the air (gas) flows from the operation area 25 side to the auxiliary working area 35 side, and scattering of dirt or dust to the operation area 25 side can be prevented by controlling the air (gas) flow in the working chamber 16 with a simple construction.
Furthermore, the operation area side exhaust hole portion 445 A and the auxiliary working area side exhaust hole portion 445 B are equal to each other in opening area, and air (gas) flows in both the operation area 25 and the auxiliary working area 35 , so that an air (gas) stream flowing from the upper side to the lower side can be formed to both the areas and thus air (gas) can be uniformly supplied to both the areas.
In the seventh embodiment, the exhaust hole portions 445 are provided over the whole width of the working chamber 16 , however, the present invention is not limited to this style. The exhaust hole portions 445 may be provided to at least the auxiliary working area 35 of the working plate 442 . For example, as shown in FIG. 16 , an operation area side working face 255 on which no operation area side exhaust hole portion 445 A is formed may be provided to the working plate 442 at the operation area 25 side. In this case, the air (gas) which is supplied by the air supply blower 13 and flows downwardly in the working chamber 16 is sucked and attracted to the exhaust filter 237 of the exhaust blower 14 disposed at the auxiliary working area 35 side, and flows into the auxiliary working area side exhaust hole portions 445 B as indicated by the arrows X in FIG. 16 . Accordingly, air (gas) can be made to flow from the operation area 25 side to the auxiliary working area 35 side, and scattering of dirt and dust to the operation area 25 side can be prevented.
Furthermore, in the seventh embodiment, the joint box door 123 A is configured to be laterally opened, however, the present invention is not limited to this style. The joint box door 123 A may be configured to be downwardly laid to the working chamber 16 side as in the case of the first embodiment. In this case, the a recess portion in which the joint box door 123 A is mounted is provided to the working plate 442 , and the joint box door 123 A is used as a working table. | An isolator for cultivating cells including a working chamber having a plurality of gloves arranged side by side into which operator's hands are inserted to operate cells, the working chamber being sectioned into at least an operation area for operating the cells, and an auxiliary working area for opening a packaged auxiliary instrument used to operate the cells, a gas supply unit that supplies gas into the working chamber so that the gas flows downwardly from an upper side in the working chamber, and a gas flow control unit for controlling the flow of the downwardly flowing gas so that the gas flows from the operation area to the auxiliary working area around the gloves, wherein the gas flow control unit has an exhaust hole portion that has an opened area for passing the gas therethrough and is provided at a lower portion of at least the auxiliary working area, and through which the gas in the auxiliary working area is exhausted. | 2 |
FIELD OF THE INVENTION
This invention relates to an improved format for recording data on a magnetic storage medium and the like and more particularly to a format that affords identification and correction of recording errors.
DESCRIPTION OF THE PRIOR ART
Data stored on magnetic disks is typically organized in sectors each of which has a unique address followed by a stream of data. The address permits the sector to be identified so that the desired data can be recovered or read. Because the weakest links in a magnetic storage system are the magnetic medium and the medium/head interface, erroneous recording and recovering of data usually arises from magnetic deficiencies rather than from electronic deficiencies. If the stored data is incorrect due to inaccuracies in recording or recovering the data, it is desirable to know that an error has occurred and to be able to correct the error.
One technique for affording an indication whether an error in data recording and/or recovering has occurred is known as a Cyclic Redundancy Check as described in Signetics "BiPolar/MOS Microprocessor Data Manual," Copyright 1977, at page 112. Cyclic Redundancy Check is referred to hereinafter as CRC. In a CRC system selected data bits are combined in accordance with a prescribed equation to produce a CRC signal which is recorded in a sector after the data is recorded in the sector. If on recovering the data and the CRC and subjecting the data to the same equation to derive a new CRC, the new CRC is different from the recorded CRC, such difference is an indication of erroneous recording and/or reading. The CRC system merely indicates the existence of an error but does not permit correction of the erroneous data recording.
SUMMARY OF THE INVENTION
In accordance with the present invention a sector of data composed of a plurality of data bits in binary or other form is converted into a group of data segments wherein each data segment is of uniform length and is smaller than a sector. If each sector is grouped or formed into n data segments, then each data segment has 1/n times the number of bits as in the entire sector so that all bits are recorded. Each data segment is recorded with a timing pattern and a CRC field that is related only to the data segment, and in addition the data in each data segment is combined with the data in all other data segments in a unique manner to produce a check segment which is recorded after all data segments are recorded. The check segment, which can be created by combining all data segments in an exclusive OR circuit, is a function of the contents of all data segments so that if one data segment is in error, its true value can be recovered by properly combining the correctly recorded data segments and the check segment. The identity of the supposed erroneous data segment is established in accordance with the prior art by comparing each CRC field with the data in its associated data segment. Accordingly, the present invention not only provides for an indication of erroneous recording but also a procedure for reconstructing the erroneously recorded data into correct data.
The above-mentioned timing signal is used in conjunction with each segment and is prevented from changing until the completion of recording of all segments in a sector. Accordingly, only if the timing signals associated with all segments in a sector are the same does the circuit attempt to recover the data.
An object of the invention is to so format data before its recordation onto a magnetic disk or like medium that any errors in recording or reading are made known and certain types of errors can be corrected.
Another object of the invention is to provide a circuit for achieving the last-mentioned object which can be introduced into existing equipment without substantial modification thereto. This object is achieved because the circuit of the invention is adapted for installation between an existing central processing unit and an existing disk drive unit and is adapted to operate on the data without adversely affecting data flow between such existing units.
The foregoing, together with other objects, features and advantages, will be more apparent after referring to the following specification and the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram of a data transmission system in accordance with the present invention.
FIG. 2 is a block diagram of a portion of FIG. 1 in more detail.
FIGS. 3A-3D are block diagrams of a portion of FIG. 2 in alternate positions and in still more detail.
FIG. 4 is a pictorial diagram of a sector of data recorded in accordance with the invention.
FIG. 5 is a pictorial diagram of the header of the data format of FIG. 4.
FIG. 6 is a pictorial diagram of the data segment of the data format shown in FIG. 4.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring more particularly to the drawings, reference numeral 12 indicates formatting apparatus according to the invention which is shown in association with a peripheral processing unit (PPU) 13 coupled to a main bus 14 to which a central processing unit (CPU) 15 is also connected. Formatting apparatus 12 is connected between PPU 13 and a disk storage system or disk drive 16. Peripheral processing unit 13 is a part of an existing computer and is controlled by the computer for effecting writing of data into disk drive 16 and reading the data therefrom. As is typical of systems of this nature there is a data bus 18 extending from peripheral processing unit 13 and a command/status bus 20. The data is supplied to and from the peripheral processing unit over the data bus, and command and other related control signals are supplied to and from the processing unit on command/status bus 20. There are circuit paths between formatting apparatus 12 and disk drive 16; they will be described in more detail herinafter.
Formatting apparatus 12 includes a nanoprocessor 26, which controls data flowing between peripheral processing unit 13 and disk drive 16, and a microprocessor 28, which is connected to command/status bus 20 and disk drive 16. Microprocessor 28 controls nanoprocessor 26.
FIG. 2 shows in more detail the construction of nanoprocessor 26. Data is coupled on bus 18 to an input/output FIFO shift register 30 which has its output coupled by a circuit path 32 to a switch 34. The functions of switch 34 will be described subsequently. Among other things, switch 34 couples data via a circuit path 35 to disk drive 16. Switch 34 also couples data to a first buffer 36 via a path 38 and to a second buffer 40 via a path 42. Buffers 36 and 40 function to store data temporarily during transfer of data between PPU 13 and disk drive 16 for purposes that are explained below; the buffers can be embodied in RAMs. Switch 34 also couples data to a CRC generator 44 via a path 46 and to input/output shift register 30 via a path 48. Additionally, switch 34 receives data inputs from first buffer 36 on a path 50, from second buffer 40 on a path 52 and from CRC generator 44 on a path 54. Finally, switch 34 has a flag output path 55 on which appears a state signal indicative of accurate (or inaccurate) recordation or recovery of data.
The circuits enumerated in the preceding paragraph respond to command signals supplied over bus 20. Such signals are processed by microprocessor 28 to cause nanoprocessor 26 to convert data received by it on bus 18 into a format according to the invention. The specific nature of the format is dictated by a control and timing circuit shown schematically at 56. Because the elements that constitute control and timing circuit 56 are not per se novel, a description of the various functions performed by the control and timing circuit suffices to afford an understanding of the circuit. There are signal paths between the control and timing circuit 56 and each of the elements previously specified. More specifically, there is a control path 60 extending from the control and timing circuit to input/output shift register 30, a control path 62 extending to CRC generator 44, a control path 64 extending to second buffer 40, a control path 66 extending to first buffer 36, a control path 68 extending to switch 34 and a control path 70 extending to disk drive 16.
There is a pattern store 72 which has an input 74 from control and timing circuit 56 and an input 76 from microprocessor 28. Pattern store 72 has an output 78 coupled to the input of switch 34. The pattern store is loaded from microprocessor 28 with a time signal for recordation in disk drive 16 which time pattern is prevented from changing during recordation of a given sector. Additionally, there is a control path 80 extending from microprocessor 28 to disk drive 16 for providing timing signals during recording and recovery of the data. A data path 81 extends from disk drive 16 to switch 34; data is transmitted over path 81 upon readout of the data from disk drive 16. A circuit path 82 from disk drive 16 to control and timing circuit 56 and a circuit path 83 from the disk drive to microprocessor 28 convey signals indicative of the status of the disk drive to the control and timing circuit and the microprocessor.
Although switch 34 can be embodied in a variety of forms, a suitable form, seen in FIGS. 3A-3D includes a read only memory (ROM) 84. At the upper left are the data inputs to the ROM which correspond to those seen in FIG. 2. At the right hand side are outputs of the switch corresponding to those shown in FIG. 2. At the lower left, control path 68 is seen to be composed of a plurality of lines, and the digital signal pattern on the lines dictates the interconnections established between the data inputs and the data outputs of the ROM. ROM 84 also is capable of generating an exclusive OR (XOR) function, such function being pictorially and schematically indicated at 85 and being described more fully hereinbelow.
As will appear subsequently, the above-described apparatus produces a data format schematically depicted in FIGS. 4, 5 and 6. Shown in those figures is a portion of a single data track on a magnetic medium in disk drive 16, the portion at the left hand extremity of each figure leading the portion at the right hand figure as the magnetic medium moves relative to a conventional read/write head (not shown). Referring to FIG. 4, each sector 86 begins with a header gap 87 which identifies the beginning of a sector and synchronizes the clock in disk drive 16. Next is a header 88 which uniquely identifies the sector so that the sector can be addressed. Gap 87 and header 88 are permanently written on the magnetic medium. As seen in FIG. 5 header 88 includes a sync portion 90, which can be composed of a bit pattern suitable for preparing system logic for receipt of further data. Next, the header has a location or address field 92. Location field 92 can include a plurality of bits, e.g., 32 bits, that provide a unique address for each sector 86 within a given disk drive system. Finally, the header includes a CRC portion 94 which contains a prescribed number of bits, e.g., 15, and has a value derived from the specific signal recorded in location field 92 so that on readout of the data a comparison of a CRC signal generated from the data stored in location field 92 and the CRC signal stored in portion 94 indicates whether an error exits in the reading process. Following header 88 is a gap 96 which produces a signal indicating termination of the header segment and commencement of a first data segment 98. The composition of the information written in first data segment 98 is seen in greater detail in FIG. 6.
Data segment 98 commences with a sync field identified at 100. The sync field defines the beginning of a data segment and is composed of a binary signal, e.g., a series of eight ones, for preparing system logic for ensuing data. Next is a data field 102 in which is recorded a segment of data, i.e., a portion of the data in the entire sector. In one system designed in accordance with the invention there are nine data segments exemplified by data segment 98, and the data field in each contains 115 32-bit words or a total of 3,680 bits. Next, data segment 98 contains a time code portion 104 which can be a series of 32 bits indicative of the time of writing the data. As has been indicated and will be recapitulated subsequently, microprocessor 28 in cooperation with pattern store 72 assures that the time code recorded in each segment will be uniform throughout all segments in a given sector. Finally, data segment 98 includes a CRC portion 106 which includes a signal having a value that is a function of the information recorded in data field 102 and time code portion 104 so that upon readout, comparison of the recorded CRC signal with a CRC signal generated from the data field and time code portion as they are read from the medium in disk drive 16 provides an indication of errors or the lack thereof in writing or reading of the data.
The remaining data segments which are identified in FIG. 4 by the legends SEG 2-SEG 9 are equivalent to data segment 98 and are recorded in sequence on the magnetic medium. After data SEG 9 is recorded a check segment 108 is generated and recorded. Check segment 108 is identical in format to data segment 98 and the information recorded in data field 102 of check segment 108 is a prescribed function of the data recorded in the data fields of the preceding nine data segments. Such function is exemplified in the apparatus shown in FIGS. 3A-3D as an exclusive OR (XOR) function. Thus, if the data field in one of the data segments is erroneously written or read, the content of such data segment can be reconstructed from the function recorded in the data field of check segment 108 and the data recorded in the remaining correctly recorded and read data segments.
The procedure for producing the check segment data field will be explained in connection with FIGS. 2 and 3A-3D. Referring to FIG. 2, data coupled over bus 18 to shift register 30 is applied to switch 34 over path 32. Under the control of control and timing circuit 56 acting on paths 60 and 68, the data field of the first data segment is recorded on disk drive 16 over path 35. The connections effected by switch 34 for recording the data in the first data segment are shown in FIG. 3A. Simultaneous with application of the data over path 35 to the disk drive, the data is also applied to second buffer 40 over path 42 for temporary storage and to CRC register 44 over path 46.
Data in the second data segment (see FIG. 3B) is similarly transmitted by switch 34 from circuit path 32 to circuit path 35. The data is also applied to CRC generator 44 over path 46. Additionally, the incoming data field for data segment 2 is combined with the data previously stored in the second buffer (applied over circuit path 52) to produce an XOR function at 85. The XOR function is applied to first buffer 36 over path 38 for temporary storage in that buffer.
During recordation of data in the third data segment (see FIG. 3C) switch 34 couples the data from path 32 to path 35 and to path 46. In addition, the data is combined with the contents of the first buffer (applied over circuit path 50) to produce an XOR function of the data contained in data segments 1, 2 and 3. Such XOR function, produced at 85, is supplied to the second buffer on path 42 for storage in that buffer.
The above procedure is alternated for succeeding data segments, switch 34 directing data as depicted in FIG. 3B during even segments and as depicted in FIG. 3C during odd segments. When the data fields in all data segments have been recorded, the data field in check segment 108 is recorded, and switch 34 controls data flow in the manner seen in FIG. 3D. The content of the second buffer, after recordation of the data field for the ninth data segment, is the XOR function of all preceding data segments and such is directly connected to path 35 for recordation in disk drive 16 and to path 46 for transmission to CRC generator 44. The connections effected by switch 34 as seen in FIG. 3D are for the case where the final data segment is an odd data segment. Obviously, if the final data segment were an even segment then circuit path 50 from the first buffer would be applied to circuit path 35.
Operation of the formatting apparatus of the present invention is typically commenced when CPU 15 sends data on main bus 14 to peripheral processing unit 13 with a command to store the data. Referring to FIG. 2, the data is conveyed over path 18 to shift register 30 and the command signals are conveyed over path 20 to microprocessor 28. The microprocessor loads pattern store 72 on path 76 with the signals for time code portion 104 (see FIGS. 4-6). When the appropriate header 88 is read by the read/write head in disk drive 16, a signal is applied on path 55 to control and timing circuit 56. The latter circuit applies a signal on path 68 which forces switch 34 to write over path 35 a series of zeros to form gap 96 on the medium in disk drive 16. Next, the control and timing circuit 56, acting over path 68, forces switch 34 to write a series of ones which constitute sync portion 100 of the first data segment 100. Then one segment of data from shift register 30 is coupled by switch 34 from circuit path 32 to circuit path 35 to effect recordation of data field 102 in disk drive 16. During such recordation of the data field of data segment 1 (see FIG. 3A), such data field is coupled over circuit path 42 to second buffer 40 in which the data is temporarily stored. At the same time, the data is coupled over path 46 to CRC generator 44. Upon completion of the recordation of the data field, a time code signal is coupled from pattern store 72 on path 78, and under the influence of the control signal on circuit path 68, the time code is transmitted over circuit path 35 for recordation in the disk drive and over circuit path 46 to CRC generator. Upon completion of recordation of the time code, CRC generator 44 generates a CRC signal that is a function of both the data recorded in data field 102 and the time code recorded in time code portion 104. Such CRC signal is connected by switch 34 from circuit path 64 to circuit path 35 for recordation in disk drive 16. Thereafter, a gap equivalent to gap 96 is recorded under control of the signal on circuit path 68 which causes switch 34 to force a series of zeros on path 35.
Data segment 2 is recorded next and commences with a sync signal 100. Then data from register 30 is connected over path 32 through switch 34 to circuit path 35 to establish data field 102 for data segment 2. The data is also coupled to CRC generator 44 on path 46. See FIG. 3B. Simultaneously with recording the data field for data segment 2, the content of second buffer 40 is applied to switch 34 on path 52 and is XORed with the data entering on path 32 by means of XOR function 85. The XORed data is conducted on path 38 for temporary storage in first buffer 36. The XORed data is stored in first buffer 36 during completion of recording of data segment number 2 which includes a time code portion 104, a CRC portion 106 and a gap 96.
Recordation of the third data signal then proceeds with recordation of a sync portion 100. During recordation of the data field in data segment 3, switch 34 is supplied with an appropriate control signal over circuit path 68 to effect the connections shown in FIG. 3C. As seen in FIG. 3C, data from register 30 is connected from input circuit path 34 to output circuit path 35 for transmittal to disk drive 16 and to path 46 for transmittal to CRC generator 44. The data is also XORed with the data stored in first buffer 36, the output of the XOR function being connected via path 42 to second buffer 40. After the data field for segment 3 is stored in disk drive 16, a time code, CRC signal and gap are recorded.
The data fields for subsequent even numbered segments are handled as seen in FIG. 3B which shows that as the data field is conveyed to disk drive 16 and to CRC generator, the data is XORed with the contents of second buffer 40. The data fields in subsequent odd segments are handled as shown in FIG. 3C in which as data is recorded in disk drive 16 the data is XORed with the contents of first buffer 36.
The final segment in sector 86, as explained previously in connection with FIG. 4, is a check segment 108. After a sync portion 100 of the check segment is recorded in disk drive 16 the output of second buffer 40 is connected to circuit path 35 for recordation in the disk drive and to circuit path 46 for transmittal to CRC generator 44. At this time, the second buffer contains the XOR function of the data fields in data segments 1-9, inclusive. When the data field for check segment 108 has been written, a time code and CRC signal are recorded and storage of the data sector is complete.
Read out of the data occurs when a unit, such as CPU 15, on main bus 14 calls for the data sector recorded as described next above. PPU 13 and the circuit of the invention cause the data in the addressed sector to be delivered from disk drive 16 to the main bus. After the desired sector is located by identification of its header 88, the data is conveyed from disk drive 16 to switch 34 on path 81. Switch 34 connects the data to register 30 on path 48 and to CRC generator 44 on path 46. The output of register 30 is coupled to PPU 13 on data bus 18 to effect delivery of the data to main bus 14. When the data from data field 102 of the first data segment has been read, the time code is applied by switch 34 to CRC generator 44 and to first buffer 36 so that the time codes in subsequent segments can be compared with the temporarily stored time code. After the time code has been read, CRC generator 44 contains a newly generated CRC signal that is a function of the data field and time code in the first data segment. Such newly generated CRC signal is applied to switch 34 on path 54 for comparison with the CRC signal 106 as read from the medium in disk drive 16 and as applied to switch 34 on path 81. The result of the comparison is manifested on flag output path 55, one state indicating equality of the two CRC signals and an opposite state indicating inequality. The flag is applied to microprocessor 28 through control and timing circuit 56 for transmission with status information over main bus 14 to the CPU.
Read out of subsequent data segments is as described in the immediately preceding paragraph except that the time code in each succeeding data segment is compared with the time code stored in buffer 36 from the first data segment. A flag signal indicating equality or inequality of the time codes is applied to flag output path 55 and to the main bus.
When check segment 108 is applied over path 81 to switch 34, it is coupled over path 42 for temporary storage in buffer 40. The flag signals produced on flag output path 55 are conveyed to microprocessor 28 through control and timing circuit 56. Microprocessor 28 determines whether the time code for the segments match and whether the CRC signal for each segment is correct. If only one segment has a CRC error and all other segments have matching time codes, the microprocessor produces a status signal that indicates that the data can be recovered. The status signal is made available to the CPU on main bus 14. If the circuit of the invention is so instructed by the CPU, the check segment temporarily stored in buffer 40 is applied to switch 34 on path 52 and then to register 30 on path 48 for delivery to the main bus.
Thus, it will be seen that the present invention provides a data format for recordation in a disk drive which permits both detection of occurrence of an error and reconstruction of the data when only one segment has been erroneously recorded. This mode of operation is made possible because, as the data field and time code in each segment are recorded, a CRC signal for that individual data segment and time code is produced and recorded and because the data in each data field are accumulated and combined according to a prescribed function with data in all other data fields to produce a check signal from which data in one segment can be reconstructed if the data in such segment are erroneously recorded or read out and if the time code in every segment is identical. In the specific embodiment described above and shown in the drawings, the prescribed function employed in combining all data fields to produce the check segment is an XOR function; such function is exemplary, not limiting. Because the formatting apparatus of the invention can be introduced between an existing peripheral processing unit and an existing disk drive, the advantages of the invention can be achieved without significant equipment replacement or redesign.
Although one embodiment of the invention has been shown and described, it will be obvious that other adaptations and modifications can be made without departing from the true spirit and scope of the invention. | A sector of data to be recorded on a magnetic medium is formatted by dividing the data sector into a plurality of data segments. Recorded with each segment is a time code which is identical for all segments in a given sector. During recordation of the data and time code for each segment, a cyclic redundancy check (CRC) signal is generated and the CRC signal is recorded after the data and the time code. As data in a segment is recorded, it is also temporarily stored. The temporarily stored data is combined according to a prescribed function with data in the succeeding segment and that function is temporarily stored for combination with the data in the next succeeding segment so that after all segments of data have been recorded there is a function that uniquely represents the data in all data segments. The function is recorded as a check segment. On recovery of the data, an error in any given segment can be detected by employment of the CRC signal associated with the segment containing an error. Reconstruction of the data in the erroneously recorded or read segment can be achieved by combining the contents of the correctly recorded and read data segments and the check segment, provided that the time codes read in these segments are identical. | 6 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This is a continuation in part of co-pending U.S. patent application Ser. No. 11/749,591, filed May 16, 2007.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not applicable
REFERENCE TO A “MICROFICHE APPENDIX”
[0003] Not applicable
BACKGROUND OF THE INVENTION
[0004] 1. Field of the Invention
[0005] The present invention relates to a method and apparatus that is of particular utility in cementing operations associated with oil and gas well exploration and production. More specifically the present invention provides an improvement to cementing operations and related operations employing a plug or ball dropping head.
[0006] 2. General Background of the Invention
[0007] Patents have issued that relate generally to the concept of using a plug, dart or a ball that is dispensed or dropped into the well or “down hole” during oil and gas well drilling and production operations, especially when conducting cementing operations. The following possibly relevant patents are incorporated herein by reference. The patents are listed numerically. The order of such listing does not have any significance.
[0000]
TABLE
PATENT
NO.
TITLE
ISSUE DATE
3,828,852
Apparatus for Cementing Well Bore Casing
Aug. 13, 1974
4,427,065
Cementing Plug Container and Method of
Jan. 24, 1984
Use Thereof
4,624,312
Remote Cementing Plug Launching System
Nov. 25, 1986
4,671,353
Apparatus for Releasing a Cementing Plug
4,671,353
4,722,389
Well Bore Servicing Arrangement
Feb. 02, 1988
4,782,894
Cementing Plug Container with Remote
Nov. 08, 1988
Control System
4,854,383
Manifold Arrangement for use with a Top
Aug. 08, 1989
Drive Power Unit
4,995,457
Lift-Through Head and Swivel
Feb. 26, 1991
5,095,988
Plug Injection Method and Apparatus
Mar. 17, 1992
5,236,035
Swivel Cementing Head with Manifold
Aug. 17, 1993
Assembly
5,293,933
Swivel Cementing Head with Manifold
Mar. 15, 1994
Assembly Having Remove Control Valves
and Plug Release Plungers
5,435,390
Remote Control for a Plug-Dropping Head
Jul. 25, 1995
5,758,726
Ball Drop Head With Rotating Rings
Jun. 02, 1998
5,833,002
Remote Control Plug-Dropping Head
Nov. 10, 1998
5,856,790
Remote Control for a Plug-Dropping Head
Jan. 05, 1999
5,960,881
Downhole Surge Pressure Reduction System
Oct. 05, 1999
and Method of Use
6,142,226
Hydraulic Setting Tool
Nov. 07, 2000
6,182,752
Multi-Port Cementing Head
Feb. 06, 2001
6,390,200
Drop Ball Sub and System of Use
May 21, 2002
6,575,238
Ball and Plug Dropping Head
Jun. 10, 2003
6,672,384
Plug-Dropping Container for Releasing a
Jan. 06, 2004
Plug Into a Wellbore
6,904,970
Cementing Manifold Assembly
Jun. 14, 2005
7,066,249
Plug-Dropping Container for Releasing a
Jan. 06, 2004
Plug into a Wellbore
BRIEF SUMMARY OF THE INVENTION
[0008] The present invention provides an improved method and apparatus for use in cementing and like operations, employing a plug or ball dropping head of improved configuration.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0009] For a further understanding of the nature, objects, and advantages of the present invention, reference should be had to the following detailed description, read in conjunction with the following drawings, wherein like reference numerals denote like elements and wherein:
[0010] FIGS. 1A , 1 B, 1 C are partial sectional elevation views of the preferred embodiment of the apparatus of the present invention wherein line A-A of FIG. 1A matches line A-A of FIG. 1B , and line B-B of FIG. 1B matches line B-B of FIG. 1C ;
[0011] FIG. 2 is a partial, sectional, elevation view of the preferred embodiment of the apparatus of the present invention;
[0012] FIG. 3 is a partial, sectional, elevation view of the preferred embodiment of the apparatus of the present invention;
[0013] FIG. 4 is a sectional view taken long lines 4 - 4 of FIG. 2 ;
[0014] FIG. 5 is a sectional view taken along lines 5 - 5 of FIG. 3 ;
[0015] FIG. 6 is a partial perspective view of the preferred embodiment of the apparatus of the present invention;
[0016] FIG. 7 is a sectional elevation view of the preferred embodiment of the apparatus of the present invention and illustrating a method step of the present invention;
[0017] FIG. 8 is a sectional elevation view of the preferred embodiment of the apparatus of the present invention and illustrating a method step of the present invention;
[0018] FIG. 9 is an elevation view of the preferred embodiment of the apparatus of the present invention and illustrating the method of the present invention;
[0019] FIG. 10 is a sectional elevation view illustrating part of the method of the present invention and wherein line A-A of FIG. 10 matches line A-A of FIG. 9 ;
[0020] FIG. 11 is a sectional elevation view illustrating part of the method of the present invention and wherein line A-A of FIG. 11 matches line A-A of FIG. 9 ;
[0021] FIG. 12 is a sectional elevation view illustrating part of the method of the present invention;
[0022] FIG. 13 is a sectional elevation view illustrating part of the method of the present invention;
[0023] FIG. 14 is a sectional elevation view illustrating part of the method of the present invention and wherein line A-A of FIG. 14 matches line A-A of FIG. 9 ;
[0024] FIG. 15 is a sectional elevation view illustrating part of the method of the present invention and wherein line A-A of FIG. 15 matches line A-A of FIG. 9 ;
[0025] FIG. 16 is a sectional elevation view illustrating part of the method of the present invention;
[0026] FIG. 17 is a partial perspective view of the preferred embodiment of the apparatus of the present invention;
[0027] FIG. 18 is a partial view of the preferred embodiment of the apparatus of the present invention and showing a ball valving member;
[0028] FIG. 19 is a partial side view of the preferred embodiment of the apparatus of the present invention and showing an alternate construction for the ball valving member;
[0029] FIG. 20 is a partial view of the preferred embodiment of the apparatus of the present invention and showing a ball valving member;
[0030] FIG. 21 is a partial side view of the preferred embodiment of the apparatus of the present invention and showing an alternate construction for the ball valving member;
[0031] FIG. 22 is a sectional view of the preferred embodiment of the apparatus of the present invention showing an alternate sleeve arrangement;
[0032] FIG. 23 is a sectional view of the preferred embodiment of the apparatus of the present invention showing an alternate sleeve arrangement;
[0033] FIG. 24 is a fragmentary view of the preferred embodiment of the apparatus of the present invention;
[0034] FIG. 25 is a fragmentary view of the preferred embodiment of the apparatus of the present invention; and
[0035] FIG. 26 is a fragmentary view of the preferred embodiment of the apparatus of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0036] FIG. 9 shows generally an oil well drilling structure 10 that can provide a platform 11 such as a marine platform as shown. Such platforms are well known. Platform 11 supports a derrick 12 that can be equipped with a lifting device 21 that supports a top drive unit 13 . Such a derrick 12 and top drive unit 13 are well known. A top drive unit can be seen for example in U.S. Pat. Nos. 4,854,383 and 4,722,389 which are incorporated herein by reference.
[0037] A flow line 14 can be used for providing a selected fluid such as a fluidized cement or fluidized settable material to be pumped into the well during operations which are known in the industry and are sometimes referred to as cementing operations. Such cementing operations are discussed for example in prior U.S. Pat. Nos. 3,828,852; 4,427,065; 4,671,353; 4,782,894; 4,995,457; 5,236,035; 5,293,933; and 6,182,752, each of which is incorporated herein by reference.
[0038] A tubular member 22 can be used to support plug dropping head 15 at a position below top drive unit 13 as shown in FIG. 9 . String 16 is attached to the lower end portion of plug dropping head 15 .
[0039] In FIG. 9 , the platform 11 can be any oil and gas well drilling platform such as a marine platform shown in a body of water 18 that provides a seabed or mud line 17 and water surface 19 . Such a platform 11 provides a platform deck 20 that affords space for well personnel to operate and for the storage of necessary equipment and supplies that are needed for the well drilling operation.
[0040] A well bore 23 extends below mud line 17 . In FIGS. 10 and 11 , the well bore 23 can be surrounded with a surface casing 24 . The surface casing 24 can be surrounded with cement/concrete 25 that is positioned in between a surrounding formation 26 and the surface casing 24 . Similarly, a liner or production casing 32 extends below surface casing 24 . The production casing 32 has a lower end portion that can be fitted with a casing shoe 27 and float valve 28 as shown in FIGS. 10-16 . Casing shoe 27 has passageway 30 . Float valve 28 has passageway 29 .
[0041] The present invention provides an improved method and apparatus for dropping balls, plugs, darts or the like as a part of a cementing operation. Such cementing operations are in general known and are employed for example when installing a liner such as liner 32 . In the drawings, arrows 75 indicate generally the flow path of fluid (e.g. cement, fluidized material or the like) through the tool body 34 . In that regard, the present invention provides an improved ball or plug or dart dropping head 15 that is shown in FIGS. 1-8 and 10 - 17 . In FIGS. 1A , 1 B, 1 C and 2 - 8 , ball/plug dropping head 15 has an upper end portion 31 and a lower end portion 33 . Ball/plug dropping head 15 provides a tool body 34 that can be of multiple sections that are connected together, such as with threaded connections. In FIGS. 1A-1C , the tool body 34 includes sections 35 , 36 , 37 , 38 , 39 . The section 35 is an upper section. The section 39 is a lower section.
[0042] Ball/plug dropping head 15 can be pre-loaded with a number of different items to be dropped as part of a cementing operation. For example, in FIGS. 1A , 1 B, 1 C there are a number of items that are contained in ball/plug dropping head 15 . These include an upper, larger diameter ball dart 40 , 41 and smaller diameter ball 42 . In FIGS. 18-26 , an alternate embodiment is shown which enables very small diameter balls, sometimes referred to as “frac-balls” 102 (which can have a diameter of between about ½ and ⅝ inches) to be dispensed into the well below toll body 34 .
[0043] The tool body 34 supports a plurality of valving members at opposed openings 90 . The valving members can include first valving member 43 which is an upper valving member. The valving members can include a second valving member 44 which is in between the first valving member 43 and a lower or third valving member 45 . Valving member 43 attaches to tool body 34 at upper opening positions 61 , 62 . Valving member 44 attaches to tool body 34 at middle opening positions 63 , 64 . Valving member 45 attaches to tool body 43 at lower opening positions 65 , 66 .
[0044] Threaded connections 46 , 47 , 48 , 49 can be used for connecting the various body sections 35 , 36 , 37 , 38 , 39 together end to end as shown in FIGS. 1A , 1 B, 1 C. Tool body 34 upper end 31 is provided with an internally threaded portion 50 for forming a connection with tubular member 22 that depends from top drive unit 13 as shown in FIG. 9 . A flow bore 51 extends between upper end 31 and lower end 33 of tool body 34 .
[0045] Sleeve sections 52 are secured to tool body 34 within bore 15 as shown in FIGS. 1A , 1 B, 1 C. Sleeves 52 can be generally centered within bore 51 as shown in FIGS. 1A , 1 B, 1 C using spacers 67 that extend along radial lines from the sections 35 - 39 .
[0046] Each valving member 43 , 44 , 45 is movable between open and closed positions. In FIGS. 1A , 1 B, 1 C each of the valving members 43 , 44 , 45 is in a closed position. In that closed position, each valving member 43 , 44 , 45 prevents downward movement of a plug, ball 40 , 42 , or dart 41 as shown. In FIG. 1A , the closed position of valving member 43 prevents downward movement of larger diameter ball 40 . Similarly, in FIG. 1B , a closed position of valving member 44 prevents a downward movement of dart 41 . In FIG. 1B , a closed position of valving member 45 prevents a downward movement of smaller diameter ball 42 . In each instance, the ball, dart or plug rests upon the outer curved surface 68 of valving member 43 , 44 or 45 as shown in the drawings.
[0047] Each valving member 43 , 44 , 45 provides a pair of opposed generally flat surfaces 69 , 70 (see FIGS. 3 , 6 , 17 ). FIG. 17 shows in more detail the connection that is formed between each of the valving members 43 , 44 , 45 and the tool body 34 . The tool body 34 provides opposed openings 90 that are receptive the generally cylindrically shaped valve stems 54 , 55 that are provided on the flat sections or flat surfaces 69 , 70 of each valving member 43 , 44 , 45 . For example, in FIGS. 6 and 17 , the flat surface 69 provides valve stem 54 . Openings 90 are receptive of the parts shown in exploded view in FIG. 17 that enable a connection to be formed between the valving member 43 , 44 or 45 and the tool body 34 . For the stem 55 , fastener 91 engages an internally threaded opening of stem 55 . Bushing 92 is positioned within opening 90 and the outer surface of stem 55 registers within the central bore 95 of bushing 92 . Bushing 92 is externally threaded at 93 for engaging a correspondingly internally threaded portion of tool body 34 at opening 90 . O-rings 60 can be used to interface between stem 55 and bushing 92 . A slightly different configuration is provided for attaching stem 54 to tool body 34 . Sleeve 94 occupies a position that surrounds stem 54 . Sleeve 54 fits inside of bore 95 of bushing 92 . The externally threaded portion 93 of bushing 92 engages correspondingly shaped threads of opening 90 . Pins 99 form a connection between the stem 54 at openings 98 and the sleeve 94 . Fastener 96 forms a connection between bushing 92 and an internally threaded opening 97 of stem 54 . As assembled, this configuration can be seen in FIG. 1A for example. The flat surfaces 69 , 70 enable fluid to flow in bore 51 in a position radially outwardly or externally of sleeve or sleeve section 52 by passing between the tool body sections 35 , 36 , 37 , 38 , 39 and sleeve 52 . Thus, bore 51 is divided into two flow channels. These two flow channels 71 , 72 include a central flow channel 71 within sleeves 52 that is generally cylindrically shaped and that aligns generally with the channel 53 of each valving member 43 , 44 , 45 . The second flow channel is an annular outer flow channel 72 that is positioned in between a sleeve 52 and the tool body sections 35 , 36 , 37 , 38 , 39 . The channels 71 , 72 can be concentric. The outer channel 72 is open when the valving members 43 , 44 , 45 are in the closed positions of FIGS. 1A , 1 B and 1 C, wherein central flow channel 71 is closed.
[0048] When the valving members 43 , 44 , 45 are rotated to a closed position, fins 73 become transversely positioned with respect to the flow path of fluid flowing in channel 72 thus closing outer flow channel 72 (see FIG. 5 ). This occurs when a valving member 43 , 44 , 45 is opened for releasing a ball 40 or 42 or for releasing dart 41 . FIG. 4 illustrates a closed position ( FIG. 4 ) of the valving member 45 just before releasing smaller diameter ball 42 . Fins 73 are generally aligned with bore 15 and with flow channels 71 , 72 when flow in channel 72 is desired ( FIG. 4 ). In FIG. 4 , valving member 45 is closed and outer flow channel 72 is open.
[0049] In FIGS. 2-3 , 5 and 7 - 8 , a tool 74 has been used to rotate valving member 45 to an open position that aligns its channel 53 with central flow channel 71 enabling smaller diameter ball 42 to fall downwardly via central flow channel 71 ( FIG. 8 ). In FIG. 5 , outer flow channel 72 has been closed by fins 73 that have now rotated about 90 degrees from the open position of FIG. 4 to the closed position. Fins 73 close channel 72 in FIG. 5 . It should be understood that tool 74 can also be used to rotate valving member 44 from an open position of FIG. 1B to a closed position such as is shown in FIG. 5 when it is desired that dart 41 should drop. Similarly, tool 74 can be used to rotate upper valving member 43 from the closed position of FIG. 1A to an open position such as is shown in FIG. 5 when it is desired to drop larger diameter ball 40 .
[0050] FIGS. 7-16 illustrate further the method and apparatus of the present invention. In FIG. 8 , lower or third valving member 45 has been opened as shown in FIG. 5 releasing smaller diameter ball 42 . In FIG. 8 , smaller diameter ball 42 is shown dropping wherein it is in phantom lines, its path indicated schematically by arrows 75 .
[0051] FIG. 10 shows a pair of commercially available, known plugs 76 , 77 . These plugs 76 , 77 include upper plug 76 and lower plug 77 . Each of the plugs 76 , 77 can be provided with a flow passage 79 , 81 respectively that enables fluid to circulate through it before ball 42 forms a seal upon the flow passage 81 . Smaller diameter ball 42 has seated upon the lower plug 77 in FIG. 10 so that it can now be pumped downwardly, pushing cement 80 ahead of it. In FIG. 11 , arrows 78 schematically illustrate the downward movement of lower plug 77 when urged downwardly by a pumped substance such as a pumpable cement or like material 80 . Each of the plugs 76 , 77 can be provided with a flow passage 79 , 81 respectively that enables fluid to circulate through it before ball 42 forms a seal upon the flow passage 81 (see FIG. 11 ). When plug 77 reaches float valve 28 , pressure can be increased to push ball 42 through plug 77 , float valve 28 and casing shoe 27 so that the cement flows (see arrows 100 , FIG. 11 ) into the space 101 between formation 26 and casing 32 .
[0052] In FIG. 12 , second valving member 44 is opened releasing dart 41 . Dart 41 can be used to push the cement 80 downwardly in the direction of arrows 82 . A completion fluid or other fluid 83 can be used to pump dart 41 downwardly, pushing cement 80 ahead of it. Once valves 44 and 45 are opened, fluid 83 can flow through openings 84 provided in sleeves 52 below the opened valving member (see FIG. 7 ) as illustrated in FIGS. 7 and 12 . Thus, as each valving member 43 or 44 or 45 is opened, fluid moves through the openings 84 into central flow channel 71 .
[0053] When valve 44 is opened, dart 41 can be pumped downwardly to engage upper plug 76 , registering upon it and closing its flow passage 79 , pushing it downwardly as illustrated in FIGS. 14 and 15 . Upper plug 79 and dart 41 are pumped downwardly using fluid 83 as illustrated in FIGS. 14 and 15 . In FIG. 16 , first valving member 43 is opened so that larger diameter ball 40 can move downwardly, pushing any remaining cement 80 downwardly.
[0054] The ball 40 can be deformable, so that it can enter the smaller diameter section 86 at the lower end portion of tool body 34 . During this process, cement or like mixture 80 is forced downwardly through float collar 28 and casing shoe 27 into the space that is in between production casing 32 and formation 26 . This operation helps stabilize production casing 32 and prevents erosion of the surrounding formation 26 during drilling operations.
[0055] During drilling operations, a drill bit is lowered on a drill string using derrick 12 , wherein the drill bit simply drills through the production casing 32 as it expands the well downwardly in search of oil.
[0056] FIGS. 18-26 show an alternate embodiment of the apparatus of the present invention, designated generally by the numeral 110 in FIGS. 22-23 . In FIGS. 18-26 , the flow openings 84 in sleeves 52 of ball/plug dropping head 110 of FIGS. 1-17 have been eliminated. Instead, sliding sleeves 111 are provided that move up or down responsive to movement of a selected valving member 112 , 113 . It should be understood that the same tool body 34 can be used with the embodiment of FIGS. 18-26 , connected in the same manner shown in FIGS. 1-17 to tubular member 22 and string 16 . In FIGS. 18-26 , valving members 112 , 113 replace the valving members 43 , 44 , 45 of FIGS. 1-17 . In FIGS. 18-26 , sleeves 111 replace sleeves 52 . While two valving members 112 , 113 are shown in FIGS. 22 , 23 , it should be understood that three such valving members (and a corresponding sleeve 111 ) could be employed, each valving member 112 , 113 replacing a valving member 43 , 44 , 45 of FIGS. 1-17 .
[0057] In FIGS. 18-26 , tool body 34 has upper and lower end portions 31 , 33 . As with the preferred embodiment of FIGS. 1-17 , a flow bore 51 provides a central flow channel 71 and outer flow channel 72 . Each valving member 112 , 113 provides a valve opening 114 . Each valving member 112 , 113 provides a flat surface 115 (see FIG. 20 ). Each valving member 112 , 113 provides a pair of opposed curved surfaces 116 as shown in FIG. 20 and a pair of opposed flat surfaces 117 , each having a stem 119 or 120 .
[0058] An internal, generally cylindrically shaped surface 118 surrounds valve opening 114 as shown in FIG. 20 . Each valving member 112 , 113 provides opposed stems 119 , 120 . Each valving member 112 , 113 rotates between opened and closed positions by rotating upon stems 119 , 120 . Each of the stems 119 , 120 is mounted in a stem opening 90 of tool body 34 at positions 61 , 62 and 63 , 64 as shown in FIG. 22 .
[0059] In FIG. 19 , valving member 122 , 123 is similar in configuration and in sizing to the valving members 43 , 44 , 45 of the preferred embodiment of FIGS. 1-17 , with the exception of a portion that has been removed which is indicated in phantom lines in FIG. 19 . The milled or cut-away portion of the valving member 112 , 113 is indicated schematically by the arrow 121 . Reference line 122 in FIG. 19 indicates the final shape of valving member 112 , 113 after having been milled or cut. In FIGS. 20 and 21 , a beveled edge at 123 is provided for each valving member 112 , 113 .
[0060] When a valving member 112 , 113 is in the closed position of FIG. 22 , flow arrows 124 indicate the flow of fluid through the tool body 34 bore 51 and more particularly in the outer channel 72 as indicated in FIG. 22 .
[0061] In FIG. 23 , the lower valving member 113 has been rotated to an open position as indicated schematically by the arrow 134 , having been rotated with tool 74 . In this position, fins 73 now block the flow of fluid in outer channel 72 . Flat surface 115 now faces upwardly. In this position, the cut-away portion of valving member 113 that is indicated schematically by the arrow 121 in FIG. 19 now faces up. Sliding sleeve 111 drops downwardly as indicated schematically by arrows 130 when a valving member 112 or 113 is rotated to an open position (see valving member 113 in FIG. 23 ). In FIG. 22 , a gap 129 was present in between upper valve 112 and sleeve 111 that is below the valve 112 . The sleeve 111 that is in between the valves 112 , 113 is shown in FIG. 22 as being filled with very small diameter balls or “frac-balls” 102 .
[0062] When valving member 113 is rotated to the open position of FIG. 23 , the gap is now a larger gap, indicated as 135 . Gap 135 (when compared to smaller gap 129 ) has become enlarged an amount equal to the distance 121 illustrated by arrow 121 in FIG. 19 . The frac-balls 102 now drop through valving member 113 as illustrated by arrows 127 in FIG. 23 . Arrows 125 , 126 in FIG. 23 illustrate the flow of fluid downwardly through gap 135 and in central channel 71 .
[0063] A sleeve 111 above a valving member 112 or 113 thus move up and down responsive to a rotation of that valving member 112 or 113 . Spacers 28 can be employed that extend from each sleeve 111 radially to slidably engage tool body 34 . In FIGS. 20 and 21 , each stem 119 , 120 can be provided with one or more annular grooves 131 that are receptive of o-rings 60 or other sealing material. As with the preferred embodiment of FIGS. 1-17 , openings 132 in each stem 119 , 120 are receptive of pins 99 . Likewise, each stem 119 , 120 provides internally threaded openings 133 . Thus, the same connection for attaching a valving member 112 , 113 to tool body 34 can be the one shown in FIGS. 1-17 .
[0064] The following is a list of parts and materials suitable for use in the present invention.
[0000]
PARTS LIST
Part Number
Description
10
oil well drilling structure
11
platform
12
derrick
13
top drive unit
14
flow line
15
ball/plug dropping head
16
string
17
sea bed/mud line
18
body of water
19
water surface
20
platform deck
21
lifting device
22
tubular member
23
well bore
24
surface casing
25
cement/concrete
26
formation
27
casing shoe
28
float valve
29
passageway
30
passageway
31
upper end
32
liner/production casing
33
lower end portion
34
tool body
35
section
36
section
37
section
38
section
39
section
40
larger diameter ball
41
dart
42
smaller diameter ball
43
first valving member
44
second valving member
45
third valving member
46
threaded connection
47
threaded connection
48
threaded connection
49
threaded connection
50
threaded portion
51
flow bore
52
sleeve
53
channel
54
stem
55
stem
56
sleeve
57
sleeve
58
plug
59
plug
60
o-ring
61
opening position
62
opening position
63
opening position
64
opening position
65
opening position
66
opening position
67
spacer
68
outer curved surface
69
flat surface
70
flat surface
71
central flow channel
72
outer flow channel
73
fin
74
tool
75
arrow
76
upper plug
77
lower plug
78
arrows
79
flow passage
80
cement
81
flow passage
82
arrow
83
fluid
84
opening
85
opening
86
smaller diameter section
87
arrow - fluid flow path
88
fastener
89
internally threaded opening
90
opening
91
fastener
92
bushing
93
external threads
94
sleeve
95
passageway/bore
96
fastener
97
internally threaded opening
98
opening
99
pin
100
arrows
101
space
102
frac-ball
110
ball/plug dropping head
111
sleeve
112
valving member
113
valving member
114
valve opening
115
flat surface
116
curved surface
117
flat surface
118
internal surface
119
stem
120
stem
121
arrow
122
reference line
123
beveled edge
124
arrow
125
arrow
126
arrow
127
arrow
128
spacer
129
smaller gap
130
arrow sleeve movement
131
annular groove
132
opening
133
internally threaded opening
134
arrow
135
larger gap
[0065] All measurements disclosed herein are at standard temperature and pressure, at sea level on Earth, unless indicated otherwise. All materials used or intended to be used in a human being are biocompatible, unless indicated otherwise.
[0066] The foregoing embodiments are presented by way of example only; the scope of the present invention is to be limited only by the following claims. | An improved method and apparatus for dropping a ball, plug or dart during oil and gas well operations (e.g., cementing operations) employs a specially configured valving member with curved and flat portions that alternatively direct fluid flow through a bore or opening in the valving member via an inner channel or around the periphery of the valving member in an outer channel. In one embodiment, the ball(s), dart(s) or plug(s) are contained in a sliding sleeve that shifts position responsive to valve rotation. | 4 |
CROSS REFERENCE TO RELATED APPLICATION
[0001] The present application is a National Stage entry from PCT Patent Application No. PCT/AU2008/000269 filed on 29 Feb. 2008, which claims priority to Australian Application 2007901765 filed on 3 Apr., 2007 the contents of each one incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The invention relates to a mounting pin assembly for an excavator wear member. In particular, although not exclusively, the invention relates to a mounting pin for mounting a wear member on a nose structure located on a lip of an excavator bucket.
BACKGROUND OF THE INVENTION
[0003] Excavator tooth assemblies mounted to the digging edge of excavator buckets and the like generally comprise a replaceable digging point, an adaptor body and an adaptor nose which is secured by welding or the like to the digging edge of a bucket or the like. The adaptor has a socket-like recess at its rear end to receivably locate a front spigot portion of the adaptor nose and a removable locking pin extends through aligned apertures in the adaptor and nose to retain the adaptor in position.
[0004] In use, excavator teeth are subjected to extensive load forces along a longitudinal axis of a tooth as well as in vertical and transverse directions. A snug fit is required between the digging point and the front portion of the adaptor and also between the adaptor socket and the nose spigot portion and their respective mounting pins to avoid premature wear between the components. As the various components wear, the locking pins can loosen thereby increasing the risk of loss of a digging point or an entire adaptor/tooth combination. This necessitates considerable downtime to replace the lost wear members and where items such as locking pins are not recovered, these can cause damage and/or further downtime in downstream operations such as ore crushing and the like.
[0005] The greatest loads experienced by excavator tooth assemblies are vertical loads which tend to generate large moment forces capable of rotating a tooth off the front of an adaptor and/or rotating the adaptor off the adaptor nose. In addition, twisting or “yaw” loads are frequently imposed on such tooth assemblies.
[0006] Despite many prior art attempts to improve the mounting of an adaptor to a nose, most of these proposals suffer from one or more deficiencies. As described hereinafter, many of the prior art references relate to direct mounting of a tooth onto an adaptor without an intermediate adaptor but in those assemblies, the mounting systems for securing teeth directly onto excavator noses is considered analogous to the mounting of an adaptor onto a nose.
[0007] U.S. Pat. No. 4,182,058 describes an excavator tooth having a rearwardly divergent tapering socket to receive a nose having a complementary-shaped front spigot portion. Resistance to rotational moment forces is borne by a resilient steel cotter pin extending through aligned vertical apertures in the socket and spigot portions.
[0008] U.S. Pat. Nos. 3,774,324, 4,338,736, 4,481,728, 4,903,420, 5,469,648, 7,100,315 and 6,735,890 all describe nose and tooth combinations wherein the nose has a generally convergently tapering spigot portion with a forward tip having a box-like configuration with at least the upper and lower surfaces thereof having faces parallel to each other and to a longitudinal axis of the nose portion. With the exception of U.S. Pat. No. 4,338,736, which describes a transverse locking pin, each of the tooth mounting arrangements is heavily reliant on a large vertical locking pin to resist rotational moment forces tending to rotate the teeth off respective noses.
[0009] U.S. Pat. No. 4,231,173 describes a tapered adaptor nose having a box-like free end, which engages in a mating box-like socket cavity to resist rotational moments. Opposed pairs of rearwardly extending tongues engage in corresponding recesses in the outer surfaces of the adaptor nose to resist rotational movements. Because the tongues themselves are unsupported, they possess a limited capacity to resist rotational moment forces.
[0010] U.S. Pat. No. 5,272,824 describes a structure similar to that of U.S. Pat. No. 4,231,173 except that the side tongues are of more robust dimensions and the upper and lower tongues are formed as box-like members with apertures to receive a vertical mounting pin passing through aligned apertures in the tooth and adaptor nose.
[0011] U.S. Pat. No. 4,404,760 provides flat rail surfaces on the adaptor nose to engage with mating grooves in the socket aperture of a corresponding tooth wherein the mating rail and groove surfaces are generally parallel to the longitudinal axis of the tooth.
[0012] U.S. Pat. No. 5,423,138 describes a generally tapered nose having a box-like front end with upper and lower transverse surfaces generally parallel to a longitudinal axis of a tooth which located directly thereon. The parallel upper and lower transverse surfaces are contiguous with upper and lower rail surfaces on each side of the nose and parallel to the longitudinal axis of the tooth. A pair of rearwardly extending side tongues locate in recesses formed in the outer side faces of the nose, ostensibly to resist rotational moment forces in the tooth. Because the side tongues are recessed to accommodate the side rail portions, the robustness of the side tongues is somewhat compromised.
[0013] U.S. Pat. No. 4,233,761 describes a fairly stubby tapered nose having a box-like front portion with upper and lower surfaces generally parallel to a longitudinal axis of an excavator tooth, an intermediate rearwardly diverging tapered portion and a rear portion having upper and lower surfaces extending generally parallel to a longitudinal axis of the tooth. Formed on the upper and lower surfaces of the front, intermediate and rear portions of the nose are spaced parallel reinforcing ribs which are located in mating grooves in the excavator tooth. A large vertical locking pin extends through aligned apertures in the tooth and nose between the reinforcing ribs. This structure is heavily reliant on the locking pin to resist rotational moment forces however it is considered that this configuration may be prone to failure in the rear portion of the adaptor.
[0014] U.S. Pat. No. 5,709,043 describes a nose/adaptor combination wherein the adaptor socket tapers convergently towards a box-like front portion having upper and lower bearing surfaces generally parallel to a longitudinal axis of the tooth, a front transverse upright bearing surface and rearwardly divergent bearing surfaces formed at obtuse angles between the converging upper and lower walls and the side walls of the socket, ostensibly to avoid areas of stress concentration.
[0015] U.S. Pat. No. 6,018,896 describes a pin/retainer system for locking an excavation tooth onto an adaptor wherein the retainer is inserted in the adaptor and a wedge-shaped pin is driven into aligned apertures in the tooth and adaptor to resiliently engage with the retainer.
[0016] United States Publication No US 2002/0000053A1 describes a mechanism for releasably retaining an adaptor into the nose of a bucket lip or the like wherein a tapered threaded socket is non-rotatably located on the inside of an aperture in the side wall of the adaptor. A threaded retaining pin extends through the threaded socket and locates in an aligned aperture in the bucket nose.
[0017] U.S. Pat. No. 5,337,495 describes a tooth assembly with a two-piece telescopically engageable adaptor secured to a nose with a tapered wedge pin assembly. A similar mounting system is described in U.S. Pat. No. 5,172,501 and U.S. Pat. No. 6,052,927. Other retention systems for digging points on adaptors or adaptors on noses are described in U.S. Pat. Nos. 6,119,378, 6,467,204, and 6,467,203.
[0018] Other devices for removably securing replaceable wear elements on earth working equipment such as a retaining pin, a bolt, a pin lock and locking blocks engageable in a top aperture in a wear member are described in U.S. Pat. Nos. 3,839,805, 3,982,339, 4,587,751, 5,088,214 and 5,653,048 respectively.
[0019] U.S. Pat. No. 5,937,550 describes a lock assembly for releasably securing an adaptor to a nose of an excavator support structure. The lock assembly comprises a body and a base coupled together and adapted for insertion, while coupled together, in a hole in the nose of the support structure. The length of the lock assembly is extended to secure the adaptor and is retracted to release the adaptor. While adequate for securing an adaptor to a nose of an excavator support structure, the lock described in this patent is relatively complex in design and operation leading to high costs and labour intensive extraction procedures in the field.
[0020] Canadian Patent Application No 2,161,505 describes a system for removably retaining an excavation point on an adaptor with at least one flanged sleeve having a screw-threaded aperture therein, the flanged sleeve being non-rotatably locatable in a transverse bore in the adaptor before fitment of the point onto the adaptor. A screw-threaded pin is inserted into the sleeve via an aperture in the point whereby portion of the head of the pin retains the point on the adaptor.
[0021] Australian Patent Application No 2003264586 describes a locking pin assembly comprising a body member having a non-circular cross-sectional shape locatable in a bore of complementary shape extending laterally between opposite sides of an excavator lip mounting nose. After locating the body member in the nose aperture, an adaptor can be engaged over the nose with apertures in opposite side walls aligned with the body member. Threaded bolts engage in threaded apertures in opposite ends of the body member, the bolts each having a tapered shank portion with an enlarged boss at a free end thereof, the boss being locatable in a respective aperture in a side wall of said adaptor to prevent the adaptor from disengaging with the nose.
[0022] Furthermore, it is also known in the art to use spool and wedge locking assemblies for attaching replaceable earth working implements to a nose of an excavator bucket. Typically, these types of assemblies include a spool and a wedge, each having complimentary ramped surfaces that cause lateral expansion of the assembly as the spool and wedge assembly is contracted, usually by relative axial movement of the wedge with respect to the spool. Whilst generally satisfactory, these types of locking assemblies include a bearing face between the wedge and spool that is orientated at an acute angle to a longitudinal axis of the nose. Due to the large forces experienced by the locking assembly in use, this arrangement is undesirable.
[0023] While generally satisfactory for their intended purpose, the abovementioned prior art nose/adaptor (or nose/tooth equivalent) combinations all suffer from one or more shortcomings or disadvantages in terms of inadequate resistance to rotation of an adaptor off a nose under the influence of vertical loads applying a rotational moment to the adaptor, a predisposition to premature wear, difficulties in retention of the adaptors on noses, inadequate locking systems and unduly complicated configurations giving rise to increased fabrication and tooling costs.
OBJECT OF THE INVENTION
[0024] It is an object of the invention to overcome or at least alleviate one or more of the above problems and/or provide the consumer with a useful or commercial choice.
[0025] In one form, although it need not be the only or indeed the broadest form, the invention resides in a mounting pin assembly for an excavator wear assembly, said mounting pin assembly comprising:
[0026] a retaining member configured to be non-rotatably located within a transversely extending mounting aperture of a mounting nose of an excavator, said retaining member having a locating surface and a boss extending from said locating surface;
[0027] a locating member, in use, slidably mountable upon said locating surface of said retaining member via a wall aperture of a wear member mounted upon said mounting nose, said wall aperture of said wear member at least partially aligned with said mounting aperture, said locating member having an enlarged portion defined by an outwardly divergent face abutting a wall of said wall aperture of said wear member; and
[0028] a tensioning member extending between and coupling said boss of said retaining member and said locating member whereby, in use, tension applied to said tensioning member causes relative contraction of said mounting pin assembly such that said locating member is drawn upon said locating surface towards said boss to force said outwardly divergent face to wedgingly engage with said wall of said wall aperture of said wear member to force said wear member into engagement with said mounting nose.
[0029] In a further form, the invention resides in a method of removably securing a wear member on to a projecting mounting nose of a digging edge of an excavator, said method comprising the steps of:
[0030] non-rotatably mounting a retaining member in a mounting aperture of said mounting nose;
[0031] locating on said mounting nose, a wear member having opposed wall apertures partially alignable with said mounting aperture to thereby captively retain said retaining member within said mounting aperture;
[0032] slidably mounting on a locating surface of said retaining member through one said opposed wall aperture a locating member having an enlarged portion defined by an outwardly divergent face extending outwardly from said mounting aperture when said locating member is at least partially located therein;
[0033] inserting through an opposite wall aperture into said mounting aperture a tensioning member to thereby couple said retaining member and said locating member to form a mounting pin assembly; and
[0034] tensioning said tensioning member to relatively contact said longitudinal length of said mounting pin assembly, said tensioning member bearing on a boss of said retaining member to draw said locating member towards said boss urging said outwardly divergent face into a wedging contact with a wall of one of said opposed wall apertures of said wear member to thereby draw said wear member on said mounting nose.
[0035] In yet a further form, the invention resides in a mounting pin assembly comprising:
[0036] a retaining member having a locating surface and a boss extending from said locating surface;
[0037] a locating member slidably mountable upon said locating surface of said retaining member and having an enlarged portion defined by an outwardly divergent face; and
[0038] a tensioning member extending between and coupling said boss of said retaining member and said locating member;
[0039] wherein, said tensioning member is configured to cause relative contraction of said mounting pin assembly such that said locating member is drawn upon said locating surface of said retaining member towards said boss when a tensile force is applied to said tensioning member.
[0040] Further features of the present invention will become apparent from the following detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
[0041] To assist in understanding the invention and to enable a person skilled in the art to put the invention into practical effect preferred embodiments of the invention will be described by way of example only with reference to the accompanying drawings, wherein:
[0042] FIG. 1 shows an exploded perspective view of an excavator wear assembly having a mounting pin assembly according to an embodiment of the invention;
[0043] FIG. 2 shows an exploded view of the mounting pin assembly shown in FIG. 1 ;
[0044] FIG. 3 shows a horizontal sectional view of the excavator wear assembly and the mounting pin assembly of FIG. 1 in an assembled position;
[0045] FIG. 4 shows an exploded perspective view of an excavator wear assembly having a mounting pin assembly according to a further embodiment of the invention;
[0046] FIG. 5 shows an exploded view of the mounting pin assembly shown in FIG. 4 ; and
[0047] FIG. 6 shows a top sectional view of the excavator wear assembly and the mounting pin assembly of FIG. 4 in an assembled position.
DETAILED DESCRIPTION OF THE INVENTION
[0048] FIG. 1 shows an exploded perspective view of an excavator wear assembly 1000 having a mounting pin assembly 100 according to an embodiment of the invention. Excavator wear assembly 1000 further comprises a mounting nose 200 and a wear member in the form of an adaptor 300 .
[0049] Mounting nose 200 is located upon a lip (not shown) of an excavator bucket. The mounting nose 200 is preferably integrally formed with the lip of the excavator bucket. Optionally, the mounting nose 200 may be formed separately from the lip of the bucket and secured thereto.
[0050] In the embodiment, mounting nose 200 has a pair of opposed side walls 210 and a front portion 220 . A mounting aperture 230 extends through mounting nose 200 between opposed side walls 210 . Suitably, mounting aperture 230 has an oval cross sectional shape. Mounting aperture 230 has an inwardly convergent opening 231 located at either end thereof on respective opposed side walls 210 .
[0051] Wear member in the form of adaptor 300 has opposed side walls 350 and a mounting portion 320 for reception of digging teeth or the like thereon. A socket cavity 310 is located in the rear portion of adaptor 300 . Socket cavity 310 has an internal shape generally complementary to the front portion 220 of mounting nose 200 . A hoist loop 330 is located on a top side of adaptor 300 to enable ease of handling by a hoist during attachment and detachment operations.
[0052] Side wall apertures 340 extend through respective side walls and each side wall aperture 340 has an inwardly convergent opening 341 . Suitably, the cross sectional area of an inner end of each side wall aperture 340 is less than the cross sectional area of mounting aperture 230 of mounting nose 200 as will be discussed in greater detail below.
[0053] Alternatively, each side wall aperture 340 may have an inwardly convergent wall extending the entire length thereof.
[0054] Excavator wear assembly 1000 further comprises a retaining pin assembly indicated generally by 100 in FIG. 1 .
[0055] FIG. 2 shows an exploded perspective view of retaining pin assembly 100 comprising a retaining member 110 , a tensioning member in the form of a bolt 120 , a locating member 130 and a washer 140 .
[0056] Retaining member 110 has a crescent shaped base 111 having a locating surface 112 . A boss 113 extends from locating surface 112 such that the cross sectional dimensions of retaining member 110 at the location where boss 113 extends from locating surface 112 is substantially the same as the cross sectional dimensions of mounting aperture 230 of mounting nose 200 as will be discussed in greater detail below.
[0057] A guide aperture 114 extends through boss 113 as shown. An annular groove 115 is located upon a face of boss 113 about guide aperture 114 .
[0058] Tensioning member in the form of bolt 120 has a head portion 121 and a shank 122 extending from head portion 121 . A threaded shank 122 A extends from shank 122 . Shank 122 has a relatively larger outer diameter than the outer diameter of threaded shank 122 A with shank 122 having an angled taper to engage washer 140 when in use.
[0059] Furthermore, a hexagonally shaped female tensioning recess 121 A is located on head portion 121 for engagement with a tensioning tool (not shown) or the like.
[0060] Locating member 130 has a body portion 131 and an enlarged portion 132 formed by an outwardly divergent face 133 . A blind bore 134 extends longitudinally within locating member 130 within a recess 135 located at an end of locating member 130 . Blind bore has a first bore portion 134 A (shown in part in FIG. 2 ) and a threaded bore portion 134 B (not shown in FIG. 2 ). Washer 140 is receivable within recess 135 and is suitably formed from nylon or the like.
[0061] Locating member 130 is slidably mountable upon locating surface 112 of retaining member 110 such that blind bore 134 corresponds with guide aperture 114 of retaining member 110 and outwardly divergent face 133 opposes a face of locating member 130 slidably mountable upon locating surface 112 . Bolt 120 is receivable through guide aperture 114 and blind bore 134 such that threaded shank 122 A is threadably engageable with threaded portion 134 B of blind bore 134 as will be discussed in greater detail below.
[0062] FIG. 3 shows a horizontal sectional view of the excavator wear assembly 1000 in an assembled position. In use, retaining member 110 is non-rotatably located within mounting aperture 230 of mounting nose 200 . This non-rotatable location is provided by the cross-sectional dimensions and area of mounting aperture 230 being substantially the same as the cross-sectional dimensions and area of retaining member 110 in the region of boss 113 . A person skilled in the art will appreciate that other arrangements will facilitate the non-rotatable location of the retaining member 110 within mounting aperture 230 .
[0063] The adaptor 300 is then slidably mounted upon mounting nose 200 such that front portion 220 of mounting nose 200 is located within socket cavity 310 of adaptor 300 and each of side wall apertures 340 at least partially align with mounting aperture 230 .
[0064] As previously discussed, side wall apertures 340 of adaptor 300 have a cross sectional area relatively less than mounting aperture 230 of mounting nose 200 . As such, when adaptor 300 is slidably mounted upon mounting nose 200 , retaining member 110 is captively retained within mounting aperture 230 .
[0065] Tensioning member in the form of bolt 120 is then located through at least partially aligned side wall aperture 340 of adaptor 300 and into mounting aperture 230 of mounting nose 200 to penetrate guide aperture 114 of retaining member 110 .
[0066] Washer 140 is secured within recess 135 of locating member 130 by way of an interference fit and locating member 130 is then inserted through side wall aperture 340 of adaptor 300 opposing side wall aperture 340 through which bolt 120 is located such that locating member 130 is slidably mounted upon locating surface 112 of retaining member 110 . In this position, body portion 131 of locating member 130 is generally located wholly within mounting aperture 230 and outwardly divergent face 133 abuts against inwardly convergent opening 341 of side wall aperture 340 .
[0067] Bolt 120 is then fully inserted through guide aperture 114 of retaining member 110 such that a face of head portion 121 abuts a face of boss 113 within annular groove 115 . In this position, a toe of threaded shank 122 A is located within blind bore 134 at the transition between first bore portion 134 A and threaded bore portion 134 B.
[0068] A drive member (not shown) of a drive tool (also not shown) is then engaged with hexagonally shaped female tensioning recess 121 A of bolt 120 to thereby threadably engage threaded shank 122 A of bolt 120 with complimentary threaded bore portion 134 B of locating member 130 .
[0069] As retaining member 110 is captively retained within mounting aperture 230 a face of retaining member 110 bears against an inner face of side wall 350 of adaptor 300 and head portion 121 of bolt 120 bears against a face of boss 113 within annular groove 115 as shank 122 A of bolt 120 is threadably engaged with complimentary threaded bore portion 134 B of locating member 130 .
[0070] As such, bolt 120 is placed in tension and mounting pin assembly 100 is relatively contracted in longitudinal length. Furthermore, location member 130 is driven into further slidable engagement with retaining member 110 in a direction of boss 113 . As this movement occurs, outwardly divergent face 133 wedgingly engages with inwardly convergent opening 341 of adaptor 300 to thereby urge adaptor 300 into tight engagement with mounting nose 200 as shown in FIG. 3 and thus move the mounting pin assembly 100 to the assembled position.
[0071] Furthermore, in the assembled position, shank 122 of bolt 120 is held in blind bore 134 by way of an interference fit by washer 140 to thereby provide resistance to any rotational movement of the bolt 120 that may occur during use.
[0072] Furthermore, washer 140 prevents ingress of dirt and fines into blind bore 134 that may cause cementation within blind bore 134 .
[0073] Furthermore, the plane of contact of the face of locating member 130 on locating surface 112 of retaining member 110 is substantially perpendicular with a longitudinal axis of adaptor 300 and mounting nose 200 . This arrangement ensures that this plane of contact is not orientated at an acute angle to the dominant forces applied to the wear assembly 1000 .
[0074] In order to remove adaptor 300 from mounting nose 200 , drive member (not shown) of drive tool (also not shown) is again engaged with hexagonally shaped female tensioning recess 121 A of bolt 120 to thereby threadably disengage threaded shank 122 A of bolt 120 with complimentary threaded bore portion 134 B of locating member 130 .
[0075] As retaining member 110 is captively retained within mounting aperture 230 , the disengagement of threaded shank 122 A of bolt 120 from complimentary threaded bore portion 134 B of locating member 130 thereby urges locating member 130 out of mounting aperture 230 .
[0076] Bolt 120 is then removed from guide aperture 114 and adaptor 300 is free to be slidably dismounted from mounting nose 200 . Although not prone to wear, retaining member 110 is readily removable from mounting aperture 230 in the event that replacement or maintenance is necessitated.
[0077] FIG. 4 shows an exploded perspective view of an excavator wear assembly 1000 having a mounting pin assembly, indicated generally by 100 , according to a further embodiment of the invention.
[0078] As before, the excavator wear assembly 1000 comprises a mounting nose 200 and a wear member in the form of adaptor 300 . Adaptor 300 has side wall apertures 340 each having an inwardly convergent opening 341 .
[0079] Mounting pin assembly 100 comprises a retaining member 110 , a tensioning member in the form of bolt 120 and a locating member 130 , This embodiment of mounting pin assembly 100 further comprises a jacking member 150 .
[0080] FIG. 5 shows an exploded perspective view of the mounting pin assembly 100 shown in FIG. 4 and FIG. 6 shows a horizontal sectional view of the excavator wear assembly 1000 in an assembled position.
[0081] Boss 113 is located at an end of retaining member 110 and has a guide aperture 114 as before. Furthermore, boss 113 has a series of screw threaded apertures 116 as will be discussed in greater detail below.
[0082] Jacking member 150 is releasably mountable on a face of boss 113 and has a bolt aperture 151 having a retaining shoulder 154 . Furthermore, jacking member 150 has a screw 153 extending through each of spaced mounting apertures 152 extending through bolt retaining member 150 .
[0083] In use, bolt is located through guide aperture 114 of boss 113 or retaining member 110 . Jacking member 150 is then releasably mounted upon a face of boss 113 by way of screws 153 extending through mounting apertures 152 of jacking member 150 and terminating within corresponding screw threaded apertures 116 of boss 113 . In this way, retaining shoulder 154 abuts a face of head portion 121 of bolt 120 to thereby captively retain an opposing face of head portion 121 in abutment with a face of boss 113 .
[0084] The retaining member 110 is then non-rotatably located within mounting aperture 230 of mounting nose 200 as before and adaptor 300 is slidably mounted upon mounting nose 200 to thereby captively retain retaining member 110 within mounting aperture 230 of mounting nose 200 .
[0085] An outer face of jacking member 150 bears against an inner face of side wall 350 of adaptor 300 .
[0086] Locating member 130 is then located within mounting aperture 230 as before and bolt 120 is tensioned to relatively contract the length of mounting pin assembly 100 and outwardly divergent face 133 wedgingly engages with inwardly convergent opening 341 of adaptor 300 to thereby urge adaptor 300 into tight engagement with mounting nose 200 as shown in FIG. 6 .
[0087] It will be apparent to a person skilled in the art that the drive member (not shown) of drive tool (also not shown) is engageable with hexagonally shaped female tensioning recess 121 A of bolt 120 through bolt aperture 151 .
[0088] In order to remove adaptor 300 from mounting nose, drive member (not shown) of drive tool (also not shown) is again engaged with hexagonally shaped female tensioning recess 121 A of bolt 120 to thereby threadably disengage threaded shank 122 A of bolt 120 with complimentary threaded bore portion 134 B of locating member 130 .
[0089] As a retaining shoulder 154 bears against a face of head portion 121 and an opposing face of head portion 121 is retained in abutment with a face of boss 113 the locating member 130 is driven from within mounting aperture 230 as any opposing force resisting relative longitudinal expansion of mounting pin assembly 100 is borne by inner face of adaptor side wall 350 through abutment with a face of jacking member 150 as previously discussed.
[0090] Once locating member 130 is ejected from mounting aperture 230 , adaptor 300 is able to be slidably dismounted from mounting nose 200 as before.
[0091] Use of jacking member 150 is particularly advantageous in environments where it is likely that locating member 130 may be difficult to extract from mounting aperture 230 due to the ingress and cementation of fines and the like within mounting aperture 230 .
[0092] It will be readily apparent to a person skilled in the art that the excavator wear assembly, the mounting pin assembly and methods of use thereof in accordance with the invention offer substantial advantages over prior art systems and methods. After a period of time in the field, some degree of wear between the wear member and the nose is inevitable. This wear usually occurs on upper and lower bearing faces of a nose and the front of a nose and the corresponding contact surfaces in the socket cavity of the wear member. When such wear occurs, any slack between the nose and wear adaptor is readily taken up by re-tensioning the bolt of the mounting pin assembly.
[0093] Furthermore, any relative movement between the nose and the adaptor generally causes wearing of the nose as the adaptor is generally relatively harder than the nose. As such, by re-tensioning the bolt during use, this relative movement is minimized and hence provides for a longer working life for the wear member and the nose.
[0094] Additionally, when casting the nose and the wear member in the form of the adaptor, there will always be manufacturing tolerances such that the manufactured member is not exactly to specification. The mounting pin assembly of the invention accommodates for these tolerances due to the wedging engagement of the pin assembly on the opening of the adaptor to engage the adaptor on the mounting nose. As such, this minimises relative movement, and hence wear, between the adaptor and the nose due to these manufacturing tolerances.
[0095] The bolt is readily accessible and the inwardly convergent opening of the adaptor side wall aperture and the outwardly divergent face of the locating member allows for a considerable degree of movement between the nose and wear member along a longitudinal axis with only a relatively small degree of rotation of the bolt of the mounting pin assembly.
[0096] The various embodiments of the invention are quick and simple to install and uninstall with readily available tools and do not require severe impacts with a sledge hammer or the like which is a slow and dangerous procedure.
[0097] Throughout the specification the aim has been to describe the invention without limiting the invention to any one embodiment or specific collection of features. Persons skilled in the relevant art may realise variations from the specific embodiments that will nonetheless fall within the scope of the invention.
[0098] Whilst the invention has been described with reference to the mounting of adaptor 300 to mounting nose 200 , it is equally applicable to the mounting of points or digging teeth to adaptors. Generally, teeth have wall apertures extending through opposed top and bottom walls and adaptors have a corresponding mounting aperture. A skilled addressee will appreciate that the mounting pin assembly 100 of the invention may be employed to releasably secure a point or digging tooth to an adaptor.
[0099] It will be appreciated that various other changes and modifications may be made to the embodiment described without departing from the spirit and scope of the invention. | A mounting pin assembly having a retaining member which includes a locating surface and a boss extending from the locating surface. The mounting pin assembly also has a locating member slidably mountable upon the locating surface of the retaining member. The locating member also has an enlarged portion defined by an outwardly divergent face. The mounting pin assembly also has a tensioning member extending between and coupling the boss of said retaining member and the locating member. The tensioning member is configured to cause relative contraction of the mounting pin assembly such that the locating member is drawn upon the locating surface of the retaining member towards the boss when a tensile force is applied to the tensioning member. | 4 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application is a continuation of U.S. Provisional patent application Ser. No. 10/826,667 filed Apr. 16, 2004, which claims the benefit of U.S. Provisional patent application Ser. No. 60/463,030, filed Apr. 16, 2003, both of which are incorporated herein by reference.
GOVERNMENT FUNDING
[0002] The invention described herein was made with government support under the following grant numbers, N-00014-00-1-0183 (ONR), F49620-01-1-0168 (AFOSR), EE C-0210835 (NSF), and GM60799/EB00264 (NIH). The United States Government may have certain rights in the invention.
BACKGROUND
[0003] Stimuli responsive polymers (SRPs) comprise a class of synthetic, naturally occurring and semi-synthetic polymers, which exhibit discrete rapid and reversible changes in conformation as a response to environmental stimuli. These stimuli may include temperature, pH, ionic strength, electrical potential and light. Some of the most studied of these so-called smart polymers are hydrogels which change their water content and excluded volume, in response to temperature. Various types of stimuli responsive polymers in ensembles to control the permeability of solutes and fluids through membranes or through bulk materials have been described. In recent years, these types of polymers have been developed for a variety of different applications including drug delivery, control of protein activity and most interestingly, systems that mimic natural cellular components, such as cellular membranes and secretory granules. Smart polymers that have found use in biotechnology and medicine have been described by I Yu Galaev in Russian Chemical Reviews 64: 471-489 (1995); A. S. Hoffman in Clinical Chemistry 46:1478-1486 (2000) and H. G. Schild, Prog. Polym. Sci. 17, 163 (1992).
[0004] Previous methods for the use of stimuli responsive polymers for the dynamic control of molecular permeability have limited ability for independent and precise control for a variety of applications. Hence, there currently is a need to enhance the application of stimuli responsive polymers.
SUMMARY OF THE INVENTION
[0005] The present subject matter relates to the design of mesoporous materials in which the transport properties of highly ordered pores of molecular dimensions can be externally and reversibly modulated. Applicants have discovered that the presence of poly(N-isopropyl acrylamide), a stimuli responsive polymer, in a porous network can be used to modulate the transport of aqueous solutes. One embodiment is the modification of mesoporous materials by atom transfer radical polymerization components to allow dynamic control of size selective molecular transport. Another embodiment is direct surfactant templating of hybrid copolymers to achieve dynamic control of size selective molecular transport. In yet another embodiment, a method for forming a mesoporous material including modifying pores of a mesoporous material with a stimuli responsive polymer and maintaining an ordered porous structure and an increase in inter-pore spacing.
BRIEF DESCRIPTION OF THE FIGURES
[0006] FIGS. 1A-C illustrate the characterization of smart porous materials formed by surface tethered living radical polymerization within mesoporous silica.
[0007] FIGS. 2A-E illustrate the uptake and release of fluorescent dyes from ATRP-modified microparticles.
[0008] FIGS. 3A-C illustrate the characterization of smart porous materials formed by copolymerization of NIPAAM and silica.
[0009] FIG. 4A illustrates comparison of the flow cytometry data.
[0010] FIG. 4B illustrates comparison of the confocal microscopy data.
[0011] FIG. 5 illustrates wettability data for mesoporous material of the present invention.
[0012] FIGS. 6A-E illustrate topographical AFM images.
[0013] FIGS. 7A-B illustrate pixel intensity histograms.
[0014] FIG. 8 is a graph showing the release of fluorescein from the polymer grafted particles at two different temperatures as measured by spectrofluorimetry.
[0015] FIG. 9 is a graph showing a comparison of flow cytometry results (fluorescein release at 50οC, FIG. 2B ) with theory (equation 4).
[0016] FIG. 10 is a comparison of confocal microscopy results (rhodamine 6G at 50° C., FIG. 2D ) with theory (equation 3).
DETAILED DESCRIPTION
[0017] In the following detailed description, reference made to the accompanying drawings which form a part hereof, and which is shown by way of illustration specific embodiments in which the invention may be practiced. These embodiments are described in sufficient detail to enable those skilled in the art to practice the invention, and it is to be understood that other embodiments may be utilized and that structural changes may be made without departing from the present invention.
[0018] The terms “mesoporous materials” or “mesoporous particles” as used herein includes porous network, microparticles, nanoparticles, nanostructured surfaces, nanotextured surfaces, supported membranes, and patterned microstructures. It will be appreciated by those skilled in the art that other related materials may be used to the control molecular transport and surface reactivity.
[0019] The term “stimuli responsive polymer” as used herein includes polymers that are sensitive to their environment or externally applied impetus.
[0020] The control of transport of aqueous molecular solutes through porous materials as described herein is critical in a number of technological areas including chromatography, membrane separations, drug delivery and environmental remediation. Control of nanotopography is also important in these areas, because of its capacity for synergistic amplification of surface phenomena and because of its ability to influence steric interactions in molecular transport and surface reactivity. The methods of the present subject matter are based on the formation of ordered mesoporous architectures via surfactant templating during sol-gel polymerization of silica and control of transport and surface properties of the mesoporous materials through the use of stimuli responsive polymers (SRPs, a.k.a. smart polymers). In an embodiment, poly(N-isopropyl acrylamide) is employed as a SRP (PNIPAAm). PNIPAAm is a temperature sensitive SRP which undergoes an aqueous lower critical solubility transition at −32° C. when in bulk solution. When this SRP is present on a surface the solubility transition can be manifested as a change in polymer excluded volume and a change in surface energy. On a pore surface these two properties can be tuned through choice of SRP and surface immobilization conditions to greatly effect adsorption and transport characteristics.
[0021] The present subject matter includes methods wherein a versatile nanostructured surface based on nanoporous aluminum oxide formed via anodization is modified by poly(N-isopropyl acrylamide) with thickness comparable to the surface corrugation. This allows direct correlation of changes in surface energy and nanotopography on macroscopic surface phenomena such as wettability.
[0022] The results of embodiments of the present invention demonstrate that the presence of a stimuli responsive polymer in the porous network may be used to modulate the transport of aqueous solutes. In one embodiment, a stimuli responsive polymer may be used to change the thickness and surface energy of a porous network as a function of temperature. At low temperatures (for example, room temperature), the stimuli responsive polymer is extended and inhibits the transport of solutes. At higher temperatures (at least about 35° C.), the stimuli responsive polymer is collapsed within the pore network and allows solute diffusion.
[0023] In one embodiment, placement of the stimuli responsive polymer within the porous network resulted in an increase in the inter-pore spacing by about at least about 30%. In another embodiment, placement of the stimuli responsive polymer within the porous network resulted in an increase in the inter-pore spacing by about at least 40%.
[0024] Although silica and poly(N-isopropyl acrylamide) have been chosen as a basis of demonstration, the design principles and synthetic methods are applicable to a wide variety of porous structures, polymers or molecules that are reversibly sensitive to external stimuli, such as temperature, pH, light, electricity, solutes, or enzymatic transformations.
[0025] FIGS. 1A-C illustrate the characterization of smart porous materials formed by surface tethered living radical polymerization within mesoporous silica. FIGS. 1A and B show transmission electron microscopy (TEM) micrographs of microtomed samples of particles before and after modification of their porous network via ATRP of NIPAAm. ATRP is very useful for the modification of pore surfaces for two reasons. First, the lifetime of the radical on the surface is high (several hours) resulting in a relatively slow polymerization rate that allows uniform polyumerization in confined spaces. This property has been exploited in the formation of surface grafted polymer burshes with predictable molar masses, low polydispersity and controllable compositions. Secondly, polymerization is restricted to the surface such that no polymer forms in solution. This also prevents clogging of the pores with free polymer and enables uniform polymerization. We have recently shown that surface grafted brushes of PNIAPAAm prepared by ATRP on flat surfaces can exhibit substantial changes in thickness and surface energy as a function of temperature. At low temperatures, the brushes are hydrophilic, hydrated and extended; at higher temperatures, the brushes are relatively hydrophobic and thus dehydrate and collapse.
[0026] FIG. 1A shows the TEM micrograph of mesoporous silica formed by templating with CTAB after calcination and prior to surface modification. FIG. 1B shows the TEM micrograph of hybrid material after modification by surface initiated ATRP of PNIPAA. The hexagonal packing of the pores visible in FIG. 1B shows that the ordered porous structure is maintained through the polymerization process, with an increase in the inter-pore spacing. FIG. 1C shows the XRD patterns of porous materials before (ο) and after(Δ) ATRP.
[0027] FIGS. 2A-C illustrate the uptake and release of fluorescent dyes from ATRP-modified microparticles. FIG. 2A shows the uptake of fluorescein into particles as a function of temperature as measured by flow cytometry. As shown in FIG. 2A , the untreated mesoporous silica (Δ) and PNIPAAm grafted mesoporous silica (ο) were immersed in dye (35 μM) for 2 h. FIG. 2B shows the release of fluorescein from PNIPAAm grafted mesoporous particles as a function of time as measured by flow cytometry. All samples were equilibrated in dye (35 μM) for 2 h. Fluorescence of beads incubated at 25° C. and released at 25° C. (•) and 50° C. (▪). Fluorescence of beads incubated at 50° C. and released at 25° C. (▴) and 50° C. (▾). FIG. 2C shows confocal micrographs demonstrating the release of rhodamine dye from the grafted particles at 50° C. FIG. 2D shows the time dependant line profiles of fluorescence intensities obtained at the vertical midline of the particle imaged in FIG. 2C . FIG. 2A shows data for uptake of the dye as a function of temperature after 2 hrs of immersion in 35 μM dye. In contrast to the bare silica particles, PNIPAAm modified particles showed enhanced uptake at high temperatures (>45° C.), at which the surface grafted polymer is in a collapsed, hydrophobic state. At lower temperatures, PNIPAAm is in an extended state that likely occludes the pores to prevent uptake of the dye. The range of temperatures over which the transition in the uptake takes place (˜35-50° C.) is quite broad, consistent with previous theoretical and experimental studies that have concluded that the solubility transition for polymer brushes in confined geometries is broad compared to that observed for free polymer in solution. Further evidence that PNIPAAm chains can be used to modulate molecular transport rates within the porous network is provided by data on the release of dye from the hybrid particles at low and high temperatures. FIG. 2B presents the fluorescence of dye loaded particles as a function of time after being washed and immersed in Tris buffer. A more rapid decrease in particle fluorescence is observed at 50° C. than at 25° C., indicating that the hydrated PNIPAAm chains restrict molecular diffusion at low temperatures. A concomitant increase in the solution fluorescence measured by parallel spectrofluorimetric measurements is also observed (Example 3). FIG. 2C presents confocal fluorescence images that show the time dependent release of rhodamine dye from a particle at 50° C. Fluorescence intensity profiles of the particle at various time intervals ( FIG. 2D ) provide a quantitative indication of the decrease in dye concentration within the particle due to its release. Images taken at 25° C. showed a much slower change in fluorescence.
[0028] FIGS. 3A-C illustrate the characterization of smart porous materials formed by copolymerization of NIPAAM and silica. FIG. 3A shows the TEM micrograph of hybrid material before removal of surfactant templates. FIG. 3B shows the TEM micrograph of hybrid material after removal of surfactant templates. While the nanoscopic ordering of the material is clearly evident before surfactant removal, it is less clear after extraction of the surfactant. Analysis of XRD confirmed the presence of ordered structures both before and after solvent extraction, with a mixture of lamellar and hexagonal phases clearly indicated before surfactant extraction.
[0029] FIG. 3C shows the permeation of crystal violet solutions through hybrid membranes coated on centrifugal filters. Permeation was measured repeatedly after 3 min of centrifugation at a field of 400.×g while cycling between 25° C. and 50° C. “Permeation” indicates that the solution permeated through the membrane and that the concentration of the filtrate and the feed were measured to be the same. “No Permeation” indicates that not even a trace of water was observed to permeate through the filter.
[0030] FIG. 3C presents data on the permeability of hybrid membranes formed by spin coating of the precursor sol onto macroporous centrifugal filters. This data shows that molecular transport is inhibited at low temperature and enabled at high temperature and that temperature can be used to reversibly modulate the transport characteristics of the porous materials. Examination of the selectivity of molecular transport was conducted by measuring the permeation of poly(ethylene glycol) (PEG) in aqueous solutions (2 wt %) which varied in the molecular weight of PEG. Under controlled permeation conditions (50° C., 400×g), only PEGs with molecular weight less than 10,000 Da permeated through the membrane materials. At high temperatures the membranes act as molecular weight cut off filters (see Table 1). These results demonstrate that this synthetic approach can successfully be used to dynamically and reversibly modulate the permeation characteristics of porous networks that exhibit molecular size selectivity.
[0031] FIG. 4A illustrates a comparison of flow cytometry data (fluorescein release at 50° C.) with theory. Theory: Total amount of dye remaining in particles (M R ), normalized to total initial amount of dye (M o ). Experiment: mean channel fluorescence (I T ) as measured by the flow cytometer normalized to the initial value (l To ).
[0032] FIG. 4B illustrates Comparison of confocal microscopy date (rhodamine 6 G at 50° C., FIG. 2C ) with theory. Theory: plot of normalized concentration at the center of the particle (C 1 =initial uniform concentration in particle, C o =constant surface concentration). Experiment: fluorescence intensity at center of particle normalized to the fluorescence intensity at t=0. Experimental values were shifted by 4 min to produce the match with the theory. This time is approximately that which elapsed between sample washing and the recording of the first fluorescence image (denoted as t=0 and 7 in FIGS. 2 A,B, respectively).
[0033] FIG. 5 illustrates wettability data for PNIPAAm grafted on the porous and nonporous surfaces at temperatures below and above the typical low critical solubility temperature observed for bulk solutions. In all cases change in temperature resulted in a change in water contact angle. Increasing the pore size of the substrate led to a gradual decrease in the contact angles measured at low temperature and a dramatic increase in contact angles measured at high temperature. The difference in contact angle measured at low and high temperature increased steadily, from ˜13° to 112°.
[0034] FIGS. 6A-C illustrate representative images for bare and PNIPAAm-modified anodic aluminum oxide membranes at temperatures below and above the low critical solubility temperature. The images reflect changes in the nanostructure due to differences in template pore size, surface grafting of PNIPAAm, and change in temperature for the PNIPAAm-modified surfaces. Roughness factors (actual surface area/projected surface area) obtained from the images of the PNIPAAm surfaces increased steadily as the pore size increased and increased significantly upon increase in temperature for the 20 nm (1.15 at 25° C. to 1.24 at 40° C.) and 100 nm (1.23 to 1.33). The 200 nm samples did not show a dramatic difference in roughness factor at low and high temperatures, consistent with the expectation that changes in topography due to swelling and contraction of the thin polymer layer are less significant for larger pore sizes. Repeated imaging of samples at high and low temperature demonstrated reversible change in the nanostructure of the PNIPAAm modified samples.
[0035] FIG. 7A shows intensity histograms for representative images of the different types of PNIPAAm-modified porous anodic aluminum oxide. A method based on principal components analysis (PCA), for quantitative correlation of changes in nanostructure, as visualized by atomic force microscopy (AFM), to changes in macroscopic water contact angles. Several multivariate statistical models based on PCA were developed to correlate features in the AFM images with measured macroscopic contact angles. The best correlations were obtained using PCA of the histograms of AFM pixel intensities. Another method that presented a meaningful relationship involved the use of PCA to correlate the Fourier transforms of the images. As shown in FIG. 7A , PCA of these histograms reveals that 91% of their variation is described by the 1 st principal component which is centered around the mean grey level intensity (˜125) and 8% is described by the 2 nd principal component that has two peaks near the extremes of the grey level intensity values (˜50 and ˜165).
[0036] FIG. 7B shows the correlation of the first and second principal components of the variation in the intensity histograms with macroscopic wettability. FIG. 7B demonstrates that these principal components are linearly correlated with the cosine of the contact angles, and thus that AFM can be used in the quantitative prediction of a dynamic macroscopic property, e.g., the wettability.
[0037] The combined results of FIGS. 5-7 show that it is possible to dynamically change crucial surface properties—the size of surface pores, the surface roughness, and the effective interfacial energy—on the nanometer scale using surface-grafted stimuli responsive polymers. The changes are controllable and reversible, and are reflected in large changes in contact angle, and in easily visible changes in AFM images. Finally the changes in macroscopic surface hydrophobicity can be quantitatively related to changes in microscopic surface structure using principle component analysis.
[0038] All of the methods described above for monitoring the release of fluorescent dyes from the particles can be used to estimate the effective diffusion coefficient (D eff ) of the dyes in the porous structure. A simple method is to adopt a model that treats the particle as a homogeneous continuum with spherical symmetry. The effects of porosity and tortuous nature of the pore structure are included in the observed D eff . The time dependant diffusion equation then reduces to a simple equation with one spatial coordinate, which has been solved analytically for various boundary and initial conditions:
[0000]
∂
C
∂
t
=
D
eff
·
1
r
2
∂
∂
r
(
r
2
∂
C
∂
r
)
[0039] Solution with a uniform initial dye concentration throughout the bead and constant concentration at the bead surface (reasonable assumptions for the cytometry and confocal microscopy experiments) yields effective diffusion coefficients for fluorescein and rhodamine dyes at 50° C. of 2×10 −11 and 3×10 −10 cm 2 /s, respectively (see Examples 4 and 5).
[0040] The invention will now be illustrated by the following non-limiting Examples.
EXAMPLE 1
[0041] Synthesis Of Mesoporous Silica
[0042] Synthesis of mesoporous silica was carried out using a two-step acid-catalyzed sol-gel process (as described by Lu et al., Nature, 398, 223 (1999)). Cetyltrimethyl ammonium bromide, a cationic surfactant was used as a structure-directing agent for the preparation of particles. In a typical preparation, tertraethylorthosilicate (TEOS) (Aldrich), ethanol, deionized water (conductivity less than 18.2 MΩ cm), and dilute HCl (mole ratios 1:3.8:1:0.0005) were refluxed at 60° C. for 90 min to provide the stock sol. 20 mL of stock sol was diluted with ethanol, followed by addition of water , dilute HCl, and aqueous surfactant solution (2.5 g of surfactant dissolved in 20 mL of water) to provide final overall TEOS/ethanol/H 2 O/HCl surfactant molar ratios of 1:27:55:0.0053:0.19. The monodisperse droplets were generated by means of a vibrating orifice aerosol generator (VOAG) (TSI Model 3450). In the VOAG, the aerosol solution was forced through a small orifice 20 μm by a syringe pump, with fluid velocities of approximately 8×10 −4 cm s −1 (˜4.7×10 −3 cm 3 s −1 ). The particles were collected on a filter maintained at approximately 80° C. by a heating tape and were subsequently calcined at 400° C. for 4 h to remove the surfactant.
EXAMPLE 2
[0043] Synthesis Of Grafted Particles
[0044] Monodisperse mesoporous silica microparticles (as reported by S.H. Chung, S. Kuyucak, Eur. Biophys. J. Biophys. Lett. 31 , 283 (2002)), were modified by surface grafting according to the procedure described by Huang and Wirth in Anal. Chem., 69, 4577 (1997) and adapted to N-isopropylacrylamide (NIPAAm). Hydroxyl groups were created on the silica surface by treatment with concentrated HNO 3 for 4 h and subsequent washing with ultra pure (>18 MΩ resistance) water and then drying at 110° C. for 2 h under N 2 stream. These particles were then added to a reactor containing 0.5 mL of the initiator, 1-(trichlorosilyl)-2[m/p-(chloromethyl) phenyl]ethane and 50 mL of anhydrous toluene. The reaction was carried out at room temperature for 12 h. The silica particles were then washed with toluene, methanol, and acetone and dried at 110° C. for 2 h. Atom transfer radical polymerization (ATRP) was performed on the initiator-derivatized particles. 0.2 g of silica particles were combined with 0.107 g CuCl, 0.5 g of bipyridine, and 3 g of NIPAAm (Aldrich) in 30 mL of dimethyl formamide. The reaction flask was deoxygenated with N 2 for 40 minutes and then sealed under N 2 . The reaction took place at 130° C. for 40 h with stiffing. The grafted particles were then washed with methanol and water and dried at 70° C. under a stream of N 2 .
[0045] Characterization
[0046] The particles were characterized by scanning electron microscope (Hitachi S-800) and X-ray diffraction (Siemens D5000, CuK α radiation 1=1.5418 Å). Surface area and pore size distribution studies were carried out using nitrogen adsorption and desorption at 77K using a Micromeritics ASAP 2000 porosimeter. Sample preparation for cross-sectional transmission electron microscopy (JEOL 2010 200 KV) required the particles to be embedded in an epoxy and then cross-sectioned using a Sorvall MT-5000 Ultra Microtome machine.
[0047] Spectrofluorimetry
[0048] Spectrofluorometric measurements were carried out using a Fluorolog-3 (ISA INC./Jobin Yvon Inc ,NJ). 2.0 mg of polymer-modified particles were added to 1.0 mL of 0.035 mM fluorescein (sodium salt) in Tris (0.05 M, pH 7.4) buffer and were incubated at either 25 or 50° C. for 2 h. The samples were then cooled down to room temperature (˜25° C.), and equilibrated at this temperature for at least 40 min. The particles were washed 3× in fresh Tris buffer. The dye concentration in the supernatant was then measured and returned to the beads. The samples were then incubated either at 50° C. or 25° C., the temperature being the same as the initial incubation conditions. Dye release was measured at various intervals during incubation.
[0049] Flow Cytometry
[0050] Polymer-modified particles (1.0 mg) were added to 1.0 mL of 0.035 mM fluorescein in Tris buffer (0.05 M, pH 7.4) and were incubated at either 25 or 50° C. for 2 h. The samples were then cooled down to room temperature (−25° C.), and equilibrated at this temperature for at least 40 min. The particles were then washed 3× in fresh Tris buffer. Flow cytometry recorded the dye remaining in the particles at both 50° C. and 25° C. The uptake of dye was also measured, using flow cytometry, at various temperatures to examine the temperature response of the grafted polymer.
[0051] Bead suspensions were analyzed by flow cytometry using a Becton-Dickinson FACScan flow cytometer (Sunnyvale, Calif.) interfaced to a Power PC Macintosh using the Cell Quest software package. The FACScan is equipped with a 15 mW air-cooled argon ion laser. The laser output wavelength is fixed at 488 nm. Experimental details of these analyses have been described elsewhere.
[0052] Confocal Laser Scanning Microscopy
[0053] 5.0 mg of polymer grafted particles were incubated in 0.4 mL of an aqueous solution containing 0.5 mM of rhodamine 6G (Molecular Probes) at either 25 or 50° C. overnight. The samples were then cooled to room temperature (˜25° C.), and equilibrated at this temperature for at least 40 mM The particles were washed 2× with water at room temperature. The dye remaining in the particles was observed at 50° C. or 25° C. using a confocal laser scanning microscope at regular intervals.
[0054] Confocal laser scanning microscopy was performed on a Zeiss Axiovert microscope using an LSM 510 (Carl Zeiss) scan head. Simultaneous DIC imaging was performed using the scan head and LSM software and a Plan Neo Fluor 40×/1.3 NA oil immersion lens. A HeNe laser (543 nm) was used to excite fluorescence. Samples were heated by placing a suspension of particles on a slide supported on a heating stage constructed from an aluminum block and a self-adhesive heating element. Temperature of the sample was probed using a thermocouple.
[0055] FIG. 8 is a graph showing the release of fluorescein from the polymer grafted particles at two different temperatures as measured by spectrofluorimetry.
[0056] FIG. 9 is a graph showing a comparison of flow cytometry results (fluorescein release at 50οC, FIG. 2B ) with theory (equation 4). Theory: Total dye remaining in particle, normalized to total initial dye. Experiment: mean channel fluorescence as measured by flow cytometer normalized to initial value.
[0057] FIG. 10 is a comparison of confocal microscopy results (rhodamine 6G at 50° C., FIG. 2D) with theory (equation 3). Theory: plot of normalized concentration at the center of the particle (C 1 =initial uniform concentration in particle, C o =constant surface concentration). Experiment: fluorescence intensity at center of particle normalized of the fluorescence intensity at t=0. Experimental values were shifted by 4.0 minutes to produce the match with the theory. This time is approximately that which elapsed between sample washing and the recording of the first fluorescence micrograph (denoted as time=0 in FIG. 2 C, D).
[0058] Permeation Experiments
[0059] Permeation experiments were carried out using an Eppendorff 5415C centrifuge at temperatures of 25 and 50° C. with a controlled temperature of ±1° C. For PEG (M w /M n ˜1.1) experiments (2 wt % aqueous solutions), the concentration of the filtrate was determined from refractive index measurements using a Kernco refractometer by comparing to a calibration curve obtained by measuring the refractive index of known concentrations of PEG. The minimum concentration of PEG, which can be measured using our refractometer, was determined to be 0.3 wt %. Table 1 shows the permeation data of PEGs through copolymer membranes.
[0000]
TABLE 1
Permeation of PEG solutions (300 μL) at 50°
C. through copolymer membrane (surfactant removed)
coated on macroporous filters (Millipore YM-30).
Refractive index
Refractive index
Molecular weight
of feed solution
of filtrate
Rejection
of PEG (Mn)
(±0.0002)
(±0.0002)
[%]
5850
1.3350
1.3351
0
7200
1.3353
1.3353
0
9000
1.3356
1.3354
0
10000
1.3355
1.3331
100
14300
1.3354
1.3330
100
29000
1.3359
1.3330
100
[0060] All publications, patents, and patent documents are incorporated by reference herein, as though individually incorporated by reference. The invention has been described with reference to various specific and preferred embodiments and techniques. However, it should be understood that many variations and modifications may be made while remaining within the spirit and scope of the invention. | The present subject matter relates generally to design, synthesis, and characterization of materials with well-defined porous networks of molecular dimensions in which the size and surface energy of the pores can be externally and reversibly controlled to dynamically modulate the adsorption and transport of molecular species. | 8 |
This application is a continuation of U.S. application Ser. No. 13/332,337 filed Dec. 20, 2011, now U.S. Pat. No. 8,793,025, which is a continuation of U.S. application Ser. No. 12/886,471 filed Sep. 20, 2010, now U.S. Pat. No. 8,108,078, which is a continuation of U.S. application Ser. No. 11/228,413, filed Sep. 15, 2005, now U.S. Pat. No. 7,826,931, all of which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to irrigation control devices and more specifically to decoder-based irrigation control system including decoder units for coupling to actuator coil-controlled irrigation equipment.
2. Discussion of the Related Art
In decoder-based irrigation control systems, an irrigation controller sends signaling along a wire path to which one or more decoder devices are attached. Each decoder device monitors transmissions on the wire path and decodes this signaling to determine when to cause irrigation devices coupled thereto to be activated and deactivated. The decoder module typically includes circuitry formed on a printed circuit board located within a housing. Wiring from the decoder module housing must be coupled to the wiring of the wire path as well as coupled to one or more actuator devices each controlling the opening and closing of an irrigation rotor or valve. In one form, the rotor or valve is operated by a solenoid coil as is well known in the art. Likewise, during installation, the operator must provide and electrically connect two separate devices, a decoder module and an actuator coil module, to each other and to the control wire path. FIG. 1 illustrates a separate decoder module 102 and a coil unit 104 that are conventionally coupled together. For example, as illustrated in FIG. 2 , for a solenoid activated rotor assembly 200 , the coil module 104 is coupled (in part by a bracket 212 and retainer 214 ) to the parts of a selector valve assembly 202 (including a pressure regulator) attached to a casing assembly 204 . The electrical wire inputs to the coil module 104 are then connected to the electrical wire outputs from the decoder module 102 , while the electrical wire inputs to the decoder module 102 are coupled to the control wire path from the irrigation controller. Thus, a typical installation requires the connection of six wires to install the decoder module 102 and a coil module 104 .
As is well known, in operation, a portion of a plunger (not shown) of the selector valve assembly 202 is disposed within the coil unit 104 while another portion is seated against a solenoid plunge port (not shown) within the selector valve assembly 202 in a normally closed position. In this position, high pressure water flow from a main water control valve (not shown) located within a main control valve portion 206 of the device is flowed up high pressure water line 208 into the selector valve assembly 202 and its regulator and is prevented from further movement by the normally closed position of the plunger against the solenoid port in the selector valve assembly 202 . This results in a back pressure that causes the main water control valve to close. In response to signals from the decoder module 102 , the coil module 104 causes the actuation of the plunger to move it off of (or unseat from) the solenoid plunge port allowing the high pressure flow in the high pressure line 208 to flow through the selector valve assembly 202 (and its pressure regulator), which relieves the back pressure and allows water to flow through the main control valve and to a pop-up sprinkler device, i.e., the main water control valve is opened. The pop-up sprinkler device is located within the casing assembly 204 and extends upwardly due to the water pressure through a top portion of the casing assembly 204 . The high pressure flow exits the selector valve assembly 202 down through a discharge flow line 210 which terminates within the casing assembly 204 at a location downstream of the main water control valve.
SUMMARY OF THE INVENTION
Several embodiments of the invention provide an integrated actuator coil and decoder module for use in decoder-based irrigation control systems.
In one embodiment, the invention can be characterized as an irrigation control device comprising: a body; decoder circuitry located within the body; a coil located within the body and coupled to the decoder circuitry, the coil adapted to develop an electromagnetic flux sufficient to cause actuation of a device controlling irrigation equipment in response to signaling from the decoder circuitry; and an electrical connection coupled to the decoder circuitry and adapted to couple to a control wire path of a decoder-based irrigation control system. The decoder circuitry and the coil are integrated into a single device.
In another embodiment, the invention can be characterized as a method of making an irrigation control device comprising the steps of: providing decoder circuitry; providing a coil unit containing a wire coil adapted to develop an electromagnetic flux sufficient to cause actuation of a device that causes opening and closing of an irrigation valve upon the application of an electrical current to the wire coil; coupling an output of the decoder circuitry to an input of the coil unit; inserting the decoder circuitry into a housing such that an electrical connection to the decoder circuitry can be made from outside of the housing; sealing the decoder circuitry within the housing; sealing at least a portion of the coil unit to the housing, whereby forming an integrated device having both the decoder circuitry and the coil unit.
In a further embodiment, the invention can be characterized as a method of electrically connecting an irrigation control device to a decoder based irrigation control system comprising the steps of: electrically coupling a first control wire of the decoder based irrigation control system to a first electrical connection of an integrated coil and decoder module; and electrically coupling a second control wire of the decoder based irrigation control system to a second electrical connection of the integrated coil and decoder module.
BRIEF DESCRIPTION OF THE DRAWINGS
The above and other aspects, features and advantages of several embodiments of the present invention will be more apparent from the following more particular description thereof, presented in conjunction with the following drawings.
FIG. 1 illustrates a separate sprinkler coil and decoder module for controlling irrigation equipment in a conventional decoder-based irrigation control system.
FIG. 2 illustrates a conventional decoder and electric sprinkler application including a separate coil module and decoder module.
FIG. 3 illustrates an integrated coil and decoder module for use in a decoder-based irrigation control system in accordance with one embodiment of the invention.
FIG. 4 illustrates a decoder and electric sprinkler application including an integrated coil and decoder module in accordance with several embodiments of the invention.
FIG. 5 illustrates decoder circuitry and a coil module of the integrated device of FIG. 3 shown without the decoder housing in accordance with one embodiment of the invention.
FIGS. 6A and 6B illustrate other views of the integrated coil and decoder module of FIG. 3 in accordance with other embodiments of the invention.
FIG. 7 illustrates the decoder housing of one embodiment of the device of FIG. 3 .
FIG. 8 illustrates a coil housing of one embodiment of the device of FIG. 3 with a partial cutaway showing a wire coil.
FIG. 9 is a diagram of a decoder-based irrigation control system including multiple integrated coil and decoder modules according to several embodiments of the invention.
Corresponding reference characters indicate corresponding components throughout the several views of the drawings. Skilled artisans will appreciate that elements in the figures are illustrated for simplicity and clarity and have not necessarily been drawn to scale. For example, the dimensions of some of the elements in the figures may be exaggerated relative to other elements to help to improve understanding of various embodiments of the present invention. Also, common but well-understood elements that are useful or necessary in a commercially feasible embodiment are often not depicted in order to facilitate a less obstructed view of these various embodiments of the present invention.
DETAILED DESCRIPTION
The following description is not to be taken in a limiting sense, but is made merely for the purpose of describing the general principles of exemplary embodiments. The scope of the invention should be determined with reference to the claims.
Referring first to FIG. 3 , a perspective view is shown of an integrated coil and decoder module 300 for use in a decoder-based irrigation control system in accordance with one embodiment of the invention. The integrated coil and decoder module 300 includes a module body 302 (also referred to simply as body 302 ) including a decoder housing 304 (also referred to as a first housing) and a coil housing 306 (also referred to as a second housing, solenoid housing or coil unit). The module 300 also includes electrical connector wires 308 and 310 (also referred to as electrical connections 308 and 310 ) extending from the decoder housing 304 . The decoder housing 304 includes decoder circuitry (e.g., shown in FIG. 5 ) and the coil housing 306 includes a wire coil or solenoid (e.g., shown in FIG. 8 ) formed within. Although the decoder housing 304 and the coil housing 306 are separate functional components, they are integrated together to form a single integrated coil and decoder module 300 .
Advantageously, since the module 300 is integrated into a single body 302 , an installer need only connect the two electrical connections 308 and 310 to the control wire path of a decoder-based irrigation control system. It is noted that any electrical connections between the decoder circuitry within the decoder housing 304 and the wire coil within the coil housing 306 are already made and sealingly contained within the body 302 .
Referring next to FIG. 4 , a perspective view is shown of a decoder and electric sprinkler application including the integrated coil and decoder module 300 of FIG. 3 . In this embodiment, in a solenoid activated rotor assembly 400 , the coil housing 306 (or solenoid housing) is coupled (in part by the bracket 212 and the retainer 214 ) to the components of the selector valve assembly 202 attached to the casing assembly 204 (which is typically buried underground or located within a valve box above or below ground). In the illustrated embodiment, the casing assembly 204 contains a pop-up and rotary sprinkler device (not shown). Accordingly, an installation in accordance with this embodiment only involves the connection of two wires (e.g., electrical connections 308 and 310 ) to install the decoder module 300 , as opposed to six wires in the separated decoder module and coil module as illustrated in FIG. 2 . Thus, with the new module according to several embodiments of the invention, the task of installing a decoder module and coil unit is simplified since there are fewer wires to connect. Additionally, this embodiment provides a space-saving design that is more streamlined and easier to install with less clutter due to excess wires. Furthermore, the installer only needs to provide and install a single integrated device rather than purchasing and providing a separate decoder module and a separate coil housing module.
In operation, a portion of a plunger (not shown) of the selector valve assembly 202 is disposed within a core tube (not shown) that extends into the opening of the coil housing 306 about which the coil is wound while another portion of the plunger is seated against a solenoid plunge port (not shown) within the selector valve assembly 202 in a normally closed position (e.g., a spring within the core tube holds the plunger against the solenoid plunge port). In this position, high pressure water flow from a main water control valve (not shown) located within a main control valve portion 206 of the device is flowed up high pressure water line 208 into the selector valve assembly 202 and its regulator and is prevented from further movement by the normally closed position of the plunger against the solenoid port in the selector valve assembly 202 . This results in a back pressure that causes the main water control valve to close. In response to signals from the decoder housing 304 portion of the integrated coil and decoder module 300 , the coil module 306 generates a magnetic field that causes the actuation of the plunger within the core tube to move it off of (or unseat from) the solenoid plunge port allowing the high pressure flow in the high pressure line 208 to flow through the selector valve assembly 202 (and its pressure regulator), which relieves the back pressure and allows water to flow through the main control valve and to a pop-up sprinkler device, i.e., the main water control valve is opened. The high pressure flow exits the selector valve assembly 202 down through a discharge flow line 210 which terminates within the casing assembly 204 at a location downstream of the main water control valve. It is noted that the core tube extends through the bracket 212 and the opening of the coil module 306 such that a portion extends through the back opening of the coil module 306 and back side of the bracket 212 . The retainer 214 is preferably a rubber end cap that is positioned over the portion of the core tube extending therethrough to hold the coil module 306 in position against the bracket 212 and the selector valve assembly 202 .
Referring next to FIG. 5 , a view shown of the decoder circuitry and coil module of the integrated device of FIG. 3 without the decoder housing in accordance with one embodiment of the invention. Illustrated is a printed circuit board 502 including decoder circuitry 504 formed on or otherwise coupled to or attached to the printed circuit board 502 . Also illustrated are the electrical connections 308 and 310 coupled to the decoder circuitry 504 for connection to the control wire path of the decoder-based irrigation control system, as well as electrical connections 506 and 508 extending from the decoder circuitry 504 into the coil housing 306 to electrically couple the decoder circuitry 504 to the wire coil of the coil housing 306 . It is noted that the decoder circuitry 504 , as well as the coil housing 306 including the coil formed within, are well-known in the art. For example, in one embodiment, the decoder circuitry 504 is found within commercial decoder modules available from the Rain Bird Corp., Glendora, Calif., for example, a single channel, single coil decoder (part number FD-101). Likewise, in one embodiment, the coil housing 306 is commercially available from the Rain Bird Corp., Glendora, Calif., as rotor coil, part number 212165.
In accordance with one embodiment, a commercially available coil housing, such as coil housing 306 , is electrically coupled to commercially available decoder circuitry, such as decoder circuitry 504 , via electrical connections 506 and 508 . Such decoder circuitry includes electrical input connections, such as electrical connections 308 and 310 to be coupled to the control wire path of a decoder-based irrigation control system. The decoder circuitry 504 and coil housing 306 are then inserted into a volume (see volume 706 of FIG. 7 ) formed within a housing, such as the decoder housing 304 , such that the electrical connections 308 and 310 extend through at least one opening formed in the decoder housing 304 . Generally, a portion of the coil housing 306 extends into the volume formed within the housing 304 , while the portion of the coil housing 306 that is adapted to mate to the selector valve assembly 202 extends out of this volume. Next, a sealant material is filled into the remaining volume within the housing 304 in order to hermetically seal the electronic components within the housing as well as to hermetically and rigidly seal the coil housing 306 to the decoder housing 304 . The sealant material may comprise any suitable potting material, such as an epoxy, that is initially in a liquid or fluid state and filled within the volume, and which hardens or cures with time. In other embodiments, other suitable sealants may be applied to the interface between the decoder housing 304 and the coil housing 306 without filling the volume of the decoder housing. Advantageously, the resulting module 300 is an integrated single device in which the decoder circuitry and the coil housing are rigidly fixed to each other and form a single integrated body 302 . This embodiment is easy to construct from commercially available components. However, it is noted that in other embodiments, the coil housing 306 and the decoder housing 304 comprise a single housing that is not required to be coupled or otherwise hermetically sealed to each other. One of ordinary skill in the art could certainly design such a housing. Thus, in such embodiments, the wire coil may be directly electrically coupled to the printed circuit board 502 and the decoder circuitry 504 within the same housing.
FIG. 6A illustrates a perspective view of the integrated coil and decoder module 300 illustrating one embodiment of connection openings 602 and 604 formed in a bottom wall 704 of the decoder housing 304 . In this embodiment, the electrical connections 308 and 310 extend through the openings 602 and 604 as the decoder circuitry 504 is positioned within the housing 304 . FIG. 6B illustrates another perspective view of the integrated coil and decoder module 300 illustrating a sealant or potting material 606 filling the interior volume of housing and preventing moisture or other contaminants from entering the housing 304 at the interface between the decoder housing 304 and the coil housing 306 and at the openings 602 and 604 . It is noted that in other embodiments, a single opening (as opposed to the two openings 602 and 604 ), is formed in the decoder housing 304 that any electrical connections extend through, while a suitable sealant or potting material seals the opening.
Referring next to FIG. 7 , a perspective view is shown of the decoder housing 304 of the device of FIG. 3 . As illustrated, in preferred form the decoder housing 304 has an elongated rectangular parallelepiped geometry formed by side walls 702 and a bottom wall 704 . A top end of the housing 304 is open illustrating a volume 706 formed within and for receiving the decoder circuitry and in some embodiments, at least a portion of the coil housing 306 . It is noted that the shape of the decoder housing 304 may take many forms other than that illustrated.
Referring next to FIG. 8 , a perspective view is shown of the coil housing 306 of the device of FIG. 3 with a partial cutaway view to show the wire coil. The coil housing 306 includes a coil portion 802 (or solenoid portion) and a neck portion 804 . In preferred form, a portion of the neck portion 804 extends into the volume 706 formed in the decoder housing 304 . However, in other embodiments, coil housing 306 does not extend into the volume but nevertheless is rigidly and sealingly coupled to the decoder housing 306 . The coil portion 802 is preferably cylindrically shaped and formed about an opening 806 . Thus, the coil portion 802 has an outer cylindrical periphery and an inner concentric cylindrical periphery. The coil portion 802 contains a wire coil 808 or solenoid (shown in the partial cutaway view of FIG. 8 ) wrapping about the inner periphery and sealingly contained within the walls of the coil portion 802 . As is well known in the art, the wire coil 808 wraps about the inner periphery in a coil shape. Upon the application of an electrical current through the wire coil 808 , an electromagnetic flux is formed in the opening 806 of the coil portion 802 about a central axis 810 extending through the opening 806 . This flux is used to actuate a component 812 or device (such as a plunger) typically moveable along the central axis 810 (e.g., along the path of arrow 814 ) within the opening 806 of the coil portion 802 in order to cause the opening or closing of a solenoid actuated irrigation valve (e.g., in one embodiment, by opening a valve of a selector valve assembly 202 controlling the solenoid actuate irrigation valve). In preferred form, the component 812 does not contact the inner surfaces of the coil portion 802 in the opening 806 and is metallic and/or magnetic in order to respond to the generated electromagnetic flux. In one example, the component 812 is a plunger contained within a core tube (not shown) that extends through the opening 806 and is coupled to a selector valve assembly (such as selector valve assembly 202 of FIG. 4 ). The plunger is held in a normally closed position within the core tube by a spring also within the core tube. Upon the application of current to the wire coil 808 , the plunger is caused to move within the core tube relative to the coil housing 306 (and wire coil 808 ) and the core tube to open the selector valve assembly as described above. One end of the core tube extends through the opening 806 to allow a retainer (such as retainer 214 ) to help hold the coil module or housing 306 in position about the core tube and the selector valve assembly. Such coil housings 306 including the wire coil 806 , as well as core tube and plunger assemblies are well-known in the art.
Referring next to FIG. 9 , one embodiment is shown of a decoder-based irrigation control system 900 including several integrated coil and decoder modules 300 according to several embodiments of the invention. An irrigation controller 902 provides a control wire path 901 extending from the controller 902 into a geographic region where irrigation is desired. The control wire path 901 is typically buried underground. It is understood that multiple separate control wire paths may be output from the controller 902 ; however, for purposes of illustration, only a single control wire path 901 is shown. Typically, the control wire path 901 includes two wires, a power wire 904 and a common wire 906 . A power signal, e.g., 24 volts AC, from the controller 902 is sent on the power line 904 to any connected devices while the common line provides a return to complete the circuit. Generally, the power signal is of sufficient voltage to cause a magnetic flux in the coil housing to open a solenoid activated valve 908 . In other words, the electromagnetic flux is sufficient to control irrigation equipment. In a decoder-based system, the power signal is modulated or encoded with data that is readable by the decoder circuitry as is known in the art so that the controller 902 can control multiple irrigation valves using the single control wire path 901 .
At various locations in the field, an integrated coil and decoder module 300 according to several embodiments of the invention is directly coupled to the control wire path 901 . For example, at various locations in the field, the electrical connections 308 and 310 are coupled to the power line 904 and the common line 906 . In one embodiment, the lines and connections are respectively coupled together using twist-on wire connectors and silicon grease to provide water resistant electrical connections. The decoder portion of the integrated coil and decoder module 300 decodes the modulated or encoded power signal on the power line 904 and determines whether or not to provide the power signal (electrical current) to the wire coil of the integrated coil and decoder module 300 (e.g., via electrical connections 506 and 508 ).
As described above, the wire coil generates a magnetic flux sufficient to cause device of an actuator or solenoid assembly 912 (e.g., in one embodiment, to actuate a plunger of a selector valve assembly 202 ) to open a normally closed solenoid operated valve 908 (e.g., in one embodiment, a main control valve of a main control valve portion 206 ), which is coupled to a water supply line on one end and to one or more sprinkler devices on the other end. It is noted that in embodiments implemented in a solenoid activated rotor assembly for a pop-up sprinkler device, that a given integrated coil and decoder module couples to a solenoid operated valve 908 that couples to a single sprinkler device; however, that in other embodiments, the solenoid activate valve 908 may be coupled to multiple sprinkler devices. It is further noted that generally, a sprinkler device may be any rotor device, stationary device, drip device, etc. As is known, there may be multiple integrated coil and decoder modules 300 coupled to the control wire path 901 at various locations. Advantageously, according to several embodiments of the invention, by providing integrated coil and decoder modules 300 instead of separate decoder modules and coil units that must be coupled to each other and to the control wire path, the installation process has been simplified by reducing the number of wires than an installer must connect and by providing a more streamlined design at the casing assembly 204 . Additionally, the decoder circuitry and the coil housing form a single rigid and integrated body.
While the invention herein disclosed has been described by means of specific embodiments, examples and applications thereof, numerous modifications and variations could be made thereto by those skilled in the art without departing from the scope of the invention set forth in the claims. | An integrated actuator coil and decoder module for use in decoder-based irrigation control systems, and related methods of manufacture and installation, are provided herein. In one implementation, an irrigation control device comprises a body, decoder circuitry located within the body, a coil located within the body and coupled to the decoder circuitry, the coil adapted to develop an electromagnetic flux sufficient to cause actuation of a device controlling irrigation equipment in response to signaling from the decoder circuitry. Also included is an electrical connection coupled to the decoder circuitry and adapted to couple to a control wire path of a decoder-based irrigation control system. The decoder circuitry and the coil are integrated into a single device. | 8 |
RELATED APPLICATIONS
This patent application is a continuation-in-part of patent application Ser. No. 09/002,875 filed Jan. 5, 1998, now abandoned, by inventors Norman S. Gordon, Robert P. Cooper and Richard L. Quick, and entitled "Needle Guidance System for Endoscopic Suture Device"; which is a continuation of patent application Ser. No. 08/554,743 filed Nov. 7, 1995, now U.S. Pat. No. 5,713,910, by inventors Norman S. Gordon, Robert P. Cooper and Richard L. Quick, and entitled "Needle Guidance System for Endoscopic Suture Device"; which is a continuation-in-part of patent application Ser. No. 08/311,967, filed Sep. 26, 1994, now U.S. Pat. No. 5,578,044, by inventors Norman S. Gordon and Robert P. Cooper, and entitled "Endoscopic Suture System"; which is a continuation-in-part of patent application Ser. No. 08/205,042, filed Mar. 2, 1994, now U.S. Pat. No. 5,540,704, by inventors Norman S. Gordon, Robert P. Cooper and Gordon C. Gunn, and entitled "Endoscopic Suture System"; which is a continuation-in-part of patent application Ser. No. 08/057,699, now U.S. Pat. No. 5,458,609, filed May 4, 1993, by inventors Norman S. Gordon, Robert P. Cooper and Richard L. Quick, and entitled "Endoscopic Suture System"; which is a continuation-in-part of patent application Ser. No. 07/941,382, filed Sep. 4, 1992, now U.S. Pat. No. 5,364,408, by inventor Norman S. Gordon, and entitled "Endoscopic Suture System". The entirety of each of the above referenced patent applications is hereby incorporated herein by reference.
FIELD OF THE INVENTION
The invention relates to devices for approximation, ligation and fixation of tissue using a suture, to various constituent parts comprising said devices, and particularly to the placement of sutures into certain difficult to access ligamental structures, to the approximation of tissue separated by means of an endosurgical trocar being inserted into a body cavity, and to approximation, ligation, and fixation of body tissue using both traditional open surgical and endosurgical techniques and instruments.
BACKGROUND OF THE INVENTION
Suturing of body tissues is a time consuming aspect of most surgical procedures. Many surgical procedures are currently being performed where it is necessary to make a large opening to expose the area of, for instance, the human body that requires surgical repair. There are instruments that are becoming increasingly available that allow the viewing of certain areas of the body through a small puncture wound without exposing the entire body cavity. These viewing instruments, called endoscopes, can be used in conjunction with specialized surgical instrumentation to detect, diagnose, and repair areas of the body that were previously only able to be repaired using traditional "open" surgery.
In the past, there have been many attempts to simplify the surgeons' task of driving a needle carrying suture through body tissues to approximate, ligate and fixate them. Many prior disclosures, such as described in Drake et al, U.S. Pat. No. 919,138 issued Apr. 20, 1909, employ a hollow needle driven through the tissue with the suture material passing through the hollow center lumen. The needle is withdrawn leaving the suture material in place, and the suture is tied, completing the approximation. A limitation of these types of devices is that they are particularly adapted for use in open surgical procedures where there is room for the surgeon to manipulate the instrument.
Others have attempted to devise suturing instruments that resemble traditional forceps, such as Bassett, U.S. Pat. No. 3,946,740 issued Mar. 30, 1976. These devices pinch tissue between opposing jaws and pass a needle from one jaw through the tissue to the other jaw, where grasping means pull the needle and suture material through the tissue. A limitation of these designs is that they also are adapted primarily for open surgery, in that they require exposure of the tissues to be sutured in order that the tissue may be grasped or pinched between the jaws of the instrument. This is a severe limitation in the case of endoscopic surgery.
The term "endosurgery" means endoscopic surgery or surgery performed using an endoscope. In conjunction with a video monitor, the endoscope becomes the surgeons' new eyes from which they operate. Operations using an endoscope are significantly less invasive when compared to traditional open surgery. Patients usually return home the next day or in some cases the same day of the endosurgical procedure. This is in contrast to standard open surgical procedures where a large incision divides the muscle layers and allows the surgeon to directly visualize the operative area. Patients may stay in the hospital for 5 to 6 days or longer following open surgery. In addition, after endosurgical procedures, patients return to work within a few days versus the traditional 3 to 4 weeks at home following open surgery.
Access to the operative site using endosurgical or minimally invasive techniques is accomplished by inserting small tubes called trocars into a body cavity. These tubes have a diameter of, for example, between 3 mm and 30 mm and a length of about 150 mm (6 inches). There have been attempts to devise instruments and methods for suturing within a body cavity through these trocar tubes. Such an instrument is disclosed by Mulhollan et al, U.S. Pat. No. 4,621,640 issued Nov. 10, 1986. Mulhollan describes an instrument that may be used to hold and drive a needle, but makes no provision for retrieval of the needle from the body cavity, nor the completion of the suture by tying. Mulhollan's instrument is limited in that the arc through which the needle must be driven is perpendicular to the axis of the device. Another such instrument intended for endoscopic use is described by Yoon, U.S. Pat. No. 4,935,027, issued Jun. 19, 1990. This instrument uses oppositional hollow needles or tracks pushed through the tissue and coapted to create a tract through which the suture material is pushed. It is not clear how these curved tracks would be adapted to both be able to pierce the tissue planes illustrated, parallel to the tips of the tracks, and be curved toward each other to form the hollow tract.
The invention herein described may be used for final closure of umbilical and secondary trocar puncture wounds in abdominal tissues including the fascia and other layers. The umbilical puncture is routinely a puncture site of 10 mm to 12 mm. Future procedures may require trocar puncture sites up to 18 mm and greater in size. Due to the large size of the puncture wound, it is important that the site be closed or approximated at the interior abdominal wall following removal of the large trocar cannula. An improper or non-existent closure can lead to a herniation of the bowel and/or bowel obstruction. The present mode for closure is to reach down to the desired tissue layer with a pair of needle drivers holding a needle and suture material and secure a stitch. Many patients are obese and present considerable fat in this region. Because the abdominal wall may be several inches thick, it is extremely difficult, tedious and time consuming to approximate the fascial tissues with a suture. Often times, following removal of a large trocar, the puncture site needs to be enlarged to accomplish this, thus negating some of the advantages of endoscopic surgery previously discussed.
One of the embodiments described herein may be of particular advantage in performing a surgery for correction of female stress incontinence, which affects over 5 million women in the United States. Stress incontinence is caused when the structures defining the pelvic floor are altered by aging or disturbed by the process of childbirth or other trauma. These structures in the pelvic floor normally hold the urinary bladder such that maintenance of a volume of urine in the bladder is accomplished by a combination of muscle tone and bladder positioning.
There are a number of surgical procedures that may be performed in order to restore the normal anatomical position of the urinary bladder. The classic open Burch suspension procedure is one such procedure and is a straightforward surgical treatment for correction of female stress incontinence. During this procedure, sutures are precisely placed in the wall of the vagina on each side of the urethra, with care being taken to avoid puncturing either the urethra or the mucosal layer of the vagina. These sutures are then looped through a ligament, called Cooper's ligament, which runs along the posterior ridge of the pubic bone. These sutures are then pulled taut, and carefully tied to suspend the urinary bladder in a more anatomically sound position, restoring normal urinary function and continence.
One of the problems with the procedure described above is that it is normally done only in conjunction with other scheduled abdominal surgical procedures such as a hysterectomy. This is because, as described earlier, an open surgical approach requiring a large abdominal incision must be used, and it is not very common for a patient to elect to have a major abdominal surgical procedure just for the treatment of incontinence.
Consequently, of late, new approaches to the performance of the classical open Burch procedure have been attempted. One approach is a procedure known as a laparoscopic Burch suspension procedure, and has begun to find favor among physicians. Another approach that has shown great promise is a transvaginal approach for the placement of the sutures.
The laparoscopic approach to the Burch procedure has all of the advantages of laparoscopy described earlier with respect to post operative pain, hospital stay and recovery time. There are three difficulties associated with the laparoscopic approach; access, suture placement, and knot tying. The present invention addresses the problems surrounding the placement of the sutures in the appropriate structures and in the optimal position, and also addresses particular aspects of needle retrieval and knot tying when using endoscopic techniques.
Currently, the placement of sutures while using endoscopic techniques involves placing a semi-circular needle, attached to and carrying a suture, in a pair of endoscopic needle holders. These needle holders, which resemble a pair of pliers with an elongated shaft between the handles and the jaws, must be placed down through one of the surgical trocars into the body cavity containing the structure to be sutured. Because of their size, the needles used in these procedures are generally not able to be held in the jaws of the needle driver while being introduced through the operative trocar. The surgeon must hold the suture string in the needle holder jaws, and push the needle holder trailing the needle and suture into the body cavity. The suture and needle combination is dropped in the body cavity, and the needle is then located and picked up and properly positioned in the needle holder jaws. This is a difficult and time-consuming aspect of the current endoscopic technique for suturing. The needle carrying the suture may then be driven by pronation of the wrist, causing rotation of the elongate shaft, and subsequent arcuate rotation of the semi-circular needle.
It may be seen that a limitation of this type of needle driver is that the needle may only be driven or rotated in a plane perpendicular to the axis of rotation, such axis being described by the elongate shaft and the position of the surgical trocar. Thus the current endoscopic needle drivers will not allow the surgeon to swing the needle in an arc parallel to the trocar's axis. This is a severe limitation in the case of the laparoscopic Burch, because of the orientation of the anatomy relative to the planes of access. The vaginal wall and the Cooper's ligament require the sutures to be placed in a orientation that makes the procedure extremely difficult and time consuming with the use of currently available instrumentation. It is also a limitation when attempting to ligate vessels, ligaments and other structures that run perpendicular to the axis of the operative trocar.
Another limitation of the current instrumentation is seen in the aspect that requires the surgeon to prepare the needle for penetration of the tissue while the needle is inside the body. This process is a time consuming, and sometimes frustrating exercise in hand to eye coordination, which is complicated by the fact that the surgeon is viewing the three dimensional space inside the body cavity through a two dimensional video monitor.
It may also be seen that the surgeon must be able to retrieve the needle trailing the suture material back through the same surgical trocar through which the needle driver is placed. This allows a knot to be tied in the suture outside of the body, and pushed down the trocar to the structure being sutured. Thus the needle driver must be able to retrieve the needle and bring the needle trailing the suture back up through the same trocar through which it is introduced allowing the tied knot to be pushed back down into the operative site.
It may also be seen that if the surgeon desires to place more than one suture throw through the tissue, he must be able to reload the needle into the needle driver. This may be done extracorporeally, that is, outside the body, in a manner similar to the initial loading of the suture device, or it may be done intracorporeally, that is, inside the body. Features which facilitate the intracorporeal loading of the needle can be seen to provide the surgeon with another option in the application of suture material to tissues, and could save operative time.
While laparoscopy has certainly found favor with many physicians as an alternative operative modality, the advanced skill set and operative time necessary to become an efficient and practiced laparoscopist have proven to be a challenge for a large portion of the surgical community. The cost pressures brought about by large scale patient management (the continued rise and success of health maintenance organizations or HMO's) have also made the surgical community to cast a critical eye on the overall costs and long-term outcomes of some of the procedures that have been tried via a laparoscopic approach. While the laparoscopic cholecystectomy (gall bladder removal) has certainly proven its worth in the past 8-10 years, many other procedures have not shown similar cost effectiveness and positive long-term outcomes.
Hence, alternatives have been sought to bridge the gap between skill and equipment intensive laparoscopic surgery and more familiar open surgery. As such, under the broad umbrella of "minimally invasive surgery" which would include laparoscopic surgery, a relatively new approach called "mini-incision surgery" has begun to emerge. This approach uses the principles of traditional open surgery, along with some of the equipment advances of laparoscopy to provide the patient with the best of both worlds.
Perhaps the most visible of these new approaches is the emergence of minimally invasive heart surgery, both for coronary bypass and for valve replacement. Techniques and tools for cardiovascular surgery have begun to be used that allow the heart surgeon to perform procedures through small incisions between the ribs that previously required a massive incision and splitting the sternum to gain access to the heart.
In a similar way, gynecologists have begun to explore alternatives to the traditional open abdominal approach for the many indications requiring reconstruction of some aspect of the pelvic floor, such indications including genuine stress incontinence, vaginal prolapse, cystocele, rectocele, and enterocele.
There have been described in the literature many transvaginal approaches to the treatment of urinary stress incontinence. This includes procedures described by Pereyra, Raz, and Stamey. Pereyra originally described his approach in 1959, with modifications to improve results and reduce complications described in 1967, 1978, and 1982. Raz disclosed his approach in 1981, and Stamey in 1973. These procedures were developed with the goal of combining the good results of a suprapubic colposuspension (for example, the above-described Burch procedure) with a vaginal repair that leaves the abdominal wall intact.
These procedures have some common elements; they all place sutures in the vaginal wall at the urethral-vesical junction (the bladder neck), and use some form of attachment to the abdominal wall for the suspension. This attachment is somewhat problematic in that the abdominal wall moves when the patient tenses or relaxes the stomach muscles. This in turn moves the bladder neck, and sometimes results in loss of urine (hence continued incontinence), or results in the opposite problem, an inability to void due to the bladder neck being kinked. The reason for the attachment to the movable abdominal wall instead of to the fixed Cooper's ligament is that the Cooper's ligament is all but impossible to reach with current instrumentation via a transvaginal approach.
It should be noted that although these procedures are easier to perform than the suprapubic approaches, and result in less post operative recovery time for the patient, the long-term continence rates have 15-30% below those for the suprapubic approaches. Thus it is clear that if one could attach the sutures to the fixed Cooper's ligament via a transvaginal approach, the best aspects of both procedures may be realized; the short recovery times of the transvaginal approach and the good long term continence results of the suprapubic approach.
As it will be obvious to those skilled in the art, the use of the techniques described above for the performance of the Burch bladder suspension procedure may be used for other suturing tasks, such as for ligating vessels and ligaments during the performance of, for example, a hysterectomy or oophorectomy, or for the approximation of tissue flaps such as in the performance of procedures, for example, for the treatment of gastro-esophageal reflux disorder.
Currently, a number of manufacturers of suture materials and needles exist. There are USP (United States Pharmacopeia) standards for the suture material diameters and tensile strengths, however no similar standards exist for the suture needles. There are however, conventional "standard" needle sizes that many manufacturers fabricate. The needles are generally specified by the needle wire diameter, needle length and the bend arc length. A common needle size for most suture manufacturers, for example, is 26 mm long by 1/2 arc (180°). As it may be seen by geometric construction, a 26 mm×180° needle describes a fixed bend radius, and this nominal bend radius is fairly consistent from manufacturer to manufacturer. Typically, the suture material is crimped in either a U shaped channel formed in the distal portion of the needle, or in a drilled hole. The crimp zone size and configuration varies between manufacturers, and generally tends to straighten out the bend radius in that localized area. Between the manufacturing tolerances in the bend radius and the straightening of the end of the needle in the crimp zone, the repeatability of the shape of the needle and suture combination may vary significantly. It is therefore desirable to construct an needle guide channel which will both guide the needle precisely, and allow for the aforementioned manufacturing tolerances and perturbations. This would allow readily available commercial suture and needle combinations to be used with the suture placement system.
None of the prior art devices are adaptable to effect the placement of a suture in the anterior abdominal wall, nor are they adaptable to place sutures precisely and controllably while making provision for needle retrieval when using endoscopic techniques. None of the prior art devices make it possible to place sutures into Cooper's ligament via a transvaginal approach. It is therefore an object of the present invention to provide a family of novel suturing devices that overcomes the above set out disadvantages of prior known devices in a simple and economical manner.
It is a further object of the present invention to provide a suture device that will permit the approximation of the separated edges of a puncture wound without making a larger incision to expose the wound margins.
A further object of the present invention is to provide a suture device that will permit the surgeon to apply substantial force to the needle, permitting it to be driven through tough tissues, for example, a ligament or the abdominal fascia.
It is a further object of the present invention to provide a suture device that can be used in conjunction with modern day endoscopic surgical techniques.
Another object of the invention is to provide a suture device that will allow a needle to be driven in an arc which describes a plane parallel to the axis of the device.
Yet another object of the invention is to provide a suture device that may be used to approximate the edges of an internal wound. Another object of the present invention is to provide a suture device that permits the penetration of two needles having suture material extending there between into and through the sides of a wound and into catches thereby creating a suture loop through the wound that may be tied to approximate the tissues.
Another object of the invention is to provide a suture device that will permit the surgeon to place sutures around vessels, ligaments, and other structures to effect ligation.
It is a further object of the present invention to provide a suture device that will permit the surgeon to place sutures in the Cooper's ligament by palpation via a transvaginal approach.
SUMMARY OF THE INVENTION
The present invention is a new medical device that allows the surgeon to quickly and easily place a suture in the interior wall of a body cavity to approximate the tissues separated as a result of a puncture wound made by the introduction of a surgical trocar into a body cavity during endoscopic surgery. The invention described herein may also be used to approximate the margins of an open wound in an internal organ, such as the uterus or the stomach, such as would be effected during the course of a resection for benign or malignant lesions, and may also be used for placing sutures into Cooper's ligament or other structures via a transvaginal approach. The transvaginal approach to the classic open Burch (the open Burch being acknowledged as the gold standard treatment for genuine urinary stress incontinence) is a new and novel procedure that has become possible due to the specific design aspects of the present invention.
One embodiment of the present invention includes needle holders that releasably hold a pair of needles that are in turn attached to each end of a single piece of suture material. Such needle holders are held within tubular guiding tracks housed within a hollow outer sleeve that may be introduced into a puncture wound. The needle holders and guiding tracks may be deployed outside the hollow sleeve to allow the needles to engage the tissue to be approximated. A plunger is coupled to rigid driving members that are in turn attached to flexible driving members adapted to follow the shape of the guiding tracks. The flexible driving members are suitably attached to the needle holders. The plunger is pushed, simultaneously driving the needle pair into opposite sides of the puncture wound and into catches also disposed within the hollow sleeve. The needle holders are retracted into the guiding tracks, and the tracks pulled back into the hollow sleeve trailing the suture material. The device may then be withdrawn, leaving a loop of suture material precisely placed in the selected tissue, for example, in the interior wall of the body cavity. The needles are removed from the ends of the suture, and the suture material is tied to complete the approximation of the tissue.
In one aspect, the present invention differs from the prior art in that it allows a suture to be placed in a retrograde fashion in the puncture wounds created during the introduction of trocars used for endoscopic surgery. These puncture wounds have margins perpendicular to the plane of tissue dissection, unlike the wounds that are addressed by prior art in which the tissues generally overlap. Presently, all the existing instruments are designed to either approximate tissues to which direct visual and physical access may be gained during open surgery, or to approximate tissues that may be pinched between the jaws of a forceps like instrument. Wounds in body organs such as the uterus or the stomach which are created during the resection or removal of benign or malignant lesions may also have wound margins which require end to end approximation instead of overlapping. The present invention allows the surgeon to independently pass a needle through each side of the wound to allow the two sides to be drawn together, approximating the tissue.
The needle driver apparatus of the present invention may be constructed in a number of different ways. Several of the preferred ways are described herein. One embodiment uses needle guides which are semicircular in shape, holding either a semicircular needle, or a semicircular needle holder with a small needle tip. These guides are disposed across their diameter within a hollow tubular sleeve when in the retracted mode, and are rotated about one end to deploy them outside the bounds of the hollow sleeve for engaging the tissue to be sutured. The needles, or the needle holders, are driven through the tissue by axial movement of a rigid cylindrical member which contacts a flexible cylindrical member that follows the semicircular shape of the guide tracks. The needles are caught in catches placed within the hollow tubular sleeve that capture the needle by means of a leaf spring disposed to flex, preferably in one direction, and squeezing into grooves or recesses in the needles, thereby retaining the needles to the hollow tubular sleeve. The needle guides may be retracted, and the instrument removed from the wound, thus trailing the suture material. The needles are removed, the suture is tied, and the approximation is completed.
Another version of the device uses semicircular needle holders similar to the previous version, but the needle guides are eliminated. The needle holders are instead rotated about their axes such that the needles attached to the ends of the holders describe an arc that encompasses the tissue to be sutured.
It is contemplated that the above embodiments may be modified to include needle paths other than circular, such as helical, elliptical or straight, by modification of the needles, the needle holders and the needle guides. It is also possible to adapt the above configurations to allow each of the needles to be actuated and driven independently by dividing the deployment controls and the needle drivers into separate left and right hand members. Further, it is possible to utilize a tool that uses only a single needle and guides it through both sides of the wound as opposed to the double needle configuration described above.
Accordingly, another embodiment of the device uses a single needle which eliminates the deployment aspect of the needle guides. The needle guide track is incorporated directly into the cannular body which is particularly adapted for use in endoscopic procedures. The cannular -body is of a diameter such that it may be placed through, for example, a standard 10 mm-12 mm trocar. The needle may be a long shouldered needle such as described previously, or may be a standard 1/2 circle, or 180° needle, with a length of, for example, 22 to 28 mm and crimped onto a length of standard suture material. As previously discussed, those skilled in the art will understand that various needle wire diameters, needle bend radii, needle cross sections, and suture materials are all adaptable to be used in the devices described herein. The needle may be loaded into the preformed needle guide track in the cannular body. It should be noted that the needle is placed in the cannular body across its diameter such that the point of the needle lies substantially perpendicular to the axis of the cannular body. As in previous embodiments, axial movement of a flexible drive member drives the needle out of the guiding track into and through tissue placed adjacent to the exit opening in the cannular member.
After having driven the needle into tissue, if the needle is a shouldered needle, it may be retrieved by using a keyhole shaped slot incorporated into the side of the cannular body. If the needle is a standard, non-shouldered needle, standard laparoscopic graspers, which have been introduced into the operative site via a secondary trocar, may be used to pull the needle up a short distance trailing the suture. The needle driver may then be used to retrieve the needle and suture combination by either pinching the suture material in a groove fashioned for that objective, or clamping the needle with a means adapted for that purpose. The needle trailing the suture may then be withdrawn through the surgical trocar.
This basic method of driving and retrieving the needle may be used in a number of ways at the surgeon's discretion to effect approximation, ligation, or fixation of tissue. Approximation involves the placement of one to multiple sutures in order to pull the edges of a wound together to effect healing. Ligation involves placing a suture circumferentially about a vessel or duct in order to tie it off. In the case of ligation, only a single suture is placed, and a knot tied to strangulate the encompassed structure. Fixation involves the placement of sutures to positionally secure tissues in a particular orientation, and may require that multiple sutures be placed. Fixation may also require that each end of the suture be driven through the tissue more than once.
As it may be apparent, provisions for needle retrieval, the capability of the needle to be reloaded into the needle guide track, and the positioning and orientation of the needle are often desirable features, making it possible to efficiently and effectively place sutures for various therapeutic reasons. The invention herein described solves these problems.
The above described embodiments may be modified to include a needle carrier adapted as described before to hold a short barbed needle. This carrier may be disposed within the preformed needle guide track in the cannular body. A similar catch mechanism as described previously is incorporated into the side of the cannular body at the end of the arcuate path described by the short needle/needle carrier combination when axial movement of the flexible drive member drives the needle and carrier combination out of the guide and through the tissue to be sutured. Use of this embodiment for closure of trocar puncture wounds can be accomplished by loading one end of a suture prepared with short needles at both ends into the needle carrier. The instrument is inserted into the puncture wound by means of the trocar placed therein. The instrument is located such that the tip of the needle is placed directly against the inside of the abdominal wall.
The needle is driven up into the abdominal fascia by the flexible needle driver coupled to the needle driver button, and into the catch. The short needle stays in the catch, the needle carrier is withdrawn back into the needle guide track, and the entire device is withdrawn from the surgical trocar. The needle is removed from the catch, the opposite end of the suture with its attached short needle is loaded into the instrument, and the entire process is repeated with the second end of the suture being driven into the tissue on the opposite side of the puncture wound, 180° from the initial stitch. The instrument and trocar are removed from the wound, and the remaining loop of suture is tied to approximate the tissues, thus closing the wound.
As it may be appreciated, this embodiment may be used in order to effect suturing in many different parts of the body, and is not limited to the closure of the wounds caused by the insertion of operative trocars into a body cavity. With the availability of both absorbable and non-absorbable suture material attached to the short needles, it is contemplated that the above described embodiment may be used in performance of procedures such as, for example, the laparoscopic Burch previously described. It is also contemplated that ligation of vessels and ligaments, such as, for instance, the ligation of uterine vessels and ligaments during the performance of a hysterectomy may be accomplished with this embodiment. This embodiment may also find application in the repair of the meniscal tissue in the knee or shoulder. It is to be clearly understood that this embodiment eliminates the manual step of needle retrieval from the wound, as the needle is automatically captured by the instrument itself.
Another embodiment of the device, which may be seen to incorporate many of the above-described features, is particularly adapted for the placement of sutures into the Cooper's ligament via a transvaginal approach. These features include the design and functional aspects of the needle carrier, the short barbed or shouldered needle carrying the suture and the needle catch. This embodiment includes additional adaptations of the elongate body and an additional degree of freedom for articulation of the head of the device.
Due to the anatomical placement of the Cooper's ligament bilaterally on the inferior aspect of the pubic ramus, it is necessary for this embodiment of the device to have a curved elongate body to allow for placement of the device head against the superior aspect of the ramus through an incision in the vaginal wall (a colpotomy). This device also has allowance for the head of the instrument, with the needle carrier and catch, to be rotated axially left or right to an angle of, for example, 45° to accommodate the pubic arch.
The head of the device also incorporates a unique design for controlling the depth of penetration of the needle and needle carrier combination in order to place the suture material consistently into the ligament without penetrating the pubic bone. This is important because the Cooper's ligament lies directly on the pubic bone, and penetration of the bone by the needle during the placement of the suture may cause osteitis pubis (bone infection).
The method of use of this device is as follows: an incision is made bilaterally in the anterior vaginal wall, just lateral to the bladder neck. The space of Retzius is dissected by sweeping the surgeon's finger along the inferior aspect of the pubic ramus, from the symphysis pubis out as far laterally as can be reached, preferably as far as the obturator fossa. The Cooper's ligament may be palpated, and using the symphysis as the medial landmark, and the obturator fossa as the lateral landmark, the instrument is guided by palpation up onto the superior aspect of the pubic ramus. A notch in the face of the head of the device is provided to allow the instrument to be accurately placed for delivery of the suture through Cooper's ligament.
After proper positioning of the instrument is verified, the needle driver button is pushed, driving the needle carrier and needle suture combination through the ligament and into the needle catch. The shouldered needle is captured in the needle catch, and the needle carrier is retracted back into the device head. The entire device is withdrawn through the colpotomy, trailing the suture. A second pass through the ligament is optional. The free ends of the suture are then passed through the vaginal mucosa, and tied with a pulley stitch to allow for proper positioning of the bladder neck. The procedure is repeated on the contralateral side, both pulley stitches tied to the appropriate tension to effect the bladder neck suspension, and the colpotomy closed with absorbable suture.
It may be seen that for an instrument to automatically capture a needle in a consistent and repeatable fashion, it is important that the needle be guided into the catching mechanism in a predictable way. This will allow the catch to function properly, and reduces the possibility that the needle would not be engaged in the catch after being driven through tissue. It is also important that the needle drive mechanism operates with as little friction as possible, in order to allow the surgeon to have some tactile sense of the tissue being sutured.
It may also be appreciated that the limitations of the angles of access and the restrictions on the lateral manipulation of instruments used during endoscopic procedures imposed by the operative trocars can make reaching certain anatomical structures difficult. Thus, the ability to articulate an instrument within the body cavity independent of the manipulation of the main body shaft can be of particular advantage in accessing these difficult to reach structures. By articulating the head of the needle driver instrument, the exit angle of the needle may be adjusted, as well as opening the possibility of accessing certain areas of the body which are inaccessible in a linear fashion due to the aforementioned mechanical constraints.
In a first aspect, the present invention is a suturing instrument comprising: an elongate body member having a longitudinal axis; a suture deployment system located within a distal end portion of the elongate body member wherein the distal end portion includes a suture exit port, the suture deployment system comprising: a curved suture carrier channel; and a curved suture carrier movably positioned in the curved suture carrier channel; and a deployment controller having a proximal end, a distal end, a retracted position and a deployed position, the deployment controller extending substantially along the longitudinal axis of the elongate body member to the distal end of the elongate body member where it is coupled to the curved suture carrier and moves the curved suture carrier through the curved suture carrier channel as it moves between the retracted position and the deployed position, the curved suture carrier channel configured within the distal end portion of the elongate body member such that the curved suture carrier exits the suture exit port and is guided along a path which includes a proximal curved path segment such that a surface of the curved suture carrier is substantially adjacent with an outer surface of the distal end portion of the elongate body member along the proximal curved path segment. The suturing instrument may further include a suture catch positioned proximate to the distal end portion of the elongate body member such that a distal path segment of the curved suture carrier path is intercepted by the suture catch as the deployment controller approaches the deployed position. The suturing instrument further include a surgical needle positioned in a distal end of the curved suture carrier. In some devices, the surgical needle further comprises a bullet needle. In other aspects, the curved suture carrier channel and the curved suture carrier are located in a distal tip assembly of the elongate body member; and the distal tip assembly is joined with the elongate body member such that the distal tip assembly is free to rotate axially about the elongate body member longitudinal axis. Another aspect of the device has the deployment controller coupled to the curved suture carrier with a flexible driver member. This flexible driver member may further comprise an alloy of nickel and titanium.
In a second aspect, the present invention is a suturing instrument comprising: a body member; a suture exit port formed in the body member; a curved suture carrier channel formed in the body member; and a curved suture carrier movably positioned in the curved suture carrier channel, wherein the curved suture carrier has a retracted position such that the curved suture carrier is positioned within an interior region of the body member and a deployed position such that a portion of the curved suture carrier is positioned exterior to the body member, the curved suture carrier configured within the curved suture carrier channel such that the curved suture carrier exits the interior region of the body member through the suture exit port and is guided along a path which includes a proximal curved path segment wherein a surface of the curved suture carrier is substantially adjacent with an outer surface of the body member along the proximal curved path segment. This device may further include a suture catch positioned on the body member such that a distal path segment of the curved suture carrier path is intercepted by the suture catch. This instrument may also include a surgical needle positioned in a distal end of the curved suture carrier. The surgical needle may further comprise a bullet needle.
In a third aspect, the present invention is a suturing instrument comprising: an elongate body member having a longitudinal axis; a distal tip suture deployment assembly joined with a distal end of the elongate body member such that the distal tip assembly is free to rotate axially about the elongate body member longitudinal axis, the distal tip suture deployment assembly comprising: a distal tip body member; a suture exit port formed in the distal tip body member; a curved suture carrier channel formed in the distal tip body member; and a curved suture carrier movably positioned in the curved suture carrier channel; and a deployment controller having a proximal end, a distal end, a retracted position and a deployed position, the deployment controller extending substantially along the longitudinal axis of the elongate body member to the distal end of the elongate body member where it is coupled to the distal tip suture deployment assembly and moves the curved suture carrier through the curved suture carrier channel as it moves between the retracted position and the deployed position. In this device, the distal tip suture deployment assembly may be configured to have a retracted position such that the curved suture carrier is positioned within an interior region of the distal tip body member and a deployed position where a portion of the curved suture carrier is positioned exterior to the distal tip body member, the curved suture carrier configured within the curved suture carrier channel such that the curved suture carrier exits the interior region of the distal tip body member through the suture exit port and is guided along a path which includes a proximal curved path segment wherein a surface of the curved suture carrier is substantially adjacent with an outer surface of the distal tip body member along the proximal curved path segment. This device may further comprise a suture catch positioned on the distal tip body member such that a distal path segment of the curved suture carrier path is intercepted by the suture catch as the deployment controller approaches the deployed position. The instrument may further comprise a surgical needle positioned in the distal end of the curved suture carrier. In some aspects, the surgical needle may be bullet needle.
In a fourth aspect, the present invention is a method for placing a suture in thin tissue adjacent bone structure comprising: placing a suturing instrument which encloses a curved suture carrier which is movably positioned within a curved suture carrier channel adjacent the tissue to be sutured; and deploying the curved suture carrier out of the suturing instrument through an exit port such that the curved suture carrier exits an interior region of the suturing instrument through the exit port along a path which approaches being substantially tangential to an outer surface of the suturing instrument surrounding the exit port.
In a fifth aspect, the present invention is a suturing instrument comprising: a body member; an exit port formed in the body member; a curved suture carrier channel formed in the body member; and a curved suture carrier movably positioned in the curved suture carrier channel, wherein the curved suture carrier has a retracted position such that the curved suture carrier is positioned within an interior region of the body member and a deployed position such that a portion of the curved suture carrier is positioned exterior to the body member, the curved suture carrier configured within the curved suture carrier channel such that the curved suture carrier exits the interior region of the body member through the exit port along a path which approaches being substantially tangential to an outer surface of the body member surrounding the exit port.
In a sixth aspect, the present invention is a suturing instrument comprising: an elongate body member having a longitudinal axis; a suture deployment system located within a distal end portion of the elongate body member wherein the distal end portion includes a suture exit port, the suture deployment system comprising: a curved suture carrier channel; and a curved suture carrier movably positioned in the curved suture carrier channel; and a deployment controller having a proximal end, a distal end, a retracted position and a deployed position, the deployment controller extending substantially along the longitudinal axis of the elongate body member to the distal end of the elongate body member where it is coupled to the curved suture carrier and moves the curved suture carrier through the curved suture carrier channel as it moves between the retracted position and the deployed position, the curved suture carrier channel configured within the distal end portion of the elongate body member such that the curved suture carrier exits the suture exit port along a path which approaches being substantially tangential to an outer surface of the body member surrounding the suture exit port. This aspect of the invention may further comprise a suture catch positioned proximate to the distal end portion of the elongate body member such that a distal path segment of the curved suture carrier path is intercepted by the suture catch as the deployment controller approaches the deployed position. A surgical needle may be positioned in a distal end of the curved suture carrier. The surgical needle may further comprise a bullet needle. Additionally, the curved suture carrier channel and the curved suture carrier may be located in a distal tip assembly of the elongate body member; and the distal tip assembly is joined with the elongate body member such that the distal tip assembly is free to rotate axially about the elongate body member longitudinal axis. The deployment controller may be coupled to the curved suture carrier with a flexible driver member. The flexible driver member may further comprise an alloy of nickel and titanium.
These and other characteristics of the present invention will become apparent through reference to the following detailed description of the preferred embodiments and accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1A through 1H illustrate the general structure and operation of a first embodiment of the present invention.
FIG. 2 is a detail plan view of a needle.
FIG. 3 is a detail plan view of an alternate needle.
FIG. 4 is a detail perspective view of a catch mechanism with a needle.
FIG. 5 is a detail perspective view of an alternate catch mechanism with a needle.
FIGS. 6A and 6B are detailed cross sectional views illustrating the general structure and operation of an alternate embodiment of a needle delivery and capture system.
FIGS. 6C and 6D are detailed cross sectional views illustrating the general structure and operation of another alternate embodiment of a needle delivery and capture system.
FIG. 7 is a projected detail view taken along the lines of view 7--7 of FIG. 6A illustrating the needle catch.
FIG. 8 is a cross sectional view taken along the lines of 8--8 on FIG. 7.
FIG. 9 is a detailed perspective view illustrating the general structure of an alternate embodiment of the needle carrier and guide track.
FIG. 9A is a detailed perspective view illustrating the general structure of an alternate embodiment of the needle carrier.
FIG. 10 is a detailed cross sectional view illustrating the relationship between the needle carrier and guide track.
FIGS. 11A and 11B are cross sectional views of two alternate designs of the needle carrier taken upon the lines of 11--11 on FIG. 9.
FIG. 12 is a cross sectional view of the needle carrier and guide track taken upon the lines of 12--12 on FIG. 10.
FIG. 13 is a cross sectional view of the needle carrier and guide track taken upon the lines of 13--13 on FIG. 10.
FIG. 14 illustrates the general structure of another embodiment of the present invention.
FIG. 15 is a cross sectional view illustrating the general internal structure of the embodiment described in FIG. 14.
FIG. 16 is a detailed cross sectional view of the head of the embodiment described in FIGS. 14 and 15.
FIGS. 17A-17D illustrate the operation of the embodiment described in FIGS. 14-16.
FIGS. 18A-18B are detailed perspective views of the distal tip of the device illustrating the general structure and operation of the axial articulation of the needle driver head.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Although the principles of the present invention are applicable to any device suitable for use in surgical procedures, whether performed on humans or animals, particular utility is effected in human abdominal surgery performed using endoscopic techniques for closure of the wounds created during the introduction of trocars into the abdominal cavity, and particularly the puncture wounds created thereof, as well as closure or approximation of the wounds created either during the resection of benign or malignant lesions, or during the performance of other therapeutic procedures on an organ or organs within a body cavity.
FIGS. 1A through 1H illustrate the general structure and operation of a first embodiment of the present invention. FIGS. 1A and 1B show a device 2, according to the present invention, which incorporates a length of standard suture material 4 with a needle 6 on each end. The needles 6 are held by a needle carrier 8 (FIG. 1D) and loaded into two guiding tracks 10. The guiding tracks 10, containing the needle carriers 8 and needles 6, are deployable outside a housing 12 of the device 2 to allow the suture material 4 to be placed outside the limits of a puncture wound 14 (FIGS. 1B and 1C). After deployment of the guiding tracks 10 (with the needle carriers 8 and needles 6 contained within) the needle carriers 8 and needles 6 are driven out of the guiding tracks 10 and into tissue surrounding the puncture wound 14 (FIGS. 1C and 1D). The needles 6 are driven into a catch mechanism 16 (FIG. 1D). The needle carriers 8 are retracted back into the guiding tracks 10 (FIG. 1E). The guiding tracks 10 (now containing only the needle carriers 8 without the needles 6) and the catch mechanism 16 with the captured needles 6, are retracted as shown in FIGS. 1F, 1G and 1H. With a loop of suture 4 having thus been placed in the tissue surrounding the puncture wound 14, the suture device 2 is removed from the wound 14, thereby pulling the ends of the suture 4 with it (FIG. 1H). Closure of the puncture wound 14 is accomplished by cutting the suture 4 to remove the needles 6, tying a knot in the suture 4, and pushing it into the wound 14. Superficial closure is then performed by normal means according to the surgeon's preference.
FIGS. 2 and 3 show detail plan views of alternate needle embodiments. Referring to FIG. 2, a needle 234 comprises a body 236, and a shoulder 238 tapering to a point 240. A length of suture material 242 is inserted into a hole 244 and attached to the needle 234 thereby. Referring now to FIG. 3, a needle 246 comprises a body 248 and a shoulder 250 formed by a groove 252 which tapers to a point 254. A length of suture material 256 is inserted into a hole 258 and attached to the needle 246 thereby.
FIGS. 4 and 5 show detail perspective views of alternate catch embodiments and illustrate their operation. A catch 260 is preferably constructed of thin stainless steel of high temper, such as ANSI 301 full hard. Although the catch 260 may be fabricated by means of stamping or laser machining, the preferred method is by chemical etching. Referring to FIG. 4, the catch 260 includes openings 262 defined by ribs 264. As the needle 234 enters the opening 262, the ribs 264 deflect slightly to allow the shoulder 238 to pass through. After the shoulder 238 has passed the ribs 264, the ribs spring back to their original position defining the openings 262. The openings 262 are chosen to be smaller in dimension than the shoulder 238. This causes the catch 260 to retain the needle 234 by the interference between the shoulder 238 and the ribs 264 around the body 236. When it is necessary to remove the needle 234 from the catch 260, it may be moved toward an opening 265 which is sized to allow the needle shoulder 238 to pass through without resistance.
Referring now to FIG. 5, a catch 266 includes a frame 268 to which is attached a woven mesh 270. Threads 272 creating the woven mesh 270 may be made out of nylon, polyester or the like woven in a common over/under pattern. The weaving of the threads 272 creates holes 274 in the mesh through which a needle 246 may be passed. The needle 246 is constructed such that the shoulder 250 defined by the groove 252 is larger than the holes 274, or conversely, the holes 274 are chosen to be smaller than the shoulder 250. The point 254 of the needle 246 pushes the threads 272 aside creating room for the shoulder 250 to pass through the holes 274. As the threads 272 return to their original positions, the catch 266 holds onto the needle 246 by means of the mismatch in the size of the holes 274 and the shoulder 250.
It may be seen and should be understood that catches 260 and 266 are capable of catching either needle 234 or 246. The examples of needle 234 coupled with catch 260 and needle 246 coupled with catch 246 are given purely to illustrate the concepts of each embodiment and do not exclude their coupling with alternate designs.
Yet another embodiment of the invention is an alternate needle driver and catch system as shown in FIG. 6A and FIG. 6B, which are detailed cross sectional views of the distal end of the suture application system. Referring to FIG. 6A an elongate cannular body 718 is comprised of the housing halves 720 a,b. It is to be understood that for clarity only one of the housing halves 720 of the cannular body 718 is shown in FIG. 6A and FIG. 6B. The housing halves 720 are configured to create a guided pathway 722 which is comprised of a needle carrier guide track 724 and a flexible carrier driver guide track 726. A needle carrier 728 and flexible carrier driver 730 are joined at an end 732 of the needle carrier 728. The attachment between the needle carrier 728 and the flexible carrier driver 730 at the end 732 can be accomplished by crimping, welding, adhesive bonding or various other techniques. A bullet needle 734 includes a shoulder 736, a point 738 and a shaft 740. A length of suture material 742 is attached to the shaft 740 by placing it in a hole 744 and holding it there by suitable means, such as crimping or adhesive bonding or the like. Further incorporated in the housing halves 720 are catch pockets 746 a,b which position and retain a needle catch 748. Referring to FIG. 7, which is a detail plan view taken along the lines of 7--7 of FIG. 6A, it may be seen that the needle catch 748 includes openings 750 defined by ribs 752. The configuration and function of the needle catch 748 is similar to that described earlier in FIG. 4. The bullet needle 734 is inserted into an end 754 of the needle carrier 728. The shoulder 736 of the bullet needle 734 rests on the end 754 of the needle carrier 728, the end 754 dimensioned to hold and retain the bullet needle 734 in a manner previously described. When the catch 748 is fabricated by means of chemical etching, the most preferred method is to etch from a single side, known in the art as single sided etching. When the catch 748 is etched from a single side, the ribs 752 have a tapered cross section 753 as shown in FIG. 8, which is a detail cross sectional view taken along the lines of 8--8 of FIG. 7. The tapered cross section 753 helps to guide the needle 734 into the catch openings 750, minimizing the chance of the needle 734 hitting the top of the ribs 752.
Referring now to FIGS. 6A and 6B, the operation of this embodiment will be described. It is to be understood that the function of this embodiment is similar to that previously described in FIGS. 1A through 1H, that is, to approximate and close the puncture wounds created when surgical trocars are introduced into a body cavity. For clarity, the imposition of tissue planes along the path of needle travel to be described in FIGS. 6A and 6B has not been shown, although it is implied. FIG. 6A shows the bullet needle 734 loaded into the needle carrier 728 which is depicted in the retracted position. In this position, the cannular body 718 may be passed through a surgical trocar and into a body cavity for operation of the device. As shown in FIG. 6B, as the flexible carrier driver 730 is advanced into the needle carrier guide track 724, the needle carrier 728, holding the bullet needle 734 and trailing the suture 742 is driven on a semi-circular path terminating in the needle catch 748. The bullet needle 734 is captured by the catch 748 in a manner previously described in FIG. 4. The flexible carrier driver 730 may be retracted back into the flexible carrier driver guide track 726, causing the needle carrier 728 to rotate back into the needle carrier guide track 724 in the body half 720. The instrument may be removed from the surgical trocar, and the process repeated on the other side of the wound. After knots have been tied, an approximation of the puncture wound is accomplished. It may be seen that a knot pusher may be incorporated into the distal end of this embodiment of the suture applicator to effect the tying of knots for approximation of the puncture wounds. As such, the knots would be pushed directly into the wound, and not necessarily through the surgical trocar.
Yet another embodiment of the invention is an alternate needle driver and catch system as shown in FIG. 6C and FIG. 6D, which are detailed cross sectional views of the distal end of a suture application system and are similar in construction to those already described in FIGS. 6A and 6B. Referring to FIG. 6C, an elongate cannular body 770 is comprised of housing halves 772 a,b. It is to be understood that for clarity only one of the housing halves 772 of the cannular body 770 is shown in FIG. 6C and FIG. 6D. The housing halves 772 are configured to create a guided pathway 774 which is comprised of a needle carrier guide track 776 and a flexible carrier driver guide track 778. A needle carrier 780 and flexible carrier driver 782 are joined at saddle 784 of the needle carrier 780. The saddle 784 comprises a channel, groove or opening formed in the proximate end of the needle carrier 780 into which the flexible carrier driver 782 may enter circumferentially as opposed to axially. The attachment between the needle carrier 780 and the flexible carrier driver 782 at the saddle 784 can be accomplished by crimping, welding, adhesive bonding or various other techniques. A bullet needle 786 includes a shoulder 788, a point 790 and a shaft 792. A length of suture material 794 is attached to the shaft 792 by placing it in a hole 796 and holding it there by suitable means, such as crimping or adhesive bonding or the like. Further incorporated in the housing halves 772 are catch pockets 798 a,b which position and retain a needle catch 800. The configuration and function of the needle catch 800 is similar to that described earlier in FIG. 4. The bullet needle 786 is inserted into an end 802 of the needle carrier 780. The shoulder 788 of the bullet needle 786 rests on the end 802 of the needle carrier 780, the end 802 dimensioned to hold and retain the bullet needle 786 in a manner previously described.
Although the operation of this embodiment is virtually identical to that described in FIGS. 6A and 6B, there are improvements included in this embodiment to the overall operation of the suture system. Referring back to FIGS. 6A and 6B, as it may be appreciated, as the needle carrier 728 approaches the end of its stroke, as illustrated in FIG. 6B, the circumferential length of the needle carrier 728 left inside the needle carrier guide track 724 is quite minimal. This can allow the needle carrier 728 holding the needle 734 to drift off of the pre described arcuate path which terminates in the needle catch 748. This drift may allow the needle 734 to miss the catch 748, causing an incomplete suturing cycle. It is desirable, then, to increase the circumferential length of the needle carrier left inside the guide track in order to improve the guidance of the needle carrier.
Accordingly, the embodiment illustrated in FIGS. 6C and 6D shows the needle carrier 780 with the saddle 784. The saddle 784 allows the flexible carrier driver 782 to exit from the needle carrier 780 at a point along the circumference, rather than at a distal end 804. This may be seen to increase the overall arc length of the needle carrier 780 when compared with the needle carrier 728 shown in FIG. 6A. As a result, when the flexible carrier driver 782 is slidably moved in the guided pathway 774, and the needle carrier 780 is caused to rotate within the needle carrier guide track 776, it may be seen by referring to FIG. 6D that when the bullet needle 786 enters the needle catch 800, a significantly larger portion of the needle carrier 780 is still captured within the needle carrier guide track 776. This may be seen to provide additional guidance to the needle carrier 780 as it penetrates tissue. It may also be seen that the geometry described above allows for a longer stroke length, and therefor greater tissue bite.
As it may be appreciated by those skilled in the art, during the performance of a surgical procedure where suturing of body tissues is required, it is often necessary to lift or twist the tissue planes with the needle in order to approximate them in their final positions. This lifting and/or twisting can place significant stresses on the needle, and indeed, breakage of needles in the operative field is a fairly common event. In the embodiments just described, the "needle" is the combination of, for example in FIG. 6C, the needle carrier 780 and the bullet needle 786. In this example, the majority of the induced stresses are absorbed by the needle carrier 780. In addition to provisions for leaving a more substantial portion of the needle carrier in the guide track for additional guidance, FIGS. 9 through 13 now describe an alternate embodiment of the needle carrier and guide track which further improves the guidance and resistance to deflection due to the stresses just described.
Referring now to FIG. 9, there may be seen the distal end of an elongate cannular body 858 which is comprised of housing halves 860 a,b. It is to be understood that for clarity only one of the housing halves 860 of the cannular body 858 is shown in FIG. 9. The housing halves 860 are configured to create a guided pathway 862 which is comprised of a needle carrier guide track 864 and a flexible carrier driver guide track 866. A needle carrier 868 includes a saddle 872, to which is attached a carrier bearing 874. The saddle 872 comprises a channel, groove or opening formed in the proximate end of the needle carrier 868 into which the flexible carrier driver 870 may enter circumferentially as opposed to axially. That is, at the intersection of the flexible carrier driver guide track 866 and the needle carrier guide track 864, lines which are tangent to the flexible carrier driver guide track 866 and the needle carrier guide track 864 are substantially parallel.
The construction of the needle carrier may be best understood by referring to FIG. 11A, where a cross sectional view shows the needle carrier 868 and the carrier bearing 874. The carrier bearing 874 further includes bearing wings 876 a,b. The carrier bearing 874 may be joined by welding, adhesive bonding or the like to the needle carrier 868.
The needle carrier 868 may also be formed by another method. FIG. 11B shows a cross sectional view of a needle carrier 878 which has been formed out of, for example, a 17-4 stainless steel alloy by a process called metal injection molding. This process allows the needle carrier 878 to be formed in a monolithic fashion such that bearing wings 880 a,b and saddle 882 may be formed in one piece, along with other features of the needle carrier previously described. Other processes, such as die casting, investment casting, or powdered metal could also be used to create a monolithic needle carrier 878.
Another embodiment of the needle carrier is shown in FIG. 9A, where there is shown a needle carrier 885 which includes a socket 886 at the distal end adapted to hold a shouldered needle and a groove 887 at the proximal end adapted to contain a flexible needle driver 888 as previously described. Pins 889 a,b,c,d are attached to the sides of the needle carrier 885. The pins 889 are dimensioned to be slidably disposed within, referring to FIG. 9, the groove 884 in the needle carrier guide track 864, and to provide guidance and stability to the needle carrier 885 in a fashion similar to that to be described with reference to FIG. 9 below.
Referring again to FIG. 9, the needle carrier 868 and flexible carrier driver 870 are joined as previously described at saddle 872 of the needle carrier 868, which incorporates bearing wings 876 a,b. The distal end 882 of the needle carrier 868 is adapted to accept a shouldered bullet needle of the type previously described in other embodiments. In this embodiment, the needle carrier guide track 864 further incorporates a groove 884 adapted to receive the bearing wings 876 a,b. By referring to FIG. 12, a detailed cross sectional view of the groove 884 and the bearing wings 876, taken along the lines of the section arrows 12--12 shown in FIG. 10, may clearly be seen. FIG. 13 is a detailed cross sectional view of the needle carrier guide track 864 taken along the lines of the section arrows 13--13 shown in FIG. 10, and illustrates an area of the needle carrier 868 and of the needle carrier guide track 864 where there are no bearing wings 876 a,b. It should be understood that the cross section shown in FIG. 13 of the needle carrier 868 could be of solid material instead of tubular material if the cross section were illustrating a monolithic part such as the needle carrier 878. It may also be understood from the foregoing illustrations, that the width and depth of the bearing wings 876 a,b shown in FIG. 11A and the bearing wings 880 a,b shown in FIG. 11B are not to be taken as literal illustrations of the physical dimensions of those features, as the width and depth may be varied in order to achieve more or less guidance and bearing surface area as the designer deems appropriate.
The operation of the embodiment described in FIGS. 9 through 13 is identical to that previously described in FIGS. 6C and 6D, with the exception that the bearing wings 876 a,b are adapted to rotationally slide in the grooves 884 a,b of the housing halves 860 a,b. This provides axial and torsional guidance and resistance to deflection of the needle carrier 868 from the anticipated path. Performance improvements over the embodiment described in FIGS. 6C and 6D relate primarily to an increased ability to be able to torque and/or lift the device while the needle carrier is exposed to the tissues to be sutured.
The preferred material for the flexible carrier driver 870 is an alloy of nickel and titanium known in the art as nitinol. This material has both austenitic and martensitic forms, and can be alloyed to exhibit properties of both forms as the material moves through a transition temperature that can be varied. The martensitic form of the alloy, when processed into, for example, wire, has a lead-solder like consistency, and easily deflects plastically to a certain point, beyond which a considerable amount of force is necessary to cause further deflection. This elastic behavior in this regime is what allows the material to be both flexible and exhibit high column strength when properly constrained. As long as the wire is not required to bend around a radius which deflects the material past the plastic limit, the wire does not offer significant spring force. However, if it is required that the wire be bent around a tight radius, and the wire enters the elastic part of the stress/strain curve, substantial spring force may be exhibited. Thus in this application, the material is used in the regime that exhibits high column strength for the purposes of driving the needle. This is accomplished by constraining the wire in a track that allows it to be moved axially, but constrains its deflection off axis.
TRANSVAGINAL SUTURING EMBODIMENT
Yet another embodiment of the invention may be seen by now considering FIGS. 14-18. There may be seen an alternate embodiment of the present invention which is particularly well suited for but not limited to the fixation of sutures to the Cooper's ligament during the performance of a Burch bladder neck suspension via a transvaginal approach. As will become apparent, this embodiment includes features for limiting the depth of the needle penetration for placing sutures in, for example, ligaments lying directly on bone, and for accommodating the anatomy of, for example, the female pelvis.
Referring now to FIG. 14, there may be seen a suturing instrument 300 which includes handles 302 a,b, an elongate body 304, distal tips 306 a,b, and an actuator button 308. Again, for purposes of clarity, FIG. 15 is a detailed cross section of FIG. 14 illustrating the internal components that will now be detailed. Referring now to FIG. 15, there may be seen a cross sectional view of the suturing instrument 300 which includes the handle 302a, the elongate body 304, the distal tip 306a, and the actuator button 308. The actuator button 308 includes a button head 310, a button shaft 312, button bearing surfaces 314 a,b,c,d, button end 316, and hole 318. The button bearing surfaces 314 ride along a cylindrical surface 320 that is formed by the inside diameter of the elongate body 304. A wireform 322 is inserted into the hole 318, coupling it to the actuator button 308. A spring 326 encircles the wireform 322, abuts the button end 316, and is compressed between the button end 316 and a spring washer 326, which spring washer 326 is seated upon a center tube 328. The center tube 328 is housed by the cylindrical surface 320, and is constrained at the distal end by the distal tips 306. A pusher wire 330 is attached to the wireform 322 by means of a weld, a coupling, adhesive or other means, and is slidably disposed within a proximal guidance sleeve 332 and a distal guidance sleeve 334, said sleeves 332 and 334 being disposed within a cylindrical surface 336 formed by the inside diameter of the center tube 328.
The pusher wire 330 is preferably constructed of nitinol wire, so chosen as previously discussed for its combination of properties that allow for bendability and high column strength when constrained. The constraints in this construction are provided by the proximal guidance sleeve 332 and the distal guidance sleeve 334.
An overview of the general structure of this embodiment may be understood by considering now FIG. 16, which is a detailed cross sectional view of the distal end of the suturing device 300. It is to be understood for the purposes of clarity, that only one of the distal tips 306 is shown, and that cross sectional representations of the center tube 328, the distal guide tube 334, and the elongate outer tube 304 are shown. From FIG. 16, it may be seen that the nitinol pusher wire 330 is attached by welding or other means to a coupling 338, which is slidably disposed within a track 340, the coupling 338 also being attached to a carrier wire 342, which by virtue of its attachment to the coupling 338 is also slidably disposed within the track 340. The carrier wire 342 is attached to a carrier 344 by welding or other means, said carrier being rotatably and slidably disposed within a guide groove 346 molded into the distal tip 306. The relationship between the carrier wire 342, the carrier 344 and the guide groove 346 is similar to that previously described in FIGS. 9-13. The coupling 338 abuts a backstop washer 348 that is slidably disposed about the nitinol pusher wire 330, and contained within a pocket 350 which includes a back wall 352, against which the backstop washer 348 rests.
The track 340 terminates distally in a pocket 354 that includes a wall 356. A downstop washer 358 is slidably disposed about the carrier wire 342, and constrained within the pocket 354. Positioned at the terminus of the path of the carrier 344 is a needle catch 360 that is held distally in a pocket 362 and proximally in a pocket 364. As will be seen in the description of the application of this embodiment, this needle catch 360 is similar in construction and function to the catch described in FIGS. 4, 7, and 8. As previously described in other embodiments, the distal tips 306 a,b are held together by rivets placed in rivet holes 366 a,b,c,d and by tip shafts 368 a,b being inserted into the cylindrical surface 320 which is the inside diameter of the elongate body 304. A depression 370 in the elongate body 304 may be formed by mechanical means such as striking with a pin or forming with a die. The depression 370 is engaged in a rotation pocket 372 a,b that is formed as a feature of the distal tips 306 a,b, and will be further described in FIGS. 18A-18B.
Referring now to FIGS. 17A-17D, the operation of this embodiment may be appreciated. Although this description attests to a specific application for the performance of a Modified Burch bladder neck suspension via a transvaginal approach, it is to be understood that the principles and construction herein described may be applied to other areas of the human body, and for other procedures requiring suturing body structures such as ligaments that are in direct communication with bone. That understood and considering FIGS. 17A-17D, there may be seen a sequence of operation of the current embodiment. Referring to FIG. 17A there may be seen a detailed cross sectional view of the distal tip of the suturing device 300. The suturing device 300 is shown with a suture 374 attached to a suture needle 376 in a manner similar to that described in FIG. 2 and is shown loaded into the carrier 344 in preparation for actuation. The suturing device 300 has been placed against a ligament 378 that lies directly on a bone 380. Referring back to FIG. 15 together with FIG. 17A, it may be seen that the pusher wire 330 is held in tension by the spring 324, as the coupling 338 shown in FIG. 17A abuts the backstop washer 348 that is held against the back wall 352, positioning the needle carrier 344 in its most proximal or rearward location.
As those skilled in the art will appreciate, it is quite difficult to drive a suture needle through a ligament that lies directly on bone, as the bone's density does not allow a typical suture needle to penetrate it. Thus a skimming path must be taken to avoid hitting bone, but ensuring good penetration of the ligament and a subsequent "good bite" of tissue. In the case of the Cooper's ligament that is the focus of the anterior fixation point for the Modified Burch bladder neck suspension procedure, the difficulty in placing those sutures is directly attributable to the ligament lying on the bone, and the problems with exposure of the ligament to the surgeon.
Again referring to FIG. 15 and now FIG. 17B, the actuator button 308 is depressed by pushing on the button head 310, which via the attachment to the wireform 322 which is attached to the pusher wire 330, moves the coupling 338 shown in FIG. 17B along the track 340, concomitantly moving the carrier wire 342 which slidably and rotatably moves the carrier 344 in the guide track 346 and drives the suture needle 376 trailing the suture 374 into the ligament 378. It may be seen in this FIG. 17B that the suture needle 376 is skimming or sliding along the surface of the bone 380, maximizing the depth of penetration but not digging in or penetrating the bone surface. This superficial, i.e., shallow penetration, needle driving geometry results in a unique needle delivery system.
Referring now to FIG. 17C, it may be seen that as the pusher wire 330 responds to greater urging of the button 308, the coupling 338 reaches a point in its travel along the track 340 where it pushes the downstop washer 358 such that it abuts the wall 356 of the pocket 354. This action limits the outward travel of the carrier 344 to prevent overdriving and eliminate the possibility of expelling the carrier 344 from the distal tips 306. The suture needle 376 trailing the suture 374 is driven through the ligament 378 and into the needle catch 360, where it is captured in a manner previously described. As the button 308 is released, the spring 324 urges the button 308 proximally, moving the pusher wire 330, the coupling 338, the carrier wire 342 and the carrier 344 proximally along with it to the position shown in FIG. 17D, where the backstop washer 348 arrests the proximal movement in a manner previously described, leaving the suture needle 376 in the needle catch 360 and the suture 374 driven through the ligament 378.
A differentiation of this embodiment may be seen by referring to FIGS. 10 and 16. In the embodiment shown in FIG. 10, the path of the needle carrier 868, illustrated by a phantom line in FIG. 10, exits the housing 860 in a direction which is substantially perpendicular to the surface of the housing 860 and presents an opportunity for the needle carrier 868 to be driven directly into the tissue surface placed against the exit. Thus, if there were bone immediately underlying that tissue, this would allow a needle loaded into the needle carrier 868 to be driven directly into bone. In the embodiment shown in FIG. 16, a different type of carrier path is illustrated by a phantom line. In this embodiment, the carrier path exits the distal tip 306 in a direction which approaches being substantially tangential to the surface of the distal tip 306. This substantially tangential exit path allows this instrument to achieve the skimming tissue bite referred to earlier. As shown in FIGS. 17A-17D, when the surface surrounding the exit port of this device is placed next to a tissue surface, a needle loaded into the carrier 344 takes a skimming tissue bite, thereby minimizing any possible penetration of bone underlying the tissue.
Another aspect of this embodiment which is advantageous to the function of the device is the ability to rotate the distal tips 306 of the instrument relative to the elongate body 304, allowing the instrument to conform to the contours of, for example, the pelvic brim. This is accomplished by incorporating a construction such as that illustrated in FIGS. 18A-18B. For clarity, the elongate body 304 has been shown in section view in order that the depression 370 may be seen to engage the rotation pockets 372 a,b. This engagement couples the distal tips 306 a,b to the elongate body 304, as previously described, and also allows the assembly of the distal tips 306 a,b to be rotated axially along the cylindrical surface 320.
As previously described, in any surgical procedure, or in fact in any application that utilizes a needle and thread, the needle is simply a vehicle that carries the suture or thread through the tissue or media to be sewn. As such, there may be contemplated alternate methods for transporting the suture through the tissue that may also incorporate the specific features of, for instance, skimming bite or flexible drive. These alternate methods are to be included within the scope of the present invention. For example, one such method not previously discussed would involve a needle with an eye near the distal end of the needle, a configuration not unlike that seen in a traditional sewing machine. In such a construction, the suture could be threaded into the eye of the needle, and the needle driven through the tissue with a capture mechanism for the suture at the end of the path. The needle could then be withdrawn, leaving the suture in situ. Such a configuration would be well within the scope of the previously described invention if it incorporated features herein described such as, for instance, skimming bite or flexible drive.
It will be understood that the apparatus and method of the present invention for an endoscopic suture system may be employed in numerous specific embodiments in addition to those described herein. Thus, these numerous other embodiments of the invention, which will be obvious to one skilled in the art, including but not limited to changes in the dimensions of the device, the type of materials employed, the location and type of needles, driving mechanisms, catching mechanisms, needle loading mechanisms, etc., are to be included within the scope of the present invention. The apparatus and method of the present invention may be embodied in other specific forms without departing from its spirit or essential characteristics. The described embodiments are to be considered in all respects only as illustrative and not restrictive. The scope of the invention is, therefore, indicated by the appended claims rather than by the foregoing description. All changes which come within the meaning and range of equivalency of the claims are to be embraced within their scope. | A method and device for the placement of sutures and for the purpose of approximating tissue. The invention relates to devices for approximation, ligation and fixation of tissue using a suture, to various constituent parts comprising said devices, and particularly to the placement of sutures into certain difficult to access ligamental structures, to the approximation of tissue separated by means of an endosurgical trocar being inserted into a body cavity, and to approximation, ligation, and fixation of body tissue using both traditional open surgical and endosurgical techniques and instruments. The invention provides for the loading of suture material including needles into the device, introduction and placement of the device into the body cavity, with the distal end having deployable needle guides, extending the needle guides either simultaneously or individually to the periphery of the wound, engaging the wound with the needle guides, driving the needles and suture material through the tissue to be approximated into a catch mechanism, retracting the needle guides and withdrawing the device, leaving a loop of suture material in the margin of tissue. The suture may then be tied to approximate the wound and excess suture material cut off. The invention also provides for the placement of sutures for the endoscopic approximation, fixation, and ligation of tissues within a body cavity including the driving and retrieval of needle and suture combinations, and facilitating the tying of knots. | 0 |
ACKNOWLEDGEMENT
This invention was made with Government support under Grant No. CA-32047-01 with the National Institutes of Health and the University of California. The Government has certain rights in this invention.
FIELD OF THE INVENTION
This invention relates to human-human hybrid cell lines that produce monoclonal antibodies against antigenic determinants on cancer cells, particularly carcinoma of the vulva, stomach, colon, lung and cervix.
BACKGROUND OF THE INVENTION
In the past few years there has been considerable research effort focused on developing immunotherapeutic regimes for treating cancer. In nearly all of these studies antibodies against tumor-associated antigens have been utilized to treat patients suffering from various malignant disorders, unfortunately, with little success. There appear to be four major reasons for the lack of success, two being: first, tumor-associated antigens are difficult to identify; and, second, it is technically difficult and laborious to prepare homogeneous antibody that recognize tumor-associated antigens. The latter difficulty has been largely circumvented by the development of the hybridoma technique of Kohler and Milstein (Nature, Vol. 256, p.495, 1975), which allows for the unlimited production of monoclonal antibody. As for identifying tumor-associated antigens, there is at present no sure way to identify antigens restricted to cancer cells.
The third problem which must be surmounted when devising an immunotherapeutic regime for treatment of cancer is to prevent an immune reaction against the immunotherapeutic agent, that is, against the antibodies directed to the tumor-associated antigen. This problem is amenable to solution by employing human antibodies generated by modification of the basic Kohler and Milstein technique, as described by Glassy et al in Monoclonal Antibodies and Cancer, eds. Boss et al(1983), Academic Press, and Glassy et al, Proc. Natl. Acad. Sci. USA 80:6327 (1983). Human monoclonal antibodies, when injected into a patient bearing a tumor, recognize and bind to the tumor by binding to the tumor-associated antigen. Since the antibody is of human origin it will not be "seen" as a foreign substance by the patient's immune system and is therefore immunologically blind.
Fourth, most of the human monoclonal antibodies generated to date are of the IgM class. This class of antibody, although useful for a variety of in vitro studies, is not as clinically useful as antibody of the IgG class. The generation of one class of monoclonal antibody over another is, at present, poorly understood, and hence not reproducible.
Despite the advent of methods for generating human-human hydridomas, there have been to date few human hydridomas that secrete monoclonal antibodies against tumor-associated antigens. As described by Handley, Royston and Glassy in Intercellular Communication in Leucocyte Function, Proceedings of the 15th International Leucocyte Culture Conference; Wiley Interscience, N.Y.; p. 617, 1983, human monoclonal antibodies have, however, been generated to date against lung tumors, gliomas, melanomas, and tumors of the prostate and mammary glands. The reason for the paucity of such potentially powerful therapeutic agents is partly due to the technique used to generate the hybridomas. While the general technique is understood conceptually, there are many factors which are poorly understood and yet are responsible for ultimately yielding a human hybridoma cell line. Thus, in essence, there is a great degree of unpredictability in generating human hybridomas that either secrete monoclonal antibody against tumor-associated antigens, or that secrete monoclonal antibody of the preferred IgG class. Indeed there is no assurance prior to attempting to generate a hybridoma that it will, in fact, be obtained at all.
At present immunotherapy has been of little use in treating or diagnosing cancers of the vulva, stomach or other organs for the above mentioned reasons. Thus the establishment of human-human hybrid cell lines that secrete IgG monoclonal antibodies against tumor-associated antigens is sorely needed.
SUMMARY OF THE INVENTION
According to this invention, human-human hybrid cell lines, i.e., hybridomas, that synthesize and secrete human IgG monoclonal antibodies are generated by fusing lymphocytes isolated from a regional draining lymph node from a patient containing carcinoma of the vulva to a drug-resistant human lymphoblastoid B cell line.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows the reactivity index of human monoclonal antibodies against various cancers.
FIG. 2 shows the growth inhibitory effect of human monoclonal antibody on the tumor cell line, A431.
DETAILED DESCRIPTION OF THE INVENTION
In accordance with the present invention B cell lymphocytes are isolated from a patient that exhibits a tumor burden. The B cells are isolated by surgical techniques from lymph nodes of the patient, particularly from regional draining lymph nodes near the tumor mass. Alternatively, B cells can be isolated from other lymphoid organs, such as spleen, tonsils and peripheral blood. Regardless of the organ used to obtain the B cells, the latter are prepared in a form suitable for hybridoma formation. To generate hybridomas using lymph nodes as a source of lymphocytes, a suitable procedure is to obtain a patients lymph nodes cells resulting from surgery, tease them apart in a suitably isotonic buffered solution with forceps to release individual lymphocytes. Lymph node cells are then fused by combining them with a suitable fusion partner cell, such as U.C. 729-6 (on deposit with the American Type Culture Collection, with accession no. CRL 8061) at a ratio of about 2 lymphocytes to 1 U.C. 729-6 cell. The latter takes place in a solution of about 35% polyethylene glycol in a suitably buffered isotonic medium, particularly Roswell Memorial Park Institute 1640 medium (RMPI-1640). The mixture of cells is then suspended in an appropriate selective media, particularly HAT medium containing about 10% fetal calf serum, and placed in wells at about 10 5 cells per well, and permitted to grow for a sufficient time. The overnight culture period increases the efficiency of hybridoma formation but is not absolutely crucial if a low yield of hybridomas is acceptable.
In order to obtain human hybrids the B lymphocytes must be fused to a human cell line that exhibits a drug selectable marker; generally such cell lines are of lymphoblastoid origin. Alternatively the human cell line could be selected against based on its ability to exhibit temperature sensitive inhibition of growth. The cell line is maintained in RPMI-1640 culture media prior to fusion.
To form human-human hybrid cell lines the lymph node lymphocytes are mixed with the lymphoblastoid cell line; usually an equal or ten-fold greater number of lymph node lymphocytes are combined with the lymphoblastoid cell line. The two cell types are pelleted to the bottom of a centrifuge tube and fused for an appropriate time with a chemical fusing agent, particularly polyethylene glycol (PEG). Alternatively, fusion can be accomplished by electro cell fusion or by viruses, particularly Sendai and Abelson. Fused cells were then plated in media containing drugs which selectively kill unfused lymphoblastoid cells. The hybrid cell lines which grow up, generally within 10 to 20 days, are screened for human antibody production by assaying for antibodies present in the culture media using one of many immunoassay methods, but particularly that described by Glassy et al in the Journal of Immunological Methods, Vol. 58, p. 119 (1983) example, a small volume of an affinity purified goat anti-human antibody, or a target cell can be immobilized on a suitable surface, particularly useful are matrices made of glass fibers. These can be positioned in an immunofiltration manifold, which can be purchased from B and P Scientific, San Diego, Calif., catalog no. BP107. The latter is particularly convenient as it permits washing of material bound to the glass fiber substrate. The glass fiber substrate material containing bound affinity purified goat anti-human antibody, or target cells, is washed to remove interfering materials, and then a suitable amount of hybrodoma supernatent which is sought to be tested for human antibody is incubated with the substrate material for 30 minutes at room temperature. The filters are washed and then incubated with a suitable detector molecule such as horseradish peroxidase conjugated goat-anti-human antibody for an additional 30 minutes. The filters can be further washed to remove unbound labeled antibody, and then incubated with a suitable substrate such as ortho-phenylene diamine in and an appropriate buffer. The result is a colored solution present in wells having hybridoma antibodies. The latter can be visually detected, or detected and quantified in a micro-Elisa reader such as, for example, that manufactured by Dynatek (Alexandria, Va.). Prior to reading the wells, a suitable amount of acid solution, such as sulfuric acid is added to stop the color reaction, and then the wells are read at 492 nM. It will be apparent to those skilled in the art that the gones that encode antibody in the hybridoma cell lines can, by DNA recombinant techniques, be transferred to other cell types, and that the latter can act as a source of monoclonal antibody.
Monoclonal antibodies present in the culture media of the hybridomas were purified by standard techniques, including exclusion and affinity chromotographic procedures and were assayed to determine which immunoglobuline class they belong to, and their cell type specificities. Antibody class determination was conducted by standard techniques using the appropriate antisera, and found to be of the IgG class as described by Glassy et al in the Journal of Immunological Methods, Vol. 58, p. 119 (1983). To determine the cell type specificity both normal and cancer tissue was assayed on frozen sections using indirect immunofluorescent staining techniques, and cell lines by an enzyme immunoassay.
The monoclonal antibodies selectively react with non-hematopoietic human cancers, particularly tumors of the prostate, stomach, vulva and to a lessor degree with cervix, colon, lung and breast. None of the monoclonal antibodies react with the normal tissues tested. It is important to note that while the monoclonal antibodies have been found to react only with the aforementioned tumors, it is to be anticipated that they will react with other tumors that express the antigen recognized by the monoclonal antibody.
Monoclonal antibodies generated as described above inhibit the growth of tumor cells in vitro. This is accomplished by adding monoclonal antibodies in the range of 5-50 micrograms/ml to tumor cells and measuring their growth rate over several days. It is to be anticipated that monoclonal antibodies generated by this invention will inhibit the growth of a wide variety of other tumor cell types, and furthermore that fragments, or combinations of antibody heavy and light chains will inhibit tumor growth as the antigen combining site of the molecule is retained.
The example disclosed below represents the best embodiment of the invention as contemplated. However, it is to be understood that various changes and modifications may be made without departing from the spirit of the invention.
EXAMPLE I
Establishment of human-human hybridomas
In order to generate human monoclonal antibodies it is first necessary to establish the hybrid cell lines termed hybridomas that secrete them. This is accomplished by chemically fusing human lymphpocyte B cells to a human lymphoblastoid cell line. Lymphocytes are obtained from regional draining lymph nodes of a patient with a carcinoma of the vulva. Lymph nodes were obtained within three hours after removal by surgery. The lymph nodes were teased apart in Rosewell Park Memorial Institute 1640 (RPMI-1640) so as to release the lymphocytes which were separated from large pieces of tissue debris by letting the debris sediment under unit gravity. The lymphocytes that remained in suspension were cultured overnight at 37° C. in an atmosphere of 5% CO 2 /95% air in RPMI-1640 media supplemented with 10% fetal calf serum and 2 mM L-glutamine. The next day the lymphocytes were counted and mixed in ratio of 2:1 with the human lymphoblastoid cell line UC 729-6. The cell mixture was washed in RPMI media minus serum by centrifugation at 150×g to yield a pellet composed of lymphocytes and lymphoblastoid cells. The supernatant was completely aspirated from the cell pellet and 1.0 ml of 35% polyethylene glycol 1500(BDH; lot no. 6229890) was added dropwise over a 30-sec interval to a dry cell pellet and allowed to stand at room temperature for 2 min. At 2-min intervals, the following volumes of serum-free RPMI 1640 medium were added: 1.0 ml, 2.0 ml, 4.0 ml, and 8.0 ml. After addition of the final 8.0-ml volume of medium, the cells were spun at 300×g for 5 minutes, the supernatant was aspirated, and the pellet was carefully suspended in medium supplemented with 10% fetal calf serum, glutamine, and 0.2 mM hypoxanthine/0.2 μM amethopterin/32 μM thymidine (HAT). Cells were plated at 1.0×10 5 per well in Costar 96-well microtiter plates without the use of feeder layer cells. Since the lymphoblastoid cell line UC729-6 is resistant to growth in 6-thioguanine, it lacks the enzyme hypoxanthine-guanine phosphoribosyl tranferase. Consequently, unfused UC729-6 cells die in HAT media. Hybridomas, however, survive and grow since the enzymes necessary for survival in HAT media are derived from the lymph node lymphocytes.
EXAMPLE II
Detection of monoclonal antibodies produced by human-human hybridomas
Within 10-20 days after the lymphocytes are fused to the lymphoblastoid cell line and plated into microtiter plates, hybridoma growth is apparent and the media was assayed for human antibody production. Media was assayed for the presence of monoclonal antibodies by an enzyme linked immunoabsorbant assay previously described by Glassy et al in the Journal of Immunological Methods, Vol. 58, p.119 (1983). The assay was conducted by adding 50 μl of an affinity purified, class specific goat antihuman Ig antibody so as to immobilize it in an immunofiltration manifold. Each well of the manifold was washed three times with 0.3% gelatin in phosphate-buffered saline before the addition of 50 microlitres of hybridoma media supernatant. The latter was incubated for 30 minutes at room temperature, and then the filters washed again three times with phosphate-buffered saline. A second incubation followed with 50 microlitres of a class-specific horseradish peroxidase-conjugated goat anti-human Ig for an additional 30 minute period. Finally, filters are washed again three times and incubated with 150 microlitres of a 400 microgram/ml solution of orthophenylenediamine in citrate buffer. 100 microlitres from each well were then transferred to a 96 well microtiter plate containing 50 microlitres of 2.5 molar sulphuric acid and the optical density at 490 nanometers read on a Dynatech micro-ELISA reader. Media from wells that gave an optical density above control levels, ≧2-fold over background, were considered positive for human monoclonal antibody, and the hybridomas in the corresponding cell culture wells were grown up and cloned by limiting dilution. As a consequence of this procedure five hybridomas producing IgG monoclonal antibodies were identified and termed VLN3G2, VLN5C7, VLN6H2, VLN1F9, and VLN3F10. The hybridomas are on deposit with the American Type Culture Collection, and have the following respective deposit numbers; VLN3G2/ HB8636, VLN567/HB8634, VLN6H2/HB8633, VLN1F9/HB8635, and VLN3F10/HB8632.
EXAMPLE III
Identification of the cancer cell type specificity of the human monoclonal antibodies.
The cancer cell type specificity of the human monoclonal antibodies was determined by one of two methods; either cancer cell lines or frozen sections of cancer tissue were assayed for antibody binding. Cancer cell lines used in the assay are shown in FIG. 1. Antibody binding to the cell lines was determined using the identical materials and methods described in Example II, that is by ELISA assay, with the exception that 2×10 5 target cells/well were immobilized on the filtration manifold. Monoclonal antibodies secreted by the hybridomas VLN3G2, VLN5C7, VLN1F9, VLN3F10 and VLN6H2 and their reactivity with a large panel of cell lines is shown in FIG. 1. Cells were considered reactive with the human monoclonal antibodies if the Reactivity Index was 2.0 or higher. Reactivity Index is defined as the number of times the irrelevant or control IgG value goes into the test human IgG value.
Screening the monoclonal antibodies on frozen sections was performed on six to eight micron thick tissue sections cut at -20° C., and incubated with the monoclonal antibody for 1-2 hours, the section was washed to remove unbound antibody, and then reincubated with a fluorescent labelled antihuman antibody. The latter can be goat antihuman, rabbit antihuman or antihuman antibodies from other species. The second incubation was for 1-2 hours, followed by thorough washing, and visualization of immunofluorescent staining with an immunofluorescent microscope.
FIG. 1 shows the reactivity index of the monoclonal antibodies with various tumor cell lines and tumor tissue. For comparative purposes the reactivity index of monoclonal antibodies produced by the hybridoma VLN2D3 is also shown. VLN2D3 secretes a monoclonal antibody hybridoma that primarily recognizes vulva tissue or developmentally related tissues.
EXAMPLE IV
Inhibition of cancer cell growth by human monoclonal antibodies.
Monoclonal antibody VLN3G2 inhibits the growth of cancer cells as assessed by the ability of VLN3G2 to inhibit the growth of the vulva carcinoma cell line A431. FIG. 2 shows that between 5-50 micrograms/ml of monoclonal antibody there is a marked inhibition of the growth rate of the cell line. About 3×10 4 cells was seeded in Rosewell Park Memorial Institute-1640 media supplemented with 10% fetal calf serum at time 0 with monoclonal antibody. Cell number was determined three days later.
EXAMPLE V
Identification of protein antigens recognized by the human monoclonal antibodies.
Human monoclonal antibodies VLN3G2, VLN5C7 and VLN6H2 recognize epitopes on a 78,000 molecular weight surface protein present on the cell line A431 and a 66,000 molecular weight protein present on the oat cell lung carcinoma cell line, T293H. This was determined by metabolically labelling the cell lines in Rosewell Park Memorial Institute-1640 media supplemented with 10% fetal calf serum and 35 S methionine. The Rosewell Park Memorial Institute-1640 media contained 10% of its normal complement of methionine, and 1-5 microcuries of 35 S methionine per millimeter. The cell lines were labelled overnight with 35 S methionine, the next day washed three times with phosphate buffered saline and then lysed in NP-40, a non-ionic detergent, and the non-soluble material pelleted by low speed centrifugation. 30 micrograms of the monoclonal antibodies were added to the cell extract supernatant and the isolated immunoprecipitate subjected to tube gel polyacrylamide gel electrophoresis. Gels were sliced into 2 mm sections and radioactivity was assessed by standard scintillation chromatography. The apparent molecular weight values were obtained from a standard curve. The isoelectric point of the antigen isolated from the A431 cells is 5.82; the isoelectric point of the antigen isolated from the T293H cells is 4.96. | Human-human hybrid cell lines that synthesize and secrete monoclonal antibodies against antigenic determinants on cancer cells, generated by fusing a human lymphoblastoid B cell line to human lymphocytes, and therapeutic and diagnostic uses of the monoclonal antibodies in both cancer treatment and research is disclosed. | 2 |
BACKGROUND OF THE INVENTION
This invention relates to a novel heat exchanger which incorporates a phase change material as an integral part of the unit. More particularly, this invention relates to a relatively inexpensive, lightweight and structurally strong phase change heat exchanger unit which can be used in series, parallel and/or stacked array to provide any desired amount of heat storage and/or heat exchange.
Many heat exchangers suffer from the disadvantage that they are constructed of heavy structurally strong materials and must be assembled in a particular size in the factory. Such heat exchangers which use phase change materials suffer from further disadvantage of high transportation costs for the relatively heavy phase change material if it is formed as part of the heat exchanger in the factory or with having to handle the phase change material and insert it into the unit when it is placed in service. Such heat exchangers allow the user little or no flexibility in changing the size or capacity of the heat exchanger after it is placed in service.
It is an object of the present invention to provide a phase change heat exchange unit which will provide the user with maximum flexibilty in initially designing and later changing the size and capacity of the heat exchange device in which the unit is used. It is a further object of the present invention to provide a relatively lightweight inexpensive phase change heat exchange unit. Another object is to allow ease of handling of the phase change material.
SUMMARY OF THE INVENTION
This invention is a phase change heat exchange unit which is comprised of upper and lower skeletal support frames. These skeletal support frames have opposing side walls wherein the upper frame is supported on the lower frame at oppositely facing edges of the side walls. Extending between the side walls remote from the oppositely facing side wall edges are at least two spaced apart grid supports which form an air passage therebetween. The grid supports are formed by a plurality of cross support beams extending between the side walls and a plurality of vertical spacers extending parallel to the side walls and intersecting and supporting the cross support beams. There is also a means for securing the upper and lower frames together. Finally, there is a container filled with phase change material disposed between the upper and lower frames and supported thereby. The container is preferably formed of a flexible lightweight material and the upper and lower frames are preferably formed of a lightweight structurally strong material.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. I is a side view showing the phase change material container in place between the upper and lower frames.
FIG. II is a top view of the device of the present invention.
FIG. III is a cross-section taken across line III--III in FIG. II.
FIGS. IV, V and VI are schematic views showing different arrangements of several units made according to the present invention and illustrating the heat exchange fluid flow path therethrough.
DETAILED DESCRIPTION OF THE INVENTION
The upper and lower skeletal support frames may be made of any rigid material which is relatively structurally strong and which can be formed into a skeletal support arrangement with the grid supports as described herein. However, it is preferred that the frames themselves be made of plastic, especially polypropylene or any other plastic compatible with heat exchange fluid. The plastic materials provide an excellent balance of strength versus cost and are also lightweight for easy transportation and arrangement and rearrangement of the heat exchanger configuration.
The container for the phase change material may be made of any material which provides good heat exchange between the exterior and interior of the container. However, it is preferred that the container be made of a flexible lightweight plastic material, especially polypropylene or polyvinylchloride. The flexibility of the container material allows the container to be used in different configurations and also to be more easily inserted into and removed from the skeletal support frames. The use of such a container provides an easy and relatively trouble-free method of handling the phase change material.
Any phase change material may be used in the present invention. There are a number of well known phase change materials which have been used in heat exchange units in the past. These include polyethylene glycol, water, salt hydrates, parafins, and mixed alkyl hydrocarbons. The mixed alkyl hydrocarbons are preferred for use in the present invention because it has a high heat capacity and phase change can be obtained at approximately 48° F. Other materials may be preferable at different temperatures.
Referring to FIG. I, the phase change heat exchange unit 10 is comprised of a phase change material container 12 disposed between upper skeletal support frame 14 and lower skeletal support frame 16. The side walls 18 of the upper frame 14 are supported on the side walls 20 of the lower frame 16 at opposing edges thereof. Vertical spacers 22 provide side support for the frames 14 and 16 to prevent them from twisting. First grids 24 provide additional structural support for the frames 14 and 16 and second grids 26 provide direct support for the container 12. It can be seen that the first and second grids, 24 and 26, together with the vertical spacers 22 form passages for flow of a heat transfer fluid through the unit 10. The open nature of the grids 26 allows direct contact between the heat exchange fluid and the phase change material container 12.
FIG. II is a top view of the unit 10 illustrating the upper frame 14 which is comprised of the first grid cross beams 28, second grid cross beams 30, the side walls 18 and the vertical spacers 22. FIG. III shows a cross-sectional view taken along lines III--III of FIG. II wherein part of the side walls 18 and 20 have been cut away and the lower skeletal support frame 16 is not shown. There is provided a male interlocking pin section 32 and a female interlocking pin section 34. The lower frame 16 will have a female pin section 34 opposing the male pin section 32 and a male pin section 32 opposing the female pin section 34. When the upper skeletal support frame 14 is placed on top of the lower skeletal support frame 16, the male pin section 32 is inserted into the female pin section 34 to lock the two frames, 14 and 16, together and prevent them from moving sidewise with respect to each other.
FIG. IV illustrates an embodiment of the present invention wherein four phase change heat exchange units 10 are used in a stacked array of one on top of the other to provide a heat exchanger which has a serpentine flow path. Heat exchange fluid enters through inlet 36 and flows through the first unit 10 to the first manifold 38 which directs the heat exchange fluid back through the second unit 10 to the second manifold 40 which then directs the fluid back through the third unit 10 to the third manifold 42. The fluid is there directed back through the fourth unit 10 and out of the outlet 44.
In another embodiment as shown in FIG. V, heat exchange fluid from inlet 46 flows through two units 10 to a manifold 48 which directs the fluid flow back through the upper two units 10 and out through the outlet 50. The embodiment of FIG. VI shows how heat exchange fluid enters through inlet 52 and is distributed by a first manifold 54 to all four units 10. The fluid flows directly through all four units 10 in parallel to the second manifold 56 which directs the fluid out through outlet 58.
A model of the phase change heat exchanger of the present invention was constructed using six units as described above. Two units each were stacked on top of each other and the three pairs were lined up in series. This arrangement provides both the axial and the vertical heat exchange characteristics. The entering and exiting air temperature was measured versus time and the storage and discharge capacity of the test unit was determined by the integration of the area between two curves of the entering and exiting air temperature with time and multiplied by the air flow rate, the specific heat of the air, and the density of the air. The storage efficiency of the unit was determined by the ratio of the discharge capacity to the storage capacity. In the present instance, the storage efficiency of the test model was approximately 90%.
The temperature distribution within the heat exchanger was measured by three thermocouples. One was located inside the storage medium within the container. Another was located at the front end of the exchanger and the third was located at the rear of the exchanger. There was very little difference between the temperatures measured by the three thermocouples over the time of operation of the exchanger. This is another indication of the high efficiency of the heat transfer within the exchanger. | This invention is a phase change heat exchange unit which is comprised of upper and lower skeletal support frames having a container for a phase change material disposed therebetween. Each of the frames has a pair of support grids which provide support for the phase change material container and provide a passage for the flow of a heat transfer fluid therethrough so that it can come into direct contact with the container. | 8 |
FIELD OF THE INVENTION
[0001] This invention relates to a fuel tank assembly and more particularly to a fuel tank assembly having a low profile fuel delivery module.
BACKGROUND OF THE INVENTION
[0002] Traditionally, fuel tank assemblies have a fuel tank with an access hole covered by a flange. An elongated fuel delivery module is carried by and projects downward from the flange, stopping just short of or bearing on the fuel tank bottom. The overall length of the module is generally dictated by an electrical motor and fuel pump disposed in series along a vertical rotational axis. The vertical module length dictates the depth or minimum vertical height of the fuel tank or reservoir. Therefore, the optimum profile of the fuel tank is limited by the vertical length of the fuel delivery module. And, to optimize the already restricted profile, the tank access hole must be located on an upper horizontal surface, and most probably, the highest elevated surface of the fuel tank.
[0003] Locating the access hole on top of the tank is seldom the preferred location for maintenance purposes since the tank must be removed from the vehicle prior to accessing the internal components of the fuel tank assembly through the access hole. Because the fuel delivery module is cantilevered from the flange, the flange and the interconnection to the fuel tank itself must be robust and designed so as to pass high speed vehicle crash tests which create high torque or torsional forces upon the flange. The larger the flange, the more likely the flange seal will fail. Unfortunately, much of the available flange surface area is occupied by the fuel delivery module so that use of the flange surface area for other component mountings, or penetrations into the fuel tank, is limited.
SUMMARY OF THE INVENTION
[0004] This invention provides a low profile fuel tank assembly having an elongated fuel delivery module mounted generally horizontally within the fuel tank independent of a flange which covers a sole fuel tank access hole. An integrated fuel pump and associated electric motor of the module has a rotational axis disposed substantially horizontal within the fuel tank. Because the fuel delivery module is supported by the fuel tank shell or bottom, independent of the flange, the access hole can be located anywhere on the fuel tank in order to simplify fuel tank ingress and minimize repair procedures. During assembly, the module is preferably inserted into the fuel tank through the access hole, and is then slid and snap-locked into a bracket attached to the bottom of the fuel tank.
[0005] Preferably, the fuel delivery module slides along interlocking rails formed on both sides of the module into the mounting bracket between a clasp of the bracket and a support structure of the module. Preferably, a forward tang of the bracket prevents the module from sliding too far forward. The module snaps locks in place with the bracket, preventing rearward movement and disengagement, via an upward projecting locking tab of the bracket and a forward projecting snap clip of the support structure which resiliently engages the locking tab.
[0006] Objects, features and advantages of this invention include providing a low profile fuel tank assembly thereby reducing surrounding design restraints of a vehicle fuel tank and the vehicle using it, simplifying fuel system maintenance procedures by enabling easier fuel tank ingress, reducing flange size to improve sealing, freeing up flange surface area for additional component penetrations into the fuel tank, and reducing fuel permeation while providing a relatively simple, design and a low cost rugged, durable, and reliable fuel delivery module and tank assembly.
DESCRIPTION OF THE DRAWINGS
[0007] These and other objects, features and advantages of this invention will be apparent from the following detailed description, appended claims, and accompanying drawings in which:
[0008] [0008]FIG. 1 is a perspective view of a fuel delivery module and tank assembly with part of the fuel tank broken away and in section to show internal detail;
[0009] [0009]FIG. 2 is a perspective view of a fuel delivery module, mounting bracket and a flange of the assembly of FIG. 1;
[0010] [0010]FIG. 3 is a section view of the fuel delivery module and mounting bracket taken along line 3 - 3 of FIG. 1;
[0011] [0011]FIG. 4 is a front end perspective view of the fuel delivery module and bracket;
[0012] [0012]FIG. 5 is a perspective view of the bracket;
[0013] [0013]FIG. 6 is an exploded partial cross section view of the fuel delivery module and bracket taken along line 6 - 6 of FIG. 3;
[0014] [0014]FIG. 7 is a perspective view of the fuel delivery module and bracket with part of a fuel filter broken away to show internal detail;
[0015] [0015]FIG. 8 is a section view of the fuel delivery module and bracket taken along line 8 - 8 of FIG. 2; and
[0016] [0016]FIG. 9 is a section view of the fuel delivery module and bracket taken along line 9 - 9 of FIG. 3.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0017] Referring in more detail to the drawings, FIG. 1 illustrates a fuel tank assembly 10 having a fuel tank 12 with an access hole 14 , being large enough, so that an elongated fuel delivery module 16 can be inserted into a fuel chamber 13 defined by the fuel tank 12 . A leading end 18 of the module 16 is positioned in front of a receiving end of an elongated bracket 20 welded to a bottom surface or wall 22 of an inner surface 23 of the fuel tank 12 . The bracket 20 and module 16 can be located on any other inner surface of the fuel tank 12 ; however, positioning the module on the bottom surface eliminates the need for a pump inlet tube which could contribute toward fuel vapor lock. Also, because the longitude of the module 16 is horizontal the shape of the fuel tank 12 is enabled to have a low profile, not otherwise available. The fuel tank 12 is preferably made of a blow molded plastic or high density polyethylene, HDPE, and the bracket 20 is made of an injected plastic or HDPE. Being of substantially like material, the plastic bracket 20 is welded to the inner surface 23 of the bottom wall 22 , likewise, in a substantially horizontal position. The access hole 14 is covered and sealed or closed by a flange 24 as best shown in FIG. 2.
[0018] Traditionally, the access hole 14 is positioned at the upper most part of the fuel tank 12 because the fuel delivery module is commonly mounted in a vertical direction and carried by the flange. Since the fuel delivery module 16 of the present invention is not carried by the flange 24 , the access hole 14 can be located any where on the fuel tank 12 . In fact, the access hole 14 can easily be located through any side of the fuel tank 12 . Such positioning options are desirable to facilitate fuel tank assembly, maintenance and repair. Aside from the vertical mounting and flange support of traditional assemblies, the module 16 of the present invention can be identical to the fuel pump assembly described in Bucci et al., U.S. Pat. No. 4,860,714 and incorporated herein by reference.
[0019] Referring to FIGS. 2 - 5 , in assembly, the fuel delivery module 16 is slidably received between opposing clasps 26 which project upward from a substantially planar base plate 30 of the bracket 20 and into the fuel chamber 13 defined by the fuel tank 12 . The base plate 30 is welded, embedded, or otherwise attached to the substantially horizontal bottom wall 22 of the fuel tank 12 and extends from a forward portion 34 to a rearward portion 32 . When utilizing HDPE fuel tank shells having multi-layers with an intermediate fuel permeation barrier layer, not shown, it is preferable not to breach the permeation barrier layer when securing the bracket 20 to the fuel tank 12 . Therefore, welding to the bottom surface 22 or inner layer of the multi-layered fuel tank is a preferred method of attachment. Another method, not shown, is to mold protrusions within the fuel tank during the tank manufacturing blow molding process. The bracket 20 , or the module 16 directly, can then be press fitted to the protrusions.
[0020] Referring to FIGS. 4 - 6 , when assembled, the clasps 26 prevents upward movement of the fuel delivery module 16 away from the base plate 30 , via an elongated guideway 36 of each clasp 26 which slideably engages an interlocking rail 38 of the fuel delivery module 16 . The guideways 36 and rails 38 extend longitudinally between the forward and rearward portions 34 , 32 of the bracket 20 . Preventing the module 16 from moving excessively forward and disengaging from the guideways 36 and rails 38 is a stop tang 40 projecting unitarily upward from the base plate 30 and being engageable with the leading end 18 of the fuel delivery module 16 . In assembly, rearward movement of the fuel delivery module 16 with respect to the bracket 20 , which could otherwise disengage the interlocking guideways and rails 36 , 38 in the rearward direction, is prevented by locking tabs 42 of the bracket 20 which project upward from each clasp 26 and a pair of snap clips 44 of the fuel delivery module 16 which engage the locking tabs 42 . The clasps 26 are generally somewhat flexible in order to act as bottom referencing springs which are capable of absorbing bottom impact loads placed upon the fuel tank 12 .
[0021] As best illustrated in FIGS. 3, 5 and 6 , the guideways 36 of each of the laterally opposed clasps 26 each have a channel 54 defined by a rail 48 extending longitudinally of the bracket and fixed at a right angle to a cross bar 47 attached to the upper edge of a substantially planar wall 46 which projects perpendicularly upward from the base plate 30 and extends longitudinally lengthwise of the bracket 20 . The rail 48 projects downward toward the base plate 30 from a longitudinal extending edge of the cross bar 47 and extends parallel to the wall 46 . In assembly each channel 54 receives and interlocks with one of the upward projecting rails 38 of a support structure or can 52 of the fuel delivery module 16 . The rail 38 extends longitudinally, projects upward, and along its lower edge is fixed to a traverse spacer bar 56 attached to the can 52 . Preferably the can has a side surface 50 which is spaced from and extends parallel to the rail 38 to define therewith a channel or slot 58 in which the rail 48 is disposed when the fuel delivery module 16 is engaged to the bracket 20 .
[0022] Referring to FIGS. 3 and 6, the snap clips 44 are attached each to one of both longitudinal sides 50 of the can 52 . The snap clips 44 are disposed over and are spaced vertically above the rails 38 of the can 52 so that the bar 47 of the clasp 26 on the bracket 20 can fit there-between. Each snap clip 44 has a catch or lip 64 on one end of a flexible arm 64 with its other end cantilevered and attached by a base 60 to the longitudinal side 50 of the can 52 . The base 60 serves to support and space the cantilevered arm 62 laterally outward from the longitudinal side 50 . The cantilevered arm 62 is disposed substantially parallel to the longitudinal side 50 and projects in a forward direction, as best shown in FIG. 2. The lip 64 projects laterally outward with respect to the arm 60 and the longitudinal side 50 . As the fuel delivery module 16 slides into the bracket 20 , the locking tab 42 causes the cantilevered arm 62 of the snap clip 44 to flex inward toward the longitudinal side 50 of the can 52 and the lip 64 to slide along an inner surface of the locking tab 42 . The cantilevered arm 62 snaps back or unflexes when the lip 64 slides past the locking tab 42 to overlap and engage a forward facing stop surface 66 of the locking tab 42 . Abutment of the lip 64 of the snap clip 44 with the stop surface 66 of the locking tab 42 prevents the fuel delivery module 16 from moving rearward and disengaging from the interlocking guideways 36 and rails 38 . To permit removal of the fuel delivery module 16 from the bracket 20 , a lateral inward force is applied to the arms 62 of the snap clips 44 (which extends vertically above the locking tab 42 ). When this disengaging lateral force is applied to both clips, the lips 64 separate from their respective locking tabs 42 permitting the fuel delivery module to slide rearwardly.
[0023] During assembly, alignment of the fuel delivery module 16 for insertion between the opposing clasps 26 is guided by angled or inclined guide plates 68 of the clasps 26 . Each guide plate 68 is substantially planar, angled outward and projects rearward from both the rear vertical edge of the locking tab 42 and the rear edge of the wall 46 of its associated clasp 26 . The combination of both guide plates 68 of the clasps 26 forms a type of funnel which helps to guide and align the fuel delivery module 16 between the opposing clasps 26 . The bar 47 reinforces the guide plate 68 by extending rearward to and engaging a midsection of the guide plate 68 .
[0024] As further illustrated in FIGS. 7 - 9 , the can 52 of the fuel delivery module 16 carries a fuel supply pressure control assembly 70 which is illustrated as a pressure control regulator mounted to the outlet of a fuel pump and motor 72 having a rotational axis 74 disposed substantially horizontal and preferably slanted not more than ten degrees from an imaginary horizontal plane when the fuel tank is in its normal orientation within the vehicle. However, the pressure control assembly 70 can also be a pressure transducer motor speed control system where a fuel pressure transducer feeds back to a variable speed fuel pump. An advantage of this system is that less energy is consumed since the pump does not run at full system voltage all the time as does the pressure regulator.
[0025] Fuel flows from a reservoir carried by the can 52 via the fuel pump and motor 72 disposed within the can 52 . From pump 72 , the fuel flows through an elongated fuel filter 75 of the module 16 and to the regulator 70 , as best shown in FIG. 8. The filter 75 partially wraps about the pump and motor 72 and has a fuel inlet nozzle 82 mounted to an end of the filter 75 which is opposite or away from the regulator 70 . A fuel level sensor assembly 77 , which includes a pivoting float arm sensor 78 and/or a fuel piezo level sensor 76 , are integral to the module 16 . The pivoting float arm sensor 78 functions off a fixed ohm resistor card with variable resistance controllable by a float engaged to the distal end of a pivoting arm.
[0026] Various attachments on the module 16 lead to and extend through the flange 24 . These attachments include a wiring harness (not shown) and a flexible tube 80 for supplying fuel to the engine and which communicates with the regulator 70 via a nozzle 81 engaged unitarily to the can 52 . Because flange 24 of the present invention does not carry or support the fuel delivery module 16 , other components are easily supported by the flange 24 . These components include, but are not limited to, an on-board diagnostic-two pressure transducer, OBD 2 , for detecting fuel tank leakage via pressure differential, and a fill limit vent valve, FLVV.
[0027] While the forms of the invention herein disclose constitute a presently preferred embodiment, many others are possible. For instance, the opposing clasps 26 can be replaced with a strap which wraps around the module 16 and engages the base plate of the alternative bracket at either end. It is not intended herein to mention all the equivalent forms or ramifications of the invention, it is understood that the terms used herein are merely descriptive rather than limiting and that various changes may be made without departing from the spirit or scope of the invention. | This invention provides a low profile fuel tank assembly having an elongated fuel delivery module mounted horizontally within the fuel tank and independent from a flange which covers a sole fuel tank access hole. An integrated fuel pump and associated motor of the module dictates the length of the module. The motor and pump has a rotational axis disposed substantially horizontal within the fuel tank. Because the fuel delivery module is supported by the fuel tank shell or bottom, independent of the flange, the access hole can be located anywhere on the fuel tank in order to simplify fuel tank ingress and minimize repair procedures. During assembly, the module is preferably inserted into the fuel tank through the access hole, and is then slide and snap-locked into a bracket welded to the bottom of the fuel tank. | 5 |
STATEMENT OF GOVERNMENT INTEREST
The conditions under which this invention was made are such as to entitle the Government of the United States under paragraph 1(a) of Executive Order 10096, as represented by the Secretary of the Air Force, to the entire right, title and interest therein, including foreign rights.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The proposed invention is related to the field of structural vibration and acoustic (noise) control.
2. Description of the Prior Art
A number of engineering applications can be described as a flexible structure surrounding a cavity. In these systems, structural vibrations induced by either force inputs or external acoustic pressure loads produce sound (or noise) within the cavity. Some common examples of acoustic cavities enclosed by a flexible structure include airplanes, trains, cars and spacecraft launch vehicles. A subset of this group of applications is civil structures or buildings, where relatively rigid walls are combined with flexible windows and other panels.
For the case of spacecraft launch vehicle fairings, the structure is typically constructed from a stiff composite material. The launch vehicle fairing is subjected to extremely high levels of structural vibration and noise at launch. This vibration and noise can damage delicate payloads. The acoustic response of the volume enclosed by the flexible composite structure is dominated at low frequency by very lightly-damped structural acoustic modes (50 Hz-250 Hz). In spacecraft applications, mass and volume are critical parameters, therefore there is a budget on how much noise treatment can be added to the fairing in order to mitigate noise and vibration. Passive methods for attenuating low-frequency disturbances such as foam linings and acoustic blankets are not effective at low frequency. Furthermore, they provide negligible structural vibration attenuation.
Active control strategies have been applied to reduce noise inside acoustic cavities such as aircraft fuselages and automobiles, and have demonstrated significant success in coupling to and attenuating low-frequency acoustic modes. (Fuller, C. R., et. al., “Experiments on Reduction of Aircraft Interior Noise Using Active Control of Fuselage Vibrations,” J. Acoust. Soc. Am., 78(S1), S79, 1985; Fuller, C. R., et. al., “Active Control of Sound Transmission/Radiation from Elastic Plates by Vibrational Inputs,” J. Sound and Vibration, 136(1), pp. 1-15, 1990). However, these strategies have the disadvantage of requiring complex control algorithms, digital signal processing hardware, power amplifiers, signal conditioning, and extensive cabling, which greatly increases the mass of the system. In addition, active acoustic control techniques do little to reduce the vibration of the structure or to prevent noise from being transmitted through the structure. Finally these techniques have never been demonstrated at acoustic levels commensurate with space launch.
There are several accepted methods of reducing noise transmission from external sources into a cavity interior. Most methods are designed to reduce structural vibration by increasing the mass, stiffness or damping of the structure. Traditional, localized, reactive vibration-suppression devices such as vibration absorbers and tuned mass-dampers are very effective at increasing localized structural impedance and structural damping, respectively. (Bies, D., and Hansen, C., Engineering Noise Control, Theory and Practice , E&FN SPON, 2 nd edition, NY, 1996). The disadvantage of such devices is the necessity of additional mass for their operation. Furthermore, these devices act only on the structure, and do little to attenuate the acoustic dynamics of the cavity.
Recently, work has been done to combine active structural control with active acoustic control. (Jolly et. al., Hybrid Active - Passive Noise and Vibration Control System for Aircraft , U.S. Pat. No. 5,845,236, 1998; Fuller, C. R., Apparatus and Method for Global Noise Reduction , U.S. Pat. No. 4,715,559, 1987; Hodgson, et. al., Broadband Noise and Vibration Reduction , U.S. Pat. No. 5,526,292, 1996; Majeed et. al., Active Vibration Control System for Attenuation Engine Generated Vibrations in a Vehicle , U.S. Pat. No. 5,332,061, 1994). These methods utilize arrays of structural sensors such as accelerometers, and acoustic sensors such as microphones to sense disturbances and actively cancel them. Typically in these control systems, loudspeakers are driven by a control signal 180° out-of-phase with the sensed disturbance to provide cancellation. Also, active vibration absorbers, passive vibration absorbers, or structural actuators such as proof-mass actuators, piezoceramic actuators, or shakers, are used by the control scheme to control structural vibration. Although these active methods have been successful at reducing structural vibration and interior noise, they require a considerable degree of sophistication and hardware to implement. The mass of the hardware (including actuators, sensors, controllers, signal conditioning hardware, power amplifiers, mounting apparatus, and cabling) can become prohibitively large and negate the value of using such systems. Furthermore, complex control systems such as these have a greater chance of component failure, which can be catastrophic in critical applications.
SUMMARY OF THE INVENTION
The passive vibroacoustic device of the present invention consists of an acoustic diaphragm, a voice-coil, a magnet, a shunting resistor, and a base suspension. Within a flexible structure surrounding a cavity, the device operates to both reduce the structural vibration by increasing the mechanical impedance of the flexible structure and to dissipate acoustic energy in the cavity. The vibroacoustic attenuating device has numerous advantages over active vibration absorbers. It is completely passive in nature, not requiring cabling, power amplifiers, signal conditioning hardware, or centralized control schemes. The device is capable of coupling to and dissipating low-frequency acoustic modes of a cavity. It also acts as a collocated structural vibration damper and couples to and dissipates structural vibration modes. Unlike tuned vibration absorbers and similar devices which have a narrow targeted bandwidth of attenuation, this device targets multiple structural modes and acts over a wider bandwidth.
Furthermore, there is no possibility of instability or catastrophic failure since the device is completely passive. It is much less expensive to produce and more easily implemented than fully-active and hybrid control systems of the prior art. This device can easily be added onto existing spacecraft fairing structures without requiring redesign of the fairing. The added mass contributed by the device itself serves to attenuate both structural vibration and the acoustic cavity modes, providing more efficient use of the added mass.
The advantages offered by this invention and further novel details and features of this device will become readily apparent from the subsequent description and drawings of the preferred embodiment.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic diagram of the invention.
FIG. 2 shows a lumped-parameter model of the invention including the flexible structure with force input, ƒ.
FIG. 3 shows an acoustic cavity with an attached shunted loudspeaker.
FIG. 4 shows an acoustic cavity terminated with a flexible panel with an attached vibroacoustic attenuator.
FIG. 5 is a plot of the pressure response in an acoustic cavity as a result of panel vibration with and without the vibroacoustic device.
FIG. 6 illustrates the optimal positioning of vibroacoustic devices to attenuate structural vibration and acoustic response of a spacecraft fairing structure.
FIG. 7 is a schematic diagram of an alternate embodiment of the vibroacoustic device with absorptive treatment added to the diaphragm.
FIG. 8 is a schematic diagram of an alternate embodiment of invention with the speaker basket attached to the base structure.
FIG. 9 is a lumped-parameter representation of the alternate embodiment presented in FIG. 8 .
FIG. 10 is a further embodiment using a secondary shunted voice coil attached to the base structure.
FIG. 11 is a plot of the damping ratio of the acoustic cavity mode as a function of shunt resistance using the model presented in FIG. 4 .
FIG. 12 is a table of the parameters used in the example shown in FIG. 4 .
FIG. 13 is a schematic diagram of an alternate embodiment of the invention showing a programmable resistor with a feedback loop and microphone.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The present invention has the advantage that it both reduces structural vibration by increasing the mechanical impedance of the flexible structure and dissipates acoustic energy in the cavity. In its most basic implementation, the impedance that this device adds to the structure is structural damping, but it also can be used as a tuned vibration absorber, which adds localized stiffness in a narrow frequency band, depending on the application. Through the shunted voice-coil loudspeaker, the device provides low frequency acoustic dissipation with almost no added weight or complexity. More efficient use of the additional mass contributed by the device is achieved by simultaneous use of the magnet (which constitutes most of the mass) to attenuate both structural vibration and acoustic energy. This is a key feature of this invention.
The present invention acts as a stand-alone device and requires no cabling, digital signal processing, or signal conditioning which is required in active control approaches. It is intended as an add-on treatment for a structure with noise or vibration problems, and requires no redesign of the structural-acoustic system. Since it is entirely passive, it requires no external power source.
The key components of this invention are an acoustic diaphragm 1 , a voice-coil 2 , a magnet 3 , a shunting resistor 4 , and a base suspension 5 . A schematic diagram of one embodiment of the device is shown in FIG. 1 . The speaker basket 6 encloses the voice coil 2 and magnet 3 in a cylindrical base section and the diaphragm in its conical section. The shunt resister 4 is connected across the input terminals 7 of the loudspeaker and hence to the voice coil. A base structure 8 is rigidly attached to the flexible structure enclosing a cavity. The base suspension connects the cylindrical base section of the speaker basket 6 to the base structure 8 .
FIG. 2 presents a lumped parameter model of the system using spring, mass, and damper elements. The moving mass of the diaphragm, m 3 , is attached to the speaker basket by the spider and surround elements which provide stiffness k 3 and damping c 3 . The mass of the speaker basket and the magnet constitute m 2 shown in FIG. 2 . The combined mass, m 2 , is attached to the base structure by the base suspension, which contributes additional stiffness and damping parameters, k 2 and c 2 , respectively. In FIG. 2, the device is attached to a flexible structure represented by ml, which is subjected to a force input, ƒ. The flexible structure inherently has internal stiffness and damping properties, which are represented as k 1 and c 1 attached to ground. The shunting resistor, R s , is applied to the input terminals of the voice coil, which increases the dissipation of mechanical/acoustic energy, and is a key feature of this invention. The shunting resistor, R s , allows the damping characteristics of the mechanical-acoustic interface to be varied to achieve optimum coupling and acoustic dissipation.
The diaphragm and voice-coil, designated by m 3 , c 3 and k 3 in FIG. 2, have the same dynamics as a traditional loudspeaker. What is different from a traditional loudspeaker is the addition of a shunt resistor in place of the external voltage input. If just the diaphragm, shunted voice-coil, and magnet were added to the end of an acoustic cavity, as shown in FIG. 3, the dynamics of the coupled systems can be described by the following set of coupled differential equations: x ¨ 3 = - ω 3 2 x 3 - ( c 2 + ( bl ) 2 R s + R ) m 3 x . 3 - A m 3 r . r ¨ = 2 ρ c ω c π x . 3 - ω c 2 r p = r . ( 1 )
where ω 3 is the uncoupled resonant frequency of the loudspeaker, c 3 represents the damping due to the suspension of the speaker diaphragm, b is the magnetic field strength, l is the length of the voice-coil, R is the resistance of the coil, R s is the resistance of the shunt resistor, A is the cross-sectional area of the acoustic cavity, m 3 is the mass of the diaphragm and coil, ρ is the density of air, c is the speed of sound in air, ω c is the fundamental resonance of the uncoupled acoustic cavity (assuming rigid-wall boundary conditions), and p is the acoustic pressure directly in front of the diaphragm. In Equation (1), only the first mode of the cavity is considered and the inductance of the voice-coil is neglected since only low frequency operation is of interest. Equation (1) shows that the equivalent damping in the loudspeaker can be represented as c 2 ′ = c 2 + ( Bl ) 2 R s + R . ( 2 )
It is apparent that the value of damping can be controlled by changing the value of the shunting resistor. The maximum value of damping in the loudspeaker will be achieved when the resistance is zero (shorted), but can be adjusted to achieve maximum coupling with incident acoustic pressure.
Now consider an acoustic enclosure terminated at one end by a flexible panel with the proposed vibroacoustic device attached to the panel as shown in FIG. 4 . Assume a disturbance acts on the panel and can be presented as a force input, ƒ, to the panel. This disturbance results in vibration which excites acoustic waves within the acoustic cavity. However, if the device suspension, designated in FIG. 2 by k 2 and c 2 , is heavily damped and the mass is tuned so that the suspension participates in the motion of the base structure, damping is added to the base structure. This damping impedes the motion of the flexible panel, and combines with the added dissipation in the acoustic cavity due to the acoustic diaphragm to reduce noise transmission. The amount of added damping depends on the selection of the mass and suspension stiffness. If the frequency of the device is coincident or nearly coincident with the frequency of the dominant mode of vibration of the flexible panel, a tuned mass-damper results and a maximum amount of damping is added to the individual structural mode. (Bies, D., and Hansen, C., Engineering Noise Control, theory and practice , E&FN SPON, 2 nd edition, NY, 1996). In the preferred embodiment of the vibroacoustic device, the frequency is set below all of the structural modes of interest. This insures participation of the device and added damping in many structural modes. If the vibroacoustic device is added to the end of an acoustic cavity as shown in FIG. 4, the behavior of the device coupled with the acoustic cavity can be described by the following set of coupled differential equations:
{umlaut over (η)} 1 =−ω 1 2 η 1 −2ζ 1 ω 1 {dot over (η)} 1 +ψ 13 (ƒ− A{dot over (r)} )
{dot over (η)} 2 =−ω 2 2 η 2 −2ζ 2 ω 2 {dot over (η)} 2 +ψ 23 (ƒ− A{dot over (r)})
{umlaut over (η)} 3 =−ω 3 2 η 3 −2ζ 3 ω 3 {dot over (η)} 3 +ψ 33 (ζ− A{dot over (r)} )
{umlaut over (r)}=B (ψ 13 {dot over (η)} 1 ψ 23 {dot over (η)} 2 +ψ 33 {dot over (η)} 3 )−ω c 2 r
p={dot over (r)} (3)
where B = 2 ρ c ω c π ,
are the structural modal degrees of freedom and ψ ij are components of the i th mode shape corresponding to the j th position.
For a cylindrical duct of length 2.125 m, and using realistic values of mass, damping, stiffness and electromagnetic properties, the pressure response in a cavity for a broadband unit force input into the panel is shown in FIG. 5 with and without the vibroacoustic device present. In this case, the vibroacoustic device reduces the overall sound pressure level by over 24 dB in the bandwidth from 0 to 200 Hz. This corresponds to an RMS pressure amplitude with the device of less than 0.4% of the RMS pressure amplitude without the device. The specific parameters used in this example are given in the table of FIG. 12 .
In more complicated structures, this same result can be generalized to get the same effect. The specific parameters of the vibroacoustic device can be tuned for the best performance for specific applications. Another added benefit of the device in more complicated structures comes from the observation that locations of high acoustic pressure on the interior of the cavity usually correspond with locations of large structural motion which is responsible for sound transmission. (Cazzolato, B., Novel Transduction Methods for Active Control of sound Transmission into Enclosures . Ph.D. Dissertation, University of Adelaide, 1998). In consideration of this, implementing a small number of the vibroacoustic devices in these optimum locations, as shown FIG. 6, would be extremely effective in reducing noise transmission in relatively large, complicated systems. The device's unique characteristic of adding both structural damping and acoustic dissipation in an optimal way at relatively few locations greatly simplifies its use and integration as compared to prior art.
Since the acoustic enclosure is coupled to the structure through the loudspeaker, damping in the loudspeaker will translate into dissipation of acoustic energy in the cavity. This effect is similar to adding foam which makes the cavity less reverberant, but has the potential for dissipating acoustic energy at low frequency where foam is ineffective. As an additional embodiment, foam can be adhered to the surface of the diaphragm to get additional attenuation at high frequency as shown in FIG. 7 . The resulting device will then be capable of increased attenuation over a broader frequency range than possible from using either foam or the device individually.
Another embodiment of the proposed invention is presented in FIG. 8 and FIG. 9 . In this implementation, the suspension of the acoustic diaphragm is connected to the vibrating base structure, but still derives damping induced from the shunted voice-coil through the relative motion between the diaphragm and the magnet. In some applications, this implementation may result in better performance. The resulting effective stiffness and damping is indicated in the lumped parameter model shown in FIG. 9 as k 3r , k 3m , c 3r , and c 3m . Each parameter can be designed to yield the best performance for the particular application.
Another possible embodiment of this invention is the inclusion of a secondary shunted voice-coil that is fixed to the base structure- as shown in FIG. 10 . The interaction of the secondary voice-coil and the magnet influences the effective damping of the magnet's suspension. Through the design of the secondary voice-coil, the damping of the magnetic suspension can be varied to best suit the particular application.
An additional embodiment of the proposed invention allows for adaptation of the damping characteristics in order to optimize acoustic dissipation. Since the dissipation of the internal cavity is coupled to the damping of the mechanical device which is directly related to the shunt resistor, a variable shunt resistor could be implemented to maximize cavity dissipation for a given application. The implementation of this would involve a programmable shunt resistor in a feedback loop with a microphone at the surface of the acoustic diaphragm. A control law could be designed which varied the shunt resistor to a value that minimized pressure on the surface. An illustration of the effectiveness of such an adaptive scheme is presented in FIG. 11 using the previously described example. In FIG. 11, the variation of the damping ratio of the cavity mode, ζ c , is plotted with respect to shunting resistance. In this case, adaptation of the shunt resistor to around 1.9 Ω maximizes dissipation in the cavity. The addition of an adaptation mechanism would require very little power since a programmable shunt resistor is a digital device, as would be the control electronics. The microphone and associated signal conditioning would also be very low power. For instance, the power requirements of the entire adaptation circuit would be much less than that of a cellular phone, which contains all of the required components and many more for operation. Furthermore, since the adaptation mechanism only affects the shunting resistor, the device is still considered a passive absorber, as opposed to an active control device. A schematic diagram of this embodiment is shown in FIG. 13 . | This invention presents a passive vibroacoustic device that serves the dual function of attenuating the vibration of a flexible structure, and providing acoustic dissipation to the volume or cavity enclosed by the structure. This reduces the transmission of sound from external sources into the enclosure, and reduces vibration of the structure. By design of the shunting resistor and the mass and suspension properties, the device can be optimized to achieve high levels of both structural vibration attenuation and acoustic attenuation. Incorporating a feedback loop or adaptation mechanism will permit the device to maintain optimum attenuation in the case of time varying systems. | 7 |
RELATED APPLICATIONS
[0001] Not applicable
FIELD OF INVENTION
[0002] The present invention relates to digestion of wood chips in a digester employing alkaline liquor for the production of paper pulp.
BACKGROUND OF INVENTION
[0003] In the papermaking industry, wood logs are converted into chips, which are subsequently treated in a digester system to separate the cellulose fibers and to remove desired amounts of lignin, etc., which binds the fibers together in the natural state of wood, for the production of paper pulp. Digestion of wood chips employing an alkaline liquor is a common practice in the industry. In this process, commonly wood chips and an alkaline digesting liquor, sometimes premixed, are introduced to a top inlet zone of a continuous digestion vessel (a digester). In the digestion process, the chips and liquor move generally, but not always, together downward through the digester, the digestion reaching generally optimal completion when the mass reaches the bottom portion of the digester. A typical digester is divided into various zones such as the inlet zone, an upper digestion zone within which, among other things, the chip/liquor mass is heated toward a full cook temperature, a full cook zone within which the mass is subjected to a full cook temperature for a selected period of time, an extraction zone within which digestion spent liquor (black liquor at this point) is withdrawn from the digester, a wash zone in which the mass is washed with process liquids to wash the dissolved solids in the black liquor from the mass, and a withdrawal zone in which the mass of (partially) washed pulp is withdrawn from the digester and passed to further treatment apparatus, such as pulp washers.
[0004] Scaling occurs on surfaces of the equipment in an alkaline pulping system and results in loss in productivity and higher operating costs. Severe scaling in a continuous digester system often leads to loss of production of up to several days a year for scale removal by acid cleaning or high-pressure hydro blasting. Currently there are no known cost-effective process modifications to prevent scaling from forming, and many mills rely on the use of a class of expensive chemicals, known as “antiscalants” in the art, as pulping additives to suppress scaling. Even with the antiscalants, costly periodic cleaning of heaters or other digester equipment is often required.
[0005] Calcium carbonate has been shown to be a key component of scale formed on surfaces of alkaline pulping equipment such as digester cooking heaters and digester screens. In addition, wood generally is the single largest source of calcium present in cooking liquor. The solubility of calcium salts in alkaline pulping liquor has been found first increases and then decreases with increasing cooking temperature and/or cooking time. When the amount of calcium in the cooking liquor exceeds its solubility, calcium precipitates as calcium carbonate and, along with lignin and other deposits, forms scale on the surface of heater, screens and digester shell wall. Thus, under typical alkaline pulping conditions, the amount of dissolved calcium in the cooking liquor increases as cooking proceeds, goes through a maximum near when the maximum cooking temperature is reached, and decreases rapidly afterward as a result of calcium carbonate precipitation onto equipment surfaces (scaling) and surfaces of chips/fibers.
[0006] Scaling tendency of calcium in cooking liquor has been shown to decrease dramatically after the liquor has been heated at or near typical full cooking temperatures. This action is, at times, referred to in the art as calcium deactivation by heat treatment, and has been practiced in some digesters. An exemplary application of this calcium deactivation, as described in European Patent Application EP 0313730 A1, comprises of heating cooking liquor high in calcium at or near full cooking temperature, holding it at this temperature in a vessel for a period of time, typically longer than ten minutes, and returning the heat treated liquor, with “deactivated” calcium, to the digester system. Because scale forms on the surfaces of this “sacrificial” vessel, generally at least two vessels are needed in order to maintain continuous operation of calcium deactivation, with at least one vessel being online and one vessel being cleaned of scales. This technology is probably effective, but requires addition capital and operating costs, and therefore is not widely practiced in the industry.
[0007] Cleaning accumulated scale from a digester requires taking the digester offline and removal of the scale, commonly by chemical dissolution of the scale and/or pressure cleaning with a liquid. This cleaning consumes several days of downtime of the digester in addition to the labor required to perform the cleaning, both of which are very costly. As a consequence of such cost, cleaning of digesters is commonly conducted no more frequently than annually. The gradual accumulation of scale within the digester over the period of a year results in ever increasing loss of efficiency as more and more scale develops. It is therefore most desirable that a method be provided for reducing or substantially eliminating the accumulation of scale within a digester.
SUMMARY OF PRESENT INVENTION
[0008] One aspect of the present invention relates to an improved method of operating a digester for converting wood chips into papermaking pulp employing an alkaline cooking liquor where the digester includes an upright generally cylindrical vessel having a top end and a bottom end in which the deposition of calcium carbonate scale onto surfaces of a digester and/or its ancillary equipment is reduced. In the first step of the improved method a first quantity of cooking liquor having a first concentration of dissolved calcium therein is extracted from a first location intermediate the top and bottom ends of the vessel. In the second step, a second quantity of cooking liquor having a second concentration of dissolved calcium therein that is less than said first concentration of dissolved calcium is extracted from the vessel at a second location spaced apart from said first location and downstream therefrom. In the third step, at least a portion of said second quantity of cooking liquor is reintroduced into the vessel at a third location upstream of said location of extraction of said second quantity of cooking liquor.
[0009] Another aspect of this invention relates to a digester including an upright generally cylindrical vessel having a top end and a bottom end for implementation of the improved method. The digester comprises a first conduit in fluid communication with a first location positioned intermediate the top and bottom ends for selectively extracting a first quantity of cooking liquor from the vessel at the first location, said first location positioned upstream of a second location within the vessel where the cooking liquor has achieved substantially full cooking temperature. The digester also comprises a second conduit in fluid communication with a third location positioned intermediate the top and bottom ends and downstream from the first and second locations and in fluid communication with a fourth location positioned at, about or upstream from the first location. The second conduit selectively extracts a second quantity of cooking liquor from the vessel at the third location, conveys at least a portion of the extracted second quantity of cooking liquor to the fourth location and introduces at least a portion of the conveyed second quantity of cooking liquor into the vessel at the fourth location.
[0010] One or more advantages flow from this process and digestor. One advantage is reduced calcium carbonate scaling. The process modifications disclosed in the present invention can be tailored to a digester system such that net reduction in pulping energy requirement, in the form of medium or high pressure steam consumption, can be realized for more cost savings. Furthermore, when the content of dissolved solids in the process stream(s) added to the early stages of a cook is lower than in the liquor removed from the cooking system, washing of the cooked chips is generally improved, and a smaller amount of weak black liquid can be used in pulp washing. As a result a smaller amount of washing liquor used, a higher total solids is sent to evaporators and additional savings are realized from a lower steam demand in the weak black liquor evaporation. In addition, removal of calcium and other non-process elements, as well as certain extractives, from the early stages of a cook has been found to improve pulp brightness and bleachability. Thus the present invention also results in still more savings from a lower pulp bleaching cost as an additional benefit.
[0011] Yet another embodiment of this invention relates to a method for increasing through-put in a digester of the type comprising an upright generally cylindrical vessel having a top end and a bottom end. In the first step of this method, a first quantity of cooking liquor at a first location and at first flow rate is extracted from the vessel. In the second step, a second quantity of process liquor equal to or greater than the first quantity is continuously introduced into the vessel at a second location which is at, about or upstream of the first location at a second flow rate which is equal to or greater than the first flow. A benefit resulting from this embodiment of the present invention is an increase in the sustainable maximum digester production throughput in a continuous digester, by increasing the amount of liquor moving downward to provide a higher downward force on the chips inside the digester.
BRIEF DESCRIPTION OF FIGURES
[0012] FIG. 1 is a schematic representation of a typical single-vessel digester system and depicting key features of the system piping associated with the method of the present invention.
[0013] FIG. 2 is a schematic representation of a typical two-vessel digester system and depicting key features of the system piping associated with the method of the present invention.
[0014] FIG. 3 is a schematic representation as in FIG. 1 and including certain aspects of Example I of the specification.
[0015] FIG. 4 is a schematic representation as in FIG. 1 and including certain aspects of Example II of the specification.
[0016] FIG. 5 is a schematic representation as in FIG. 1 and including certain aspects of Example III of the specification.
[0017] FIG. 6 is a schematic representation as in FIG. 1 and depicting typical ranges of calcium concentration associated with the single-vessel digester.
DETAILED DESCRIPTION OF INVENTION
[0018] With reference to FIG. 1 , there is schematically depicted a typical single-vessel hydraulic continuous digester 12 suitable for use in carrying out the method of the present invention. The depicted digester 12 includes an upright generally cylindrical vessel 14 having a top end 16 where there is received a supply of wood chips and alkaline cooking liquor 18 and a bottom end 20 which includes a blow assembly 22 by means of which a stream 24 of cooked chips and spent cooking liquor (pulp) is removed from the vessel. In the depicted embodiment, intermediate the top and bottom ends of the vessel there are provided a wash circulation sub-system 28 , a lower extraction location 30 , a lower cook circulation sub-system 32 , an upper extraction location 34 , an upper cook circulation sub-system 36 , and a top circulation subsystem 38 .
[0019] At the bottom of the vessel, the removed pulp stream is sent to a first pulp washer (not shown) via 24 , and the washing filtrate 42 from the first pulp washer is often cooled in cooler 40 , “cold blow filtrate” 26 as commonly known in the art, and introduced to the bottom of the digester for cooling and washing the cooked chips above the blow assembly 22 . This filtrate is available for recirculation to the vessel, either with or without cooling, and with or without further treatment before or after having been mixed with a stream of white liquor (WL) 44 and/or black liquor extracted from the upper and/or lower extraction locations on the digester, and reintroduced into the vessel, such as at the top end of the vessel. In FIG. 1 , the key feature of the process piping involved in the method of the present invention is set forth as dashed lines. With reference to FIG. 2 , there is schematically depicted a typical two-vessel continuous digester 50 suitable for use in carrying out the method of the present invention. As depicted in FIG. 2 , the digester has associated therewith a upright generally cylindrical first vessel and second vessel, where the first vessel 80 having a top circulation sub-system 82 , a bottom circulation sub-system 84 and a liquor makeup sub-system 86 including a makeup-liquor pump 88 . This first vessel serves as a source of pretreated wood chips mixed with cooking liquor that may originate from any one or more sources such as cold blow filtrate 90 , and/or white liquor (WL) 92 . The wood chips are pretreated in this first vessel and discharged from the bottom end 94 of the first vessel, thence conveyed as a supply stream 96 to the top end of the second vessel. As desired, liquor extracted from the lower extraction location 68 on the second vessel may be added to the supply stream to the second vessel. In FIG. 2 , the key features of the process piping involved in the practice of the present invention is set forth as dashed lines.
[0020] The depicted digester 50 includes an upright generally cylindrical second vessel having a top end 54 where there is received a supply of wood chips and alkaline cooking liquor 56 and a bottom end 58 which includes a blow assembly 60 by means of which a stream 62 of cooked chips and spent cooking liquor (pulp) is removed from the vessel, such stream being sent to a pulp washer 9 not shown).
[0021] The washing filtrate from the pulp washer 64 , also known as cold blow filtrate in the art, may be cooled and sent to the bottom of the second vessel for cooling and washing the cooked chips above the blow assembly 60 . This cold blow filtrate is also available for recirculation to the first vessel 80 , either without further treatment or after having been mixed with a stream of white liquor 92 and conveyed into the first vessel. In the depicted embodiment of FIG. 2 , intermediate the top and bottom ends of the vessel there are provided a wash circulation sub-system 66 , a lower extraction location 68 , and a trim circulation sub-system 70 . An upper extraction location 72 is associated with the trim circulation sub-system.
EXAMPLE I
[0022] The preferred embodiment of the method of the present invention was employed with the digester depicted in FIG. 1 . In this single-vessel continuous digester, cooking liquor rich in dissolved calcium of ˜40-120 ppm is withdrawn from the first row of screens of the upper cook circulation screen set at a flow rate of 0.10-0.50 (GPM for each ton per day production rate, or GPM/TPD) factor. (For example, for a pulp production rate of 750 tons per day, 0.1-0.5 times 750, yields 75-350 gallons per minute (GPM). A mixture of cold blow filtrate and wash extraction streams, the sum of which is about the same as the upper extraction flow and the concentration of dissolved calcium is less than 40 ppm, is added to the top of the digester via the makeup liquor pump. In this example, up to about 45% of the total dissolved calcium may be removed from the digester system, significantly reducing the tendency of calcium scaling on digester screens and cooking heaters.
EXAMPLE II
[0023] In a further example of the preferred embodiment of the method of the present invention, employing a single vessel digester as depicted in FIG. 1 , cooking liquor with ˜100 ppm dissolved calcium is withdrawn from the first row of screens of the upper cook circulation screen set at a flow rate of 0.35 (gallons per minute for each ton per day production rate, or GPM/TPD) factor, For example, for a pulp production rate of 750 tons per day, the extraction flow rate is 0.35 times 750, or ˜262 gallons per minute (GPM). A mixture of cold blow filtrate and wash extraction flows, the sum of which is about the same as the upper extraction flow and concentration of dissolved calcium is less that 40 ppm is added to the top of the digester via the makeup liquor pump. In this example, up to about 35% of the total dissolved calcium may be removed from the digester system, significantly reducing the tendency of calcium scaling on digester screens and cooking heaters.
EXAMPLE III
[0024] In a still further example employing the preferred embodiment of the method of the present invention, in a single vessel digester as depicted in FIG. 1 , cooking liquor rich in dissolved calcium of ˜100 ppm is withdrawn from the first row of screens of the upper cook circulation screen set at a flow rate of 0.35 gallons per minute for each ton per day production rate (GPM/TPD) factor. For example, for a pulp production rate of 750 tons per day, the flow rate is 0.35 times 750, or 262 gallons per minute (GPM). A cooking liquor taken from the wash circulation, at about the same flow rate with concentration of dissolved calcium less than 40 PPM, is added to the suction side of the upper cook circulation pump to replace the extracted calcium-rich cooking liquor, thus keeping the hydraulic balance of the digester. The upper circulation in this example is connected to the second (bottom) row of the upper cook screens. In this example, more than about 35% of the total dissolved calcium may be removed from the digester system, significantly reducing the tendency of calcium scaling on digester screens and cooking heaters.
[0025] The present method is operable with both hardwood pulp and softwood pulp.
[0026] Table I presents typical ranges of calcium concentrations in the cooking liquor in various locations in a digester as shown in FIG. 6 .
TABLE I Process Point Calcium (ppm) White liquor (WL) 10-30 Impregnation vessel/zone, 40-120 (before the first heating circulation) Between heating and full 20-60 cooking temperature More than 60 minutes after 5-20 reaching full cooking temperature Cold blow (washing) filtrate 10-40
[0027] Employing these calcium concentration ranges, one skilled in the art may readily determine the optimal locations at which cooking liquor may be extracted from the digester and where makeup liquor of lesser calcium concentration should be introduced to the digester.
[0028] Inasmuch as the dissolved calcium concentration in a cooking liquor may vary as a function of the initial carbonate ion concentration, a significant amount of the cooking liquor should be withdrawn around the process point where the dissolved calcium concentration peaks. At what cooking temperature (corresponding to a certain digester location) the dissolved calcium concentration peaks depends on the carbonate concentration in the liquor. The higher the initial carbonate concentration in the liquor, the earlier the dissolved calcium concentration peaks within the digester.
[0029] Logistically, the preferred location in the digester for replacing a cooking liquor high in dissolved calcium with a liquor low in dissolved calcium is the first set of cooking circulation screens in a single-vessel continuous digester. Similarly the most suitable location to replace the extracted calcium-rich liquor with a liquor low in dissolved calcium is the chip transfer line (bottom circulation as known in the art) leading into the digester (the second vessel in FIG. 2 ) or the first set of screens immediately after the transfer line in a two-vessel continuous digester system.
[0030] Alternatively, (1) one may extract a sufficient amount of one of the process streams from a process point in a continuous digester that is located at least several minutes after full cooking temperature is reached, adding this process stream to an early stage of the cook, e.g. the feeding system or the bottom circulation, and extract an optimal amount of cooking liquor downstream of the addition point and upstream of the process point where full cooking temperature is reached
[0031] Further, same as Item (1) above, except that the temperature of the added process stream may be controlled by use of a heat exchanger, such that a desire pulping temperature profile is maintained.
[0032] Still further, same as Item (1) above, except that more than one process stream may be extracted from different process points after full cooking temperature is reached and that the temperature of one or more of the streams may be controlled by the use of one or more heat exchangers.
[0033] Another significant benefit, namely an increased maximum sustainable pulp production, is achieved from another preferred embodiment of the present invention. According to this embodiment, the upper extraction flow rate described in Examples I-III above (also depicted in FIGS. 3-5 ) is controlled to be significantly lower than the flow rate of the cooking liquor or a mixture of cold blow filtrate and a cooking liquor low in dissolved calcium, such that the amount of liquor (expressed as flow rate) around the chips in a digester, and thus the downward force acting on the chips, is significantly increased. This increased downward force acting on the chips results in a more stable chip column movement, and an increased maximum sustainable digester pulp production if column movement has been the limiting factor in obtaining a higher maximum digester pulp production.
[0034] Other variations in the method of the present invention will be recognized by one skilled in the art and the invention is to be limited only as set forth in the claims appended hereto. | One aspect of this invention relates to a method and digester for reducing the deposition of calcium-based scale in a wood chip digester including extraction from the digester of first and second quantities of cooking liquor having respective first and second calcium concentrations, treating the extracted cooking liquors to produce a cooking liquor having a calcium concentration less that the calcium concentration of the either of the first and second extracted cooking liquors, and, reintroducing the treated cooking liquor to the digester. Another aspect of this invention relates to a method and digester in which through put through the digester is increased by the continuous addition of process liquor into the digester preferably at an upper region of the digester. | 3 |
This application is a continuation-in-part of application Ser. No. 07/911,054 filed Jul. 9, 1992 abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a foldable structure having collapsible compartments. More particularly, the invention relates to a multi-compartment defining structure which is foldable to collapse one or more compartments.
2. State of the Art
Collapsible structures having compartments for organizing and protecting different items such as grocery bags in the trunk of an automobile are well known in the art. U.S. Pat. No. 3,986,656 to November discloses a collapsible package holding structure for dividing the area of a car trunk to hold grocery bags securely during transport. November's area divider consists of several cardboard panels having slots and folds which may be assembled to form a rectangular structure with up to seven internal compartments. While November's structure is collapsible, it is not adjustable in its outer dimensions. It may be collapsed into an unusable disassembled storage condition or assembled to its full size for use. The number and shape of compartments inside the fixed size rectangular structure may be varied, but the outer dimensions of the rectangular frame remain fixed and the dimensions of the inner compartments are only partly adjustable.
U.S. Pat. No. 4,029,244 to Roberts discloses another type of collapsible structure for use in transporting grocery bags. Roberts teaches a railed support stand for preventing grocery bags from spilling. The stand is constructed from seven segments having upper and lower rails connected by risers forming ladder-like structures. Segments are hingedly joined so that the stand folds from a closed position to an open position having two compartments. Each compartment is a rectangular structure with hinges at each of four corners. The two rectangular compartments share a common side. Roberts' stand is somewhat more flexible than November's, but it is costly having many components and moving parts. Moreover, it is not readily adjustable for use in different sized spaces. Although one of the two compartments may be folded closed to shorten the overall length of the structure, this results in a corresponding increase in the overall width of the structure.
A folding separator with an adjustable outer dimension is disclosed in U.S. Pat. No. 4,951,867 to McManus. In one embodiment of the invention, McManus shows a folding cardboard structure similar to November's fixed rectangular outer structure but with extra folds in two opposite sides of the rectangular structure so that its overall width may be adjusted without affecting its overall length. Nevertheless, the overall length of McManus' folding separator remains fixed.
Thus, it will be appreciated that while many of the known collapsible folding structures have definite advantages and are useful for their intended purpose of preventing unwanted movement of packages in the trunk of an automobile while it is in motion, they all suffer a common drawback. None of the known structures is fully adjustable as to its overall size. This is a serious disadvantage since the space available for such a structure in an automobile trunk is not definite or predictable. Automobile trunks vary in size considerably and depending on other contents in the trunk, such as a spare tire, the space available for an organizing structure is tremendously variable. So in many cases, the known organizing structures prove useless since they cannot fit in the limited space available for them.
SUMMARY OF THE INVENTION
It is therefore an object of the invention to provide a multi-compartment foldable organizer which is adjustable in overall size.
It is also an object of the invention to provide a foldable organizer which includes a selectable number of compartments.
It is another object of the invention to provide a foldable organizer where any of its compartments may be selectively collapsed.
It is still another object of the invention to provide a foldable organizer where the area of each compartment is infinitely adjustable.
It is yet another object of the invention to provide a foldable organizer which is inexpensive to manufacture.
It is still another object of the invention to provide a foldable organizer which will collapse to a substantially flat configuration.
It is yet another object of the invention to provide a foldable organizer which is light weight.
In accord with these objects which will be discussed in detail below, the foldable organizer of the present invention includes a plurality of collapsible compartments each having a plurality of rectangular panels hingedly coupled to each other at two opposite sides such that each hinged coupling has a hinging range of 90° or more, and preferably of approximately 180° or more.
Preferred aspects of the foldable organizer include forming all of the panels with substantially identical dimensions and using multiples of four panels. The panels are preferably made of corrugated cardboard, plastic, or other light weight inexpensive material. Hinged couplings may be constructed from tape or cloth, or preferably constructed as integral live hinges between panels formed from a flat blank. The preferred embodiment of the invention is constructed from one or more flat blanks defining a multiple of four in-line panels. The blank is folded and opposite ends of the blank are glued or otherwise fastened to provide an endless group of hinged panels in multiples of four. Groups of panels may be joined to each other at one or more hinges to form a larger foldable organizer. A preferred clip device having a substantially C-shape with free ends close together is used to couple groups of panels.
Additional objects and advantages of the invention will become apparent to those skilled in the art upon reference to the detailed description taken in conjunction with the provided figures.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a plan view of a first embodiment of the invention having sixteen panels;
FIG. 2 is a close view of area A in FIG. 1 showing a first embodiment of joints between panels;
FIG. 3 is a view similar to FIG. 2 showing the panels folded flat;
FIG. 4 is a plan view of the embodiment of FIG. 1 in the fully collapsed position;
FIG. 5 is a top view of the embodiment of FIG. 1 in a partially folded condition;
FIG. 6 is a plan view of a second embodiment of the invention having four 4-panel modules;
FIG. 7a is a side view of a connecting clip used to couple modules of the second embodiment;
FIG. 7b is a view of a second embodiment of a connecting clip used to couple modules together.
FIG. 7c is a view of a third embodiment of a connecting clip used to couple modules together;
FIG. 8 is a plan view of a cardboard blank for creating one of the modules of FIG. 6;
FIG. 9 is a plan view of the blank of FIG. 8 partially folded;
FIG. 10 is a perspective view of four modules, each created from a blank as shown in FIG. 8;
FIG. 11 is a plan view of a cardboard blank for creating an 8-panel module according to a third embodiment of the invention;
FIG. 12 is a perspective view of two 8-panel modules, each created from a blank as shown in FIG. 11;
FIG. 13 is a plan view of a cardboard blank for creating a 16-panel module according to a fourth embodiment of the invention; and
FIG. 14 is a perspective view of a 16-panel module created from the blank of FIG. 13.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to FIGS. 1 through 5, a foldable organizer 10 according to a first embodiment of the invention includes sixteen rectangular panels 12 attached to each other by fabric strips 22 and 23. Arranged as shown in FIG. 1, the sixteen panels form five compartments 24, 26, 28, 30, and 32. It will be appreciated that compartments or modules 24, 26, 28, and 30 are each formed from four panels 12 internally joined at their edges with fabric strips 22 to form four sides (a,b,c,d). These four discrete compartments 24, 26, 28, and 30 are arranged so that the "a" side of each forms a fifth compartment 32. Thus, compartment 32 is defined by side 24a from compartment 24, side 26a from compartment 26, side 28a from compartment 28, and side 30a from compartment 30. Compartments 24, 26, 28, and 30 are externally joined to each other with fabric strips 23 to form the fifth compartment 32 and thereby couple all of the compartments to form a single foldable unit 10. For example, as shown in FIG. 1, side 26a of compartment 26 is externally joined by a fabric strip 23 to side 24a of compartment 24; side 26b of compartment 26 is externally joined by another fabric strip 23 to side 24b of compartment 24. Similarly, side 24c of compartment 24 is joined to side 30c of compartment 30 by another fabric strip 23 and so on.
The rectangular panels 12 which form the sides of the compartments described above may be formed of any suitable material such as plastic, corrugated cardboard, or the like. The fabric strips 22, 23 used in the first embodiment of the invention may be glued to the edges of the panels or attached in any other suitable way. Moreover, the fabric strips 22, 23 may be plastic material, tape, or any other suitable flexible material as will be appreciated by those skilled in the art after reading the complete disclosure herein. It will be appreciated, however, that the strips 22, 23 must be dimensioned and spaced relative to the thickness of panels 12 such that the panels are foldable relative to each other as will be described in more detail below.
Turning now to FIGS. 3-5, it will be appreciated that the hinged connections 22, 23 between panels 12 are sufficient to allow the panels to hinge relative to each other through a range of approximately 180°. Thus, when the compartments 24, 26, 28, 30, 32 are empty, the panels may be folded to lie substantially flat against each other as shown in FIGS. 3 and 4. It will be appreciated that while FIG. 1 shows the foldable organizer 10 in its fully expanded configuration, FIG. 4 shows the organizer 10 in its fully collapsed configuration. It should be recognized, however, that intermediate of its fully expanded and fully collapsed configurations, the foldable organizer 10 may be partially collapsed to close one or more compartments as desired.
FIG. 5 shows the foldable organizer 10 with compartments 24, 28, and 30 partially collapsed so that the organizer fits in an automobile trunk 50 alongside spare tire 60. As shown, only compartment 30 is substantially closed. Compartments 24 and 28 are only slightly collapsed so that the overall dimensions of the organizer are adjusted to fit in the limited space available in the automobile trunk 50. FIG. 5 shows four grocery bags 62, 64, 66, 68 occupying respective compartments 32, 24, 26, 28. Thus, it will be appreciated that according to the the invention, the compartments of the organizer are adjustable from a fully opened to a fully closed position through an infinite number of intermediate positions, many of which intermediate positions are still useful for organizing and protecting items such as the grocery bags shown in FIG. 5. It will also be appreciated that because of the overall configuration of the organizer 10, additional compartments, e.g. 55, may be created between the outer walls of the organizer and the walls of the space in which the organizer is placed. It will also be appreciated that while it is preferred that the hinged connections between panels allow a hinge range of 180° or more, it is possible to construct a useful organizer where the hinge range is only 90° such that, e.g., the compartments collapse in one direction only.
Turning now to FIGS. 6-10, a second embodiment of the foldable organizer 70 includes four 4-panel modules 724, 726, 728, 730 and four resilient connecting clips 722. Each 4-panel module is formed from a flat blank 712 which is cut and folded as described below. The resilient connecting clips 722 couple corners of each module as shown in FIGS. 6 and 10 to form a contiguous space 732 substantially the same size as the space within each module 724, 726, 728, 730. As seen in FIG. 7a, according to one embodiment of the invention, the connecting clip 722 is a substantially C-shaped resilient member having two free ends 721, 723 which are relatively close together. The connecting clip 722 must be very flexible and resilient so that at least one of its ends may be bent out of the way in order place the clip over the hinges of two adjacent modules, and then resume its shape when released. Alternatively, as seen in FIG. 7b, the connecting clip (822) may take the form of a flexible tube 824 and two bobby pins 825 where the bobby pins have one end 826a inserted into the tube and one end 825b free to extend over the hinged areas of the modules. The bobby pins 825 are preferably chosen to be of a length and thickness such that two bobby pins extend along almost the entire length of the flexible tube, and such that the bobby pins slightly deform the flexible tube when mating therewith. As a result, the connecting clip 822 forms into a substantially C-shaped clip which will hold two adjacent modules together, and the connection can be made by sliding one end 825a of one of the two bobby pins into the tube 824 while simultaneously sliding the free end 825b of the same bobby pin over the adjacent hinge. Another alternative clip 832 is seen in FIG. 7c where two flexible tubes 834a and 834b and two bobby pins 835 with ends 835a and 835b which engage the tubes 834a and 834b are provided. In the clip 832 of FIG. 7c, one bobby pin may be inserted into one end of each tube 834a and 834b prior to clipping modules together, and the partially assembled clip may be slid over adjacent corners or a module. Then, the ends of the other bobby pin may be slid into the open ends of the tubes 834a and 834b to complete the clip. As indicated in FIG. 7c, when assembled, clip 832 takes an O-shape. It will also be appreciated that in lieu of clips 722, 822, or 832, an encircling string or wire may be satisfactorily used to couple adjacent corners of the modules as shown. Regardless, after modules are arranged with corners adjacent as shown in FIGS. 6 and 10, the clips 722 (or 822) are secured around adjacent corners as shown in a manner which will be understood from the drawings.
As can be seen in FIGS. 8 and 9, blank 712 from which each 4-panel module is formed is a substantially rectangular flat sheet of corrugated cardboard such as "200 lb. test corrugate B- flute" or another cardboard, plastic or suitable material. Blank 712 has an overall width indicated at 900 of preferably approximately 12 inches and an overall length indicated at 999 of preferably approximately 50 inches. As can be seen in FIG. 9, blank 712 is provided with six equally spaced substantially U-shaped cut- outs 902, 904, 906, 908, 910, 912 which define four substantially identical pairs of ears: 901, 909; 903, 911; 905, 913; 907, 915. Each ear has a width slightly less than approximately one fourth of the overall width of the blank and a length slightly less than approximately one fourth of the overall length of the blank and is foldable along a respective fold line 920, 922, 924, 926, 928, 930, 932, 934. One end of the blank 712 is preferably provided with an extending tongue flap 936 which is foldable along a fold line 938 and which ultimately engages free end 940 at the opposite end of the blank. In the preferred embodiment, tongue flap 936 (folded at fold line 938) extends approximately 2 inches beyond fold line 938.
When ears 901, 909; 903, 911; 905, 913; 907, 915 are folded along respective fold lines 920, 922, 924, 926, 928, 930, 932, 934 as shown in FIG. 9, the blank 712 assumes an overall width as indicated at 900a of approximately half the overall width (900 in FIG. 8) before folding. In the preferred embodiment, the overall width 900a is approximately 6 inches. The partially folded blank 712 shown in FIG. 9 thus defines four reinforced (substantially two-ply) panels 9a, 9b, 9c, 9d separated by fold lines 914, 916, 918. A module (724, 726, 728, 730) is formed by folding panels 9a, 9b, 9c, and 9d along fold lines 914, 916, 918 and attaching tongue flap 936 to free end 940, as shown in FIG. 10.
FIGS. 10 and 6 show four modules 724, 726, 728, 730 coupled at adjacent corners with clips 722. As can be seen in FIG. 10, tongue flap 936 may be attached to free end 940 in any of several manners. As seen with respect to module 730, the tongue flap 936 is simply glued to one side of the free end 940. As seen with respect to module 728, however, tongue flap 936 may be inserted under ears 907, 915 and either glued or stapled or secured in any other suitable manner.
From the description in connection with FIGS. 6-10, it will be appreciated that the dimensions of the cutouts 902, 904, 906, 908, 910 and 912 will depend to some extent on the thickness of the material used to form blank 712. Moreover, the placement of fold lines 920, 922, 924, 926, 928, 930, 932 and 934 will also depend to a certain extent on the thickness of the material used. It will be understood by those skilled in the art of constructing containers from blanks having cut lines and fold lines, that the dimensions and depictions above are approximate. It will also be understood that the shaping of the U-shaped cutouts is designed to provide a single-ply hinge-like area between adjacent reinforced double-ply panels. In this regard, the length and attachment of the tongue flap to the free end should also be arranged to provide a hinge-like area between the panels connected. Finally, it will be appreciated that the hinge-like areas should be sufficiently large enough to accommodate the clip 722 and still allow folding of the panels of the modules through a range of approximately 180° or more.
With the benefit of the above disclosure, the third embodiment of the invention shown in FIGS. 11 and 12 will be readily understood. The embodiment of FIGS. 11 and 12 is very similar to the embodiment of FIGS. 6-10 except that each module is an 8-panel module rather than a 4-panel module. The modules 110 are constructed from blanks 112 in substantially the same manner as the modules described above with reference to FIGS. 6-10. As will be appreciated from FIG. 12, however, the resulting module has eight panels 11a-11h forming two compartments per module. The hinge-like portion formed by fold line 1115 between panels 11b and 11c is coupled to the hinge-like portion formed by fold line 1118 between panels 11f and 11g by a clip 722 as described above. The resulting module 110 assumes a "double diamond" configuration. Two or more modules 110 may be coupled by coupling adjacent corners as indicated by dashed lines 1201, 1202 in FIG. 12. In FIG. 12, the hinge-like portion formed by fold line 1117 between panels 11e and 11f of a first module is coupled to the hinge-like portion formed by fold line 1116 between panels 11c and 11d of a second module by a clip 722; and hinge-like portion formed by fold line 1119 between panels 11g and 11h of the first module is coupled to the hinge-like portion formed by fold line 1114 between panels 11a and 11b of the second module by a second clip 722.
With the benefit of the disclosure thus far, the fourth embodiment of the invention shown in FIGS. 13 and 14 will be readily understood. Turning now to FIGS. 13 and 14, a 16-panel module 130 is shown as formed from a 16-panel flat blank 132. It will be appreciated that the blank 132 is substantially the same as blanks 112 and 712 described above except that its length 1399 is longer. In this embodiment, blank 1399 is approximately twice as long as blank 112 or approximately four times as long as blank 712. It will be understood that the width 1300 of blank 132 is substantially the same as the width of blanks 112 and 712. Blank 132 is folded in a similar manner as the blank 712 shown in FIG. 9 resulting in a a strip of sixteen substantially double- ply panels separated by fifteen substantially single-ply hinge- like areas. Tongue flap 1336 and free end 1340 are substantially the same as the tongue flaps and free ends described above. After folding, the blank 132 is arranged in a somewhat different manner from the blanks described above. FIG. 14 shows how the folded blank 132 is arranged to form five compartments. Tongue flap 1336 and free end 1340 are coupled as described above and the panels are folded at their hinge-like separating areas as shown in FIG. 14. Four clips 722 couple adjacent hinge-like portions: the hinge-like portion formed by fold line 1314 between panels 13f and 13g is coupled to the hinge-like portion formed by fold line 1316 between panels 13n and 13o by a clip 722; hinge-like portion formed by fold line 1318 between panels 13c and 13d is coupled to the hinge-like portion formed by fold line 1320 between panels 13o and 13p by a second clip 722; hinge- like portion formed by fold line 1322 between panels 13a and 13p (between tongue flap 1336 and panel 13a) is coupled to the hinge- like portion formed by fold line 1324 between panels 13l and 13m by a third clip 722; hinge-like portion formed by fold line 1326 between panels 13i and 13j is coupled to the hinge-like portion formed by fold line 1328 between panels 13m and 13n by a fourth clip 722. Thus, it will be appreciated that in FIG. 14, certain clips 722 (e.g., the clip between panels 13i, 13j and 13m, 13n) function to serve as hinges between panels of a single compartment, while certain fold lines (e.g., the line between 13i and 13j, and the line between 13m and 13n) serve as coupling means between corners of compartments.
It will be appreciated that regardless of whether the starting components are single panels, or blanks with two, four, eight, or sixteen connected panels, organizers having more than five compartments (four outer defining one inner) may be formed. For example, additional compartments may be added to the previously described embodiments, so that the final structure may have any number of compartments greater than two. While five compartments may be preferred (as shown in the Figures), it will be readily appreciated that a structure with eight or eleven compartments is easily constructed. An eight compartment structure would typically include the five compartments of FIG. 1 with two additional compartments creating a third additional compartment. The additional compartments would require the use of three additional connecting clips. Likewise, an eleven compartment structure could be created by adding two more compartments to corners which create yet another compartment. 0f course, structures with different numbers of compartments may also be built in accord with the teachings of the invention.
There have been described and illustrated herein several embodiments of a foldable organizer. While particular embodiments of the invention have been described, it is not intended that the invention be limited thereto, as it is intended that the invention be as broad in scope as the art will allow and that the specification be read likewise. Thus, while particular dimensions have been disclosed, it will be appreciated that other dimensions could be utilized. Indeed, rather than providing compartments with sides of equal length (i.e., square), the compartments could have adjacent sides of different lengths (i.e., rectangular) as long as the opposite sides are of the same length. Alternatively, hexagonal (i.e., honeycomb) or octagonal arrangements could be utilized, although it is preferable that the compartments of such arrangements not be packed closely (e.g., the hexagonal inner compartment should preferably only have three hexagonal compartments around it). Also, while certain materials have been discussed, it will be recognized that other types of materials could be used with similar results obtained. For example, rather than the preferred corrugated cardboard structure with flaps, the compartments may be easily made of plastic sheets or grids with live hinges and no flaps, or of non-corrugated cardboard sheets or grids with or without flaps, or metal sheets or wire grids, etc. Moreover, while particular configurations have been disclosed in reference to connecting clips, it will be appreciated that other configurations could be used as well. Furthermore, while one embodiment of the organizer has been disclosed as having cloth or tape connections between panels, it will be understood that different types of hinged connections can achieve the same or similar function as disclosed herein. It will therefore be appreciated by those skilled in the art that yet other modifications could be made to the provided invention without deviating from its spirit and scope as so claimed. | A foldable organizer includes a number of panels hingedly coupled to each other to form a number of defined compartments. The hinged couplings between panels allow the panels to hinge relative to each other preferably through approximately 180 degrees or more. The organizer is foldable to collapse one or more compartments and the area of each compartment is infinitely adjustable so that the organizer can be adjusted to fit in different sized spaces. Expanding the organizer to its maximum allowable size within a given space keeps the organizer secure from movement. The foldable organizer is advantageously used in the trunk of an automobile to protect grocery bags from spilling their contents when the automobile is in motion. The organizer can be constructed from a single flat blank which is cut, folded and fastened or from several such blanks. A kit containing one or more blanks with appropriate fasteners is also disclosed. | 8 |
BACKGROUND OF THE INVENTION
[0001] The present invention relates to an improvement of a film scanning device scanning a color film to obtain image data provided in an automatic photographic processing and scanning apparatus conducting a series of photographic processes for the color film.
[0002] As a general rule, a color negative film is subjected to film development, and then, is scanned by a film scanner so that images on the color negative film are converted into digital images which are used by a digital printer to make a print. However, in the winter season, or in a dry area, charged dust floating in a job environment or in air tends to stick to a processed film, and when converting into a digital image with a scanner by using the film on which the dust is sticking, there are caused noises and print quality is deteriorated, which has been a big problem.
[0003] Therefore, a neutralizing device or an air spray has been provided in a scanner section to remove dust, but it was not sufficient in the actual circumstances.
[0004] Further, it has been strongly demanded from the market side that efficiency of recording, on an image data recording medium, the image data obtained through scanning is enhanced in point of time and management of an image data recording medium is further made to be easy.
[0005] As an apparatus to comply with the aforesaid demand, there has been known an automatic photographic processing and scanning apparatus which conducts a series of photographic processes for a color negative film and obtains image data by scanning the color film that is not dried on the way of the series of developing processes.
SUMMARY OF THE INVENTION
[0006] Image data obtained through scanning are used for making prints to be offered to a customer, or they are stored in a recording medium for recording the data desired by the customer. On the other hand, a film for which photographing processing has been finished is handed to a user, and the developed film can be used for reprinting for the customer, image reading under the individual condition by a film scanner and for image processing.
[0007] In the conventional system, however, film scanning has been separated from outputting of images obtained through reading. In the conventional system, for example, print processing has been started after scanning of the film and photographic processing are completely finished, or only scanning of a film is conducted, and the film is scrapped on the way of processing, resulting in no implementation of print processing. Under this condition, a customer has to wait, and it is impossible for a photofinisher to conduct efficient processing.
[0008] In scanning of a film which is not dried on the way of a series of processing stated above, it is difficult to obtain image data with stabilized image quality, which needs to be solved.
[0009] Tasks to be achieved by the invention include enhancement of output of image data obtained through scanning in the apparatus stated above, namely, enhancement of efficiency in terms of time for print processing or for recording on an image data recording medium, easy management of image data recording media, and improvement of image quality of image data obtained through scanning.
[0010] The object of the invention is attained by either one of the following structures 1 through 22.
Structure 1
[0011] An automatic photographic processing and scanning apparatus that conducts photographic processing for a transmission type film and scans the transmission type film to read as image data, wherein there is provided an image data acquiring means that acquires image data by scanning the transmission type film on the way of a processing step of the photographic processing, and the image data acquiring means scans a part of the transmission type film that is almost in the vertical direction.
Structure 2
[0012] An automatic photographic processing and scanning apparatus that conducts a series of processes including color developing, bleaching, fixing and stabilizing for a color film, and acquires image data by scanning the color film, wherein there are provided a processing tank with fixing ability, a stabilizing tank that conducts the stabilizing processing, and an image data acquiring means that acquires image data by scanning the color film that is on the way from the fixing tank to the stabilizing tank, and the image data acquiring means scans a part of the color film that is almost in the vertical direction.
Structure 3
[0013] An automatic photographic processing and scanning apparatus that conducts photographic processing for a transmission type film and scans the transmission type film to read as image data, wherein there is provided an image data acquiring means that acquires image data by scanning the transmission type film on the way of a processing step of the photographic processing, and the image data acquiring means scans a part of the transmission type film that is almost in the horizontal direction, and is positioned above the part of the transmission type film in the vertical direction.
Structure 4
[0014] An automatic photographic processing and scanning apparatus that conducts a series of processes including color developing, bleaching, fixing and stabilizing for a color film image data acquiring means, and acquires image data by scanning the color film, wherein there are provided a processing tank with fixing ability, a stabilizing tank that conducts the stabilizing processing, and an image data acquiring means that acquires image data by scanning the color film that is on the way from the fixing tank to the stabilizing tank, and the image data acquiring means scans the color film that is almost in the horizontal direction, and is positioned above the part in the vertical direction.
Structure 5
[0015] An automatic photographic processing and scanning apparatus that conducts photographic processing for a transmission type film and scans the transmission type film to read as image data, wherein there are provided an image data acquiring means that acquires image data by scanning the transmission type film on the way of a processing step of the photographic processing, and a roller that comes in contact with the transmission type film immediately before the path through which the transmission type film advances to the image data acquiring means, and a material of the roller has the water absorption property.
Structure 6
[0016] An automatic photographic processing and scanning apparatus that conducts a series of processes including color developing, bleaching, fixing and stabilizing for a color film image data acquiring means, and acquires image data by scanning the color film, wherein there are provided a processing tank with fixing ability, a stabilizing tank that conducts the stabilizing processing, an image data acquiring means that acquires image data by scanning the color film that is on the way from the fixing tank to the stabilizing tank, and a roller that comes in contact with the color film on the path through which the color film arrives at the image data acquiring means after coming out of a solution in the fixing tank, and a material of the roller has the water absorption property.
Structure 7
[0017] The automatic photographic processing and scanning apparatus according to Structures 5 and 6, wherein the roller having the water absorption property is porous.
Structure 8
[0018] The automatic photographic processing and scanning apparatus according to Structures 5 and 6, wherein a material of the surface of the roller having the water absorption property is either one of polybutyl terephthalate, polyphenylene ether, polypropylene, polyurethane, vinyl chloride, polyethylene and polyvinyl alcohol.
Structure 9
[0019] An automatic photographic processing and scanning apparatus that conducts photographic processing for a transmission type film and scans the transmission type film to read as image data, wherein there is provided an image data acquiring means that acquires image data by scanning the transmission type film on the way of a processing step of the photographic processing, and the image data acquiring means scans the transmission type film whose conveyance is stopped.
Structure 10
[0020] An automatic photographic processing and scanning apparatus that conducts a series of processes including color developing, bleaching, fixing and stabilizing for a color film, and acquires image data by scanning the color film, wherein there are provided a processing tank with fixing ability, a stabilizing tank that conducts the stabilizing processing, and an image data acquiring means that acquires image data by scanning the color film that is on the way from the fixing tank to the stabilizing tank, and the image data acquiring means scans the color film whose conveyance is stopped.
Structure 11
[0021] The automatic photographic processing and scanning apparatus according to Structures 9 and 10, wherein each of the transmission type film in Structure 9 and the color film in Structure 10 has a plurality of image frames, and the image data acquiring means scans the color film whose conveyance is stopped for each image frame.
Structure 12
[0022] An automatic photographic processing and scanning apparatus that conducts photographic processing for a transmission type film and scans the transmission type film to read as image data, wherein there are provided an image data acquiring means that acquires image data by scanning the transmission type film on the way of a processing step of the photographic processing, and an image data recording means that records image data acquired by the image data acquiring means on an image data storing medium, and the image data recording means records collectively image data equivalent to one roll of the transmission type film.
Structure 13
[0023] An automatic photographic processing and scanning apparatus that conducts a series of processes including color developing, bleaching, fixing and stabilizing for a color film, and acquires image data by scanning the color film, wherein there are provided a processing tank with fixing ability, a stabilizing tank that conducts the stabilizing processing, an image data acquiring means that acquires image data by scanning the color film that is on the way from the fixing tank to the stabilizing tank, and an image data recording means that records image data acquired by the image data acquiring means on an image data storing medium, and the image data recording means records collectively image data equivalent to one roll of the color film.
Structure 14
[0024] An automatic photographic processing and scanning apparatus that conducts photographic processing for a transmission type film having a magnetic layer, and scans the transmission type film to read as image data, wherein there are provided an image data acquiring means that acquires image data by scanning the transmission type film on the way of a processing step of the photographic processing and a magnetic information reading means that reads magnetic information recorded on the magnetic layer, and the magnetic information reading means reads out specific magnetic information recorded on the magnetic layer before the photographic processing.
Structure 15
[0025] An automatic photographic processing and scanning apparatus that conducts a series of processes including color developing, bleaching, fixing and stabilizing for a color film having a magnetic layer, and acquires image data by scanning the color film having the magnetic layer, wherein there are provided a magnetic information reading means that reads magnetic information recorded on the magnetic layer, a processing tank with fixing ability, a stabilizing tank that conducts the stabilizing processing, and an image data acquiring means that acquires image data by scanning the color film having the magnetic layer that is on the way from the fixing tank to the stabilizing tank, and the magnetic information reading means reads out specific magnetic information recorded on the magnetic layer before a series of color developing, bleaching, fixing and stabilizing processes are conducted.
Structure 16
[0026] The automatic photographic processing and scanning apparatus according to Structures 14 and 15, wherein the specified magnetic information represents information concerning print sizes.
Structure 17
[0027] The automatic photographic processing and scanning apparatus according to Structures 14 and 15, wherein the specified magnetic information represents information concerning conditions of photographing by a camera on the transmission type film in Structure 14 having the magnetic layer or the color film in Structure 15.
Structure 18
[0028] The automatic photographic processing and scanning apparatus according to Structures 14 and 15, wherein the specified magnetic information represents information that specifies image frames which have been exposed.
Structure 19
[0029] The automatic photographic processing and scanning apparatus according to Structures 14 and 15, wherein the specified magnetic information represents information that specifies image frames to be scanned by the image data acquiring means.
Structure 20
[0030] An automatic photographic processing and scanning apparatus that conducts photographic processing for a transmission type film and scans the transmission type film to read as image data, wherein there are provided at least an image data acquiring means that acquires image data by scanning the transmission type film on the way of a processing step of the photographic processing, an image data storing means that stores image data acquired by the image data acquiring means, and an image recording means that records image data stored by the image data storing means on a recording medium.
Structure 21
[0031] An automatic photographic processing and scanning apparatus that conducts photographic processing for a transmission type film and scans the transmission type film to read as image data, wherein there are provided at least an image data acquiring means that acquires image data by scanning the transmission type film on the way of a processing step of the photographic processing, an image data storing means that stores image data acquired by the image data acquiring means, and an image output means that outputs image data stored by the image data storing means.
Structure 22
[0032] An automatic photographic processing and scanning apparatus that conducts photographic processing for a transmission type film and scans the transmission type film to read as image data, wherein there are provided at least an image data acquiring means that acquires image data by scanning the transmission type film on the way of a processing step of the photographic processing, an image data storing means that stores image data acquired by the image data acquiring means, and a communication means that makes it possible to transmit the image data stored by the image data storing means through network.
BRIEF DESCRIPTION OF THE DRAWINGS
[0033] [0033]FIG. 1 is an external view.
[0034] [0034]FIG. 2 is a first schematic structure diagram.
[0035] [0035]FIG. 3 is a second schematic structure diagram.
[0036] [0036]FIG. 4 is a block diagram.
[0037] [0037]FIG. 5 is a perspective view.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0038] An embodiment of the invention will be explained as follows, referring to FIG. 1 - FIG. 5. However, the embodiment of the invention is not limited to the following. Incidentally, in FIG. 1 - FIG. 5, those which are common in other drawings are given the same symbols.
[0039] Though processing of color films may be explained in the following, the invention is not limited to this and it can be applied to almost all of transmission type films. A color film (included in a transmission type film) and a transmission type film may also be one provided with a magnetic layer on which magnetic information can be written. Incidentally, the transmission type film means those including a color negative film, a color reversal film, a black and white film, a copying film, an X-ray film and a lith film.
[0040] Examples of general processing steps for a color negative film (included in a color film) are as follows.
[0041] (1) Color developing → bleaching → fixing → washing → drying
[0042] (2) Color developing → bleaching → fixing → washing → stabilizing → drying
[0043] (3) Color developing → bleaching → fixing → stabilizing → drying
[0044] (4) Color developing → bleaching → fixing → first stabilizing → second stabilizing → drying
[0045] (5) Color developing → bleaching → bleach-fixing → washing → drying
[0046] (6) Color developing → bleaching → bleach-fixing → washing → stabilizing → drying
[0047] (7) Color developing → bleaching → bleach-fixing → stabilizing → drying
[0048] (8) Color developing → bleaching → bleach-fixing → first stabilizing → second stabilizing → drying
[0049] (9) Color developing → bleaching → bleach-fixing → fixing → washing → stabilizing → drying
[0050] (10) Color developing → bleaching → bleach-fixing → fixing → first stabilizing → second stabilizing → drying
[0051] (11) Color developing → bleach-fixing → stabilizing → drying
[0052] (12) Color developing → bleaching → first fixing → second fixing → stabilizing → drying
[0053] (13) Color developing → bleaching → fixing → first fixing → second fixing → third stabilizing → drying
[0054] Among the aforesaid processing steps, (3), (4), (7), (10), (11), (12) and (13) are preferable, wherein (3) and (11) are especially preferable, and (3) is used in the following.
[0055] Incidentally, the photographic processing in this case includes a series of processing stated above.
[0056] [0056]FIG. 1 is an external view of automatic photographic processing and scanning apparatus 1 . This will be explained in detail as follows, referring to FIGS. 2 - 5 .
[0057] [0057]FIG. 2 is one explaining an outline concerning a series of chemical processes for a color film in automatic photographic processing and scanning apparatus 1 and others.
[0058] A trailing edge of color film 3 taken out of color film container 2 (which is generally called a patrone or a cartridge) is cut by cutter 9 , and the color film 3 is conveyed through the inside of the automatic photographic processing and scanning apparatus 1 . Incidentally, the cutter 9 is not always needed, and in the case of a type in which color film container 2 is engaged with color film 3 , a means to release the engagement has only to be provided in place of the cutter.
[0059] In the case where the color film 3 has thereon a magnetic layer, specified magnetic information recorded on the magnetic layer is read out by magnetic information reading means 10 provided on a conveyance path for color film 3 that is on this side of a color developing tank. Namely, the magnetic information reading means 10 reads out specified magnetic information recorded on the magnetic layer before a series of color developing, bleaching, fixing and stabilizing processes which will be described later are conducted for color film 3 .
[0060] Now, the color film 3 is subjected to color developing processing in color developing tank 4 , to bleaching processing in bleaching tank 5 , to fixing processing in fixing tank 6 , to stabilizing processing in stabilizing tank 7 and finally to drying processing in drying section 8 , to be ejected out.
[0061] With regard to color film 3 which is on the way from fixing tank 6 to stabilizing tank 7 , image data are acquired by image data acquiring means 11 from images recorded on the color film 3 . As the image data acquiring means 11 , there is used CCD that acquires image data through photoelectric conversion. Further, on a path for color film 3 to go to image data acquiring means 11 after emerging out of a solution of fixing tank 3 , there are provided at least a pair of rollers 12 which come in contact with the color film 3 . It is preferable that at least one of the paired rollers 12 has water absorption property. The reason for this is as follows. In the case of acquiring image data by scanning color film 3 with image data acquiring means 11 , when many droplets are sticking to the color film 3 , these droplets disturb an optical path of an image and deteriorate quality of image data to be acquired originally. However, it is possible to lighten this adverse effect by making a material of the roller to have water absorption property. Incidentally, it is preferable that this water absorptive roller is provided on a conveyance path for a transmission type film that is located between a processing tank immediately before image data acquiring means 11 and the image data acquiring means 11 , when processing a general transmission type film, and in particular, when a plurality of rollers are positioned before image data acquiring means 11 , the roller immediately before the image data acquiring means 11 among the aforesaid rollers is preferable. In a method to make the roller to be water-absorptive, the material is made to be porous, or the superficial material is made to be either one of polybutyl terephthalate, polyphenylene ether, polypropylene, polyurethane, vinyl chloride, polyethylene and polyvinyl alcohol, or, a roller hardness is made to be 10 - 70 (Roller hardness is a hardness obtained by a measuring method by Indentec Rockwell Tester, a measuring method for Durometer hardness and a measuring method by barcol Impressor.). In this case, if surface tension of a processing solution in a processing tank positioned immediately before the roller is made to be 5 - 70 dyne/cm, wettability of the film surface is improved and occurrence of droplets is repressed, which is preferable. Incidentally, surface tension mentioned here is one measured by a static measuring method which measures under the static conditions, and its measuring method includes a capillary method, a bubble pressure method, a drop weight method, a pendant drop method, a sessile drop method and a ring method.
[0062] Further, when many droplets are sticking to color film 3 in a path for the color film 3 to go to image data acquiring means 11 after emerging out of a solution of fixing tank 6 , the droplets fall to stick to the image data acquiring means 11 and deteriorate scanning efficiency. In FIG. 2, however, image data acquiring means 11 scans a part of color film 3 that is almost in the horizontal direction, from the position which is high in the vertical direction, which is consideration free from the problems stated above.
[0063] Since image data acquiring means 11 scans a part to be photographed on color film 3 whose conveyance is stopped, probability of vibration of droplets is low even when droplets are present on a part to be photographed on color film 3 , and thereby scattering of image light of color film 3 caused by vibration of droplets can be prevented, which is an effect, and thus, image data can be obtained without being disturbed in terms of image quality. Incidentally, since the image data acquiring means 11 scans for each frame of image frames of color film 3 , the color film 3 is conveyed while it is stopped intermittently for each frame in image frames at the position where the color film 3 faces the image data acquiring means 11 . For this reason, it is also possible to provide an accumulator of color film 3 between fixing tank 6 and image data acquiring means 11 , though the accumulator is not illustrated here.
[0064] Next, explanation will be given based on FIG. 3, and only differences between FIG. 3 and FIG. 2 are the position of image data acquiring means 11 and the direction for conveyance of color film 3 at that position, and only these differences will be explained.
[0065] In FIG. 3, image data acquiring means 11 scans a part of color film 3 standing upright in the vertical direction from the position where the image data acquiring means 11 faces the color film 3 . Due to this, it is devised to prevent, even when many droplets are sticking to color film 3 , that the droplets fall and stick to image data acquiring means 11 to deteriorate scanning efficiency of image data acquiring means 11 , in the same way as in the case in FIG. 2.
[0066] Incidentally, the image data acquiring means 11 may be either one wherein a one-dimensional linear photosensor is used or one wherein two-dimensional sheet-shaped photosensor is used. A scanning method may be either a reflection type scanning method or a transmission type scanning method.
[0067] Next, explanation will be given based on FIG. 4. FIG. 4 is one to explain an embodiment of the invention in a block diagram manner, by adding further a means for processing of electric signals to those explained in FIG. 2 and FIG. 3.
[0068] Control means 13 controls all over in cooperation with magnetic information reading means 10 , image data acquiring means 11 , storing means 14 , image data recording means 15 and display means 16 . As stated above, when color film 3 has a magnetic layer, the magnetic information reading means 10 is one that reads specified magnetic information recorded on the magnetic layer. This specified information includes the following four items of information; (1) information concerning print sizes (an example of the print size includes a conventional size and a panorama size, and it is sometimes required that a size of image data to be acquired by image data acquiring means 11 is changed depending on a difference between the print sizes, or image processing for the acquired image data (such as a size change, and an unillustrated image processing means is needed in this case) is conducted), (2) information concerning exposure to color film 3 by a camera (for example, information about using an electronic flash on a camera, a location for photographing and photographing time are given, and it is sometimes required that conditions for image acquisition by image data acquiring means 11 are changed by using the information stated above, or image processing for the acquired image data (such as processing to convert colors, and an unillustrated image processing means is needed in this case) is conducted), (3) information to specify exposed image frames (utilization of this information can shorten the scanning time because image data acquiring means 11 has only to scan an area where image frames actually exist) and (4) information to specify image frames to be scanned by image data acquiring means 11 (utilization of this information makes it possible to prevent acquisition of unnecessary image data because it is possible to scan only image frames designated to be necessary for acquisition of image data, and to use effectively a capacity of an image data storing medium when storing image data in the image data storing medium). These have an influence on processing for image data, when acquiring image data with image data acquiring means 11 , or after the image data are acquired by the image data acquiring means 11 . Therefore, these pieces of information are required to be acquired before scanning by image data acquiring means 11 is conducted. In an embodiment of the invention, this requirement is satisfied, because these pieces of information are read by the magnetic information reading means 10 before a series of processes of color developing, bleaching, fixing and stabilizing are conducted for color film 3 .
[0069] Image data recording means 15 is one that records image data acquired by image data acquiring means 11 and stored in storing means 14 (HDD, ROM and RAM) on an image data recording medium (removable media such as a floppy disk, CD-ROM, ZIP and DVD are preferable). With regard to this recording, it is preferable that all image frames equivalent to one roll of color film 3 are recorded collectively when they are completed in the storing means 14 . The reason for this lies in the following. When color film 3 is conveyed improperly, or troubles are caused on the apparatus, there is a possibility that an image data recording medium in which all image data of image frames equivalent to one roll of color film 3 are not stored yet is caused, and when this is caused, extremely troublesome jobs need to be carried out when controlling the image data recording medium physically or when recording image data of remaining image frames on the image data recording medium again.
[0070] Display means 16 is one that can display images based on image data acquired by image data acquiring means 11 , and it is preferable that an arrangement is made so that image data are automatically displayed before the image data are recorded on an image data recording medium by image data recording means 15 . Further, there may also be provided a recording permission information inputting means with which an operator who has observed the display means can input information that allows, or does not allow the image data representing a basis of the image observed by the operator to be recorded on an image data recording medium. By doing this, image data can be recorded properly on the image data recording medium. When information that does not allow the image data to be recorded is inputted, it is possible either to scan again with image data acquiring means 11 or to acquire image data with another image data acquiring means 11 after drying at drying section 8 because processing of the succeeding color film is delayed if the scanning is conducted again by the image data acquiring means 11 .
[0071] Network connection means 17 (which means communication means 17 in the drawing) is a means to connect image data storing means 14 with the outside. Being connected with outer network 18 through the network connection means 17 (communication means 17 ), it may also be made useful for the service through an outer personal computer (not shown) and the internet (a type of outer network 18 ). In this case, image data stored in image storing means 14 may be made useful, after being converted by a prescribed image conversion processing program, for the service wherein image data are delivered to the customer's personal computer through the network connection means 17 and public lines, or for the service to store images in the server installed in a photofinishing laboratory, or for the service wherein a customer can peruse through WWW browser. It is also possible to provide a service to make prints based on image data delivered to the outside through network connection means 17 .
[0072] Incidentally, as information to be recorded on an image data recording medium, in addition to image data acquired by image data acquiring means 11 , there may also be recorded thumbnail images for the image data and a software which displays regular images (images based on original image data) when the thumbnail images are selected.
[0073] Though the speed (unit: bps) of recording on an image data recording medium by image data recording means 15 is faster than that (unit: bps) of reading image data by image data acquiring means 11 , it is possible to reduce a capacity of storing means 14 when storing successively image data obtained from color film 3 by image data acquiring means 11 in an image data recording medium, which is preferable.
[0074] Though image data acquiring means 11 and paired rollers 12 are provided between fixing tank 6 and stabilizing tank 7 in the example stated above, it is also possible to arrange so that image data acquiring means 11 shown in FIGS. 2 and 3 and paired rollers 12 are provided between stabilizing tank 7 and drying section 8 . Further, though an example of one stabilizing tank 7 is shown in the example stated above, a plurality of stabilizing tanks may also be used, and in this case, image data acquiring means 11 shown in FIGS. 2 and 3 and paired rollers 12 may also be provided between these stabilizing tanks. It is also possible to arrange so that image data acquiring means 11 is a path covering from the point where a transmission type film emerges out of the first processing tank to the point immediately before entering a drying section in the whole transmission type films, and it is provided on the conveyance path outside a solution. Incidentally, with regard to a scanning method of the image data acquiring means 11 , reflection type scanning is advantageous in the processing step where a desilvering step is not completed such as those after color developing processing or bleaching processing, while, transmission type scanning is advantageous after fixing processing and stabilizing processing where desilvering step is completed.
[0075] [0075]FIG. 5 shows one wherein image outputting means 21 is further added integrally to automatic photographic processing and scanning apparatus 1 explained in FIGS. 1 - 4 . The numeral 20 is a print. In this case, control means 13 is not shown. As the image outputting means 21 , there are given a developing machine to obtain a print by using a silver halide photographic light-sensitive material, a printer to obtain a print by using sublimation type heat-sensitive recording material, an ink jet printer, a printer employing a full-color direct heat-sensitive recording material and a printer employing a thermal sublimation transfer recording material of a postchelating type. By doing this, it is possible to deliver a print and CD-R simultaneously to a customer when film developing is about finished.
[0076] In the automatic photographic processing and scanning apparatus to conduct a series of developing processes for a color film and to obtain image data by scanning a color film which is not dried on the way of the processes in a series, the invention makes it possible to improve image quality of image data obtained through scanning, to enhance efficiency in point of time for recording the image data obtained through scanning on an image data recording medium, and to make the control of the image data recording medium easy. | In an automatic processing apparatus for photographic-processing a film, the apparatus includes: a processing station for photographic-processing the film; a scanner for scanning the film on the way of a photographic-processing on the processing station; an image data memory device for storing image date acquired by the scanner; and an image output device for outputting the image data stored in the image data memory device in parallel with a following photographic-processing. | 7 |
TECHNICAL FIELD
[0001] The present invention relates to cell lines, compositions comprising them for treating melanomas, procedures for preparing compositions, and treatment methods. More particularly, the invention relates to diverse human melanoma cell lines for treatment of malignant diseases, where the cell lines are: (a) Mel-XY1 (deposited at German Collection of Microorganisms and Cell Cultures DSMZ—Deutsche Sammlung von Mikroorganismen und Zellkulturen GmbH, Inhoffenstraβe 7 B 38124 Braunschweig, Germany on Mar. 23, 2007 under access number DSM ACC2830), (b) Mel-XY2 (deposited at German Collection of Microorganisms and Cell Cultures DSMZ—Deutsche Sammlung von Mikroorganismen und Zellkulturen GmbH, Inhoffenstraβe 7 B 38124 Braunschweig, Germany on Mar. 23, 2007 under access number DSM ACC2831), (c) Mel-XY3 (deposited at German Collection of Microorganisms and Cell Cultures DSMZ—Deutsche Sammlung von Mikroorganismen und Zellkulturen GmbH, Inhoffenstraβe 7 B 38124 Braunschweig, Germany on Mar. 23, 2007 under access number DSM ACC2832), (d) Mel-XX4 (deposited at German Collection of Microorganisms and Cell Cultures DSMZ—Deutsche Sammlung von Mikroorganismen und Zellkulturen GmbH, Inhoffenstraβe 7 B 38124 Braunschweig, Germany on Mar. 23, 2007 under access number DSM ACC2829) or (e) subpopulations thereof. Cell lines may be irradiated, thus obtaining populations with apoptotic phenotype, and populations with necrotic phenotype of such lines. The compositions may comprise adjuvants, and/or immuno-modifiers, and/or autologous dendritic cells.
BACKGROUND OF THE INVENTION
[0002] Currently, many efforts are done, and many resources are used to research on the area of cancer immunotherapy. Important existing evidences indicate a central role of T lymphocytes in cancer effective immune responses (Oliver R T, Nouri A M. T; Cancer Sury 1992; 13:173-204). To such purpose, treatments with allogenic cells alone, with adjuvants, or in combination with some cytokines have been used.
[0003] On the other hand, it is known that dendritic cells (DC) are antigen presenting cells that may initiate a T cell response, due to their extraordinary ability to stimulate naïve T lymphocytes (Schuler G, Steinman R M. J. Exp. Med. 1997; 186:1183-7, and Banchereau J, Steinman R M. Nature 1998; 392:245-52).
[0004] Several authors have shown in mouse models, and in humans that DC incorporate apoptotic cells, and thus the antigens for the generation of Class I HLA complexes/peptides are presented, allowing the induction of cytotoxic T lymphocytes (Albert M L, Pearce S F, Francisco L M, Sauter B, Roy P, Silverstein R L, Bhardwaj N. J Exp Med. 1998, 188: 1359-1368; Chen Z, Moyana T, Saxena A, Warrington R, Jia Z, Xiang J. Int J. Cancer. 2001, 93: 539-548 and Shaif-Muthana M, McIntyre C, Sisley K, Rennie I, Murray A. Cancer Res. 2000, 60: 6441-6447). For this process it is fundamental that the apoptotic cells induce maturity of the dendritic cells (DC), however, many authors have informed that human apoptotic cells do not mature DC, or induce loss of maturity of such DC (Pietra G, Mortarini R, Parmiani G, Anichini A. Cancer Res 2001, 61: 8218-8226; Labarriere N, Bretaudeau L, Gervois N, Bodinier M, Bougras G, Diez E, Lang F, Gregoire M, Jotereau F. Int J Cancer 2002, 101: 280-286 and Demaria S, Santori F R, Ng B, Liebes L, Formenti S C, Vukmanovic S. J Leukoc Biol. 2005, 77: 361-368).
[0005] U.S. Pat. No. 6,187,306 by Pardoll et al. discloses a method of treating and protecting against melanoma, which comprises the use of at least one or more allogenic cell lines expressing melanoma immunodominant antigens, wherein the cell line has been modified in such a way that it expresses cytokines, and administering such transformed line to a patient carrying melanoma, or at risk of getting the disease. Although the importance of the cell line or the cell lines used, which expresses most of the immunodominant antigens, a new cell line or a combination of cell lines expressing most of such antigens have not been disclosed. The invention comprises essentially transformed cell lines expressing cytokines such as GM-CSF.
[0006] U.S. Pat. No. 5,882,654, and U.S. Pat. No. 5,840,317 disclose irradiated melanoma cell lines used as allogenic vaccines. The disclosed treatment reaches levels of NED patients below 50% (16/37), and shows an effective humoral-type anti-tumor activity.
[0007] US patent 2006/0034811 by Wallack et al. discloses vaccines comprising antigen presenting cells charged with lysed or ruptured tumor cells including cytosol and membranes. Tumor cells may be cells from the patient, cell lines, or cells infected with the recombinant vaccinia virus codifying IL-2. US patent 2006/0140983 by Palucka et al. discloses a composition inducing immunity in cancer patients which comprises the isolation and purification of antigen presenting cells primed for exposition with one or more heat-shock proteins, and dead tumor cells. Antigen presenting cells are dendritic cells, and tumor cells may be syngenic or allogenic cells, for example cell lines. This document discloses the need of incorporating heat-shock proteins by rupture through heating of tumor cells. The shown assays do not necessarily disclose that the composition have immunity-inducing activity in melanoma patients.
[0008] U.S. Pat. No. 6,602,709 by Albert et al., discloses the use of apoptotic cells to present antigens to dendritic cells for T cell induction. The method is useful to induce antigen-specific cytotoxic T lymphocyte helper cells. Dendritic cells are primed by apoptotic cells or fragments thereof, and are capable of processing and present processed antigens, and induce the activity of cytotoxic T lymphocytes, which may be used as therapeutic vaccines.
BRIEF DESCRIPTION OF THE INVENTION
[0009] In one aspect of the present invention several human melanoma cell lines for the treatment of malignant diseases are provided, wherein the cell lines are (a) Mel-XY1 (deposited at German Collection of Microorganisms and Cell Cultures DSMZ under access number DSM ACC2830), (b) Mel-XY2 (deposited at German Collection of Microorganisms and Cell Cultures DSMZ under access number DSM ACC2831), (c) Mel-XY3 (deposited at German Collection of Microorganisms and Cell Cultures DSMZ under access number DSM ACC2832), (d) Mel-XX4 (deposited at German Collection of Microorganisms and Cell Cultures DSMZ under access number DSM ACC2829), or (e) sub-populations thereof. The cell lines may further be irradiated in order to obtain populations with apoptopic phenotype, and populations with such lines necrotic phenotype.
[0010] In another aspect of the present invention, a composition for the treatment of melanoma is provided, wherein such composition comprises al least one allogenioc melanoma cell line, for example (a) Mel-XY1 (deposited at German Collection of Microorganisms and Cell Cultures DSMZ under access number DSM ACC2830), (b) Mel-XY2 (deposited at German Collection of Microorganisms and Cell Cultures DSMZ under access number DSM ACC2831), (c) Mel-XY3 (deposited at German Collection of Microorganisms and Cell Cultures DSMZ under access number DSM ACC2832), (d) Mel-XX4 (deposited at German Collection of Microorganisms and Cell Cultures DSMZ under access number DSM ACC2829), or combinations thereof, wherein such cell lines are incapable of proliferate. The composition may also comprise excipients, adjuvants such as BCG, and immunomodulators such as GM-CSF, or IFNα. In a preferred embodiment, the composition comprises combinations of the four allogenic melanoma cell lines (a) Mel-XY1 (deposited at German Collection of Microorganisms and Cell Cultures DSMZ under access number DSM ACC2830), (b) Mel-XY2 (deposited at German Collection of Microorganisms and Cell Cultures DSMZ under access number DSM ACC2831), (c) Mel-XY3 (deposited at German Collection of Microorganisms and Cell Cultures DSMZ under access number DSM ACC2832) and (d) Mel-XX4 (deposited at German Collection of Microorganisms and Cell Cultures DSMZ under access number DSM ACC2829), where such cell lines have been irradiated and are incapable of proliferate. In another preferred embodiment, the composition of the invention comprising combinations of the three allogenic melanoma cell lines (a) Mel-XY1 (deposited at German Collection of Microorganisms and Cell Cultures DSMZ under access number DSM ACC2830), (b) Mel-XY2 (deposited at German Collection of Microorganisms and Cell Cultures DSMZ under access number DSM ACC2831), and (c) Mel-XY3 (deposited at German Collection of Microorganisms and Cell Cultures DSMZ under access number DSM ACC2832), where such cell lines have been irradiated and are incapable of proliferate.
[0011] In another aspect of the present invention, a composition for adjuvant treatment of melanoma is provided, wherein such composition comprises at least one allogenic melanoma cell line, for example (a) Mel-XY1 (deposited at German Collection of Microorganisms and Cell Cultures DSMZ under access number DSM ACC2830), (b) Mel-XY2 (deposited at German Collection of Microorganisms and Cell Cultures DSMZ under access number DSM ACC2831), (c) Mel-XY3 (deposited at German Collection of Microorganisms and Cell Cultures DSMZ under access number DSM ACC2832), (d) Mel-XX4 (deposited at German Collection of Microorganisms and Cell Cultures DSMZ under access number DSM ACC2829), and combinations thereof, and where such cell lines have been irradiated and are incapable of proliferate. The composition may also comprise excipients, adjuvants such as BCG, and immunomodificadores such as GM-CSF and/or IFNα. In one preferred embodiment the composition of the invention comprises a combination of the allogenic melanoma cell lines (a) Mel-XY1 (deposited at German Collection of Microorganisms and Cell Cultures DSMZ under access number DSM ACC2830), (b) Mel-XY2 (deposited at German Collection of Microorganisms and Cell Cultures DSMZ under access number DSM ACC2831), (c) Mel-XY3 (deposited at German Collection of Microorganisms and Cell Cultures DSMZ under access number DSM ACC2832), or (d) Mel-XX4 (deposited at German Collection of Microorganisms and Cell Cultures DSMZ under access number DSM ACC2829), where such cell lines have been irradiated and are incapable of proliferate. In another preferred embodiment, the composition of the invention comprises a combination of the allogenic melanoma cell lines (a) Mel-XY1 (deposited at German Collection of Microorganisms and Cell Cultures DSMZ under access number DSM ACC2830), (b) Mel-XY2 (deposited at German Collection of Microorganisms and Cell Cultures DSMZ under access number DSM ACC2831), or (c) Mel-XY3 (deposited at German Collection of Microorganisms and Cell Cultures DSMZ under access number DSM ACC2832), where such cell lines have been irradiated and are incapable of proliferate.
[0012] In another aspect of the present invention, a composition is provided for the treatment of human melanomas comprising mature autologous dendritic cells, autologous dendritic cells charged with cells with at least a allogenic human melanoma cell line, apoptotic cells of such at least one heterologous human melanoma cell line of such at least one heterologous human melanoma cell line. The human melanoma cell line is one or more of the following lines: (a) Mel-XY1 (deposited at German Collection of Microorganisms and Cell Cultures DSMZ under access number DSM ACC2830), (b) Mel-XY2 (deposited at German Collection of Microorganisms and Cell Cultures DSMZ under access number DSM ACC2831), (c) Mel-XY3 (deposited at German Collection of Microorganisms and Cell Cultures DSMZ under access number DSM ACC2832), (d) Mel-XX4 (deposited at German Collection of Microorganisms and Cell Cultures DSMZ under access number DSM ACC2829), or (e) subpopulations thereof.
[0013] In another aspect of the invention, a composition for adjuvant treatment of human melanoma is provided, comprising mature dendritic cells, dendritic cells charged with cells of at least one allogenic human melanoma cell line, apoptotic cells of one heterologous human melanoma cell line and necrotic cells of one heterologous human melanoma cell line. The melanoma cell line is one or more of the following cell lines: (a) Mel-XY1 (deposited at German Collection of Microorganisms and Cell Cultures DSMZ under access number DSM ACC2830), (b) Mel-XY2 (deposited at German Collection of Microorganisms and Cell Cultures DSMZ under access number DSM ACC2831), (c) Mel-XY3 (deposited at German Collection of Microorganisms and Cell Cultures DSMZ under access number DSM ACC2832), (d) Mel-XX4 (deposited at German Collection of Microorganisms and Cell Cultures DSMZ under access number DSM ACC2829), or sub-populations thereof.
[0014] In another aspect of the present invention, a procedure for preparing the composition is provided, wherein such procedure is carried out in the following stages:
a) thawing and culturing cell lines (a) Mel-XY1 (deposited at German Collection of Microorganisms and Cell Cultures DSMZ under access number DSM ACC2830), (b) Mel-XY2 (deposited at German Collection of Microorganisms and Cell Cultures DSMZ under access number DSM ACC2831), and (c) Mel-XY3 (deposited at German Collection of Microorganisms and Cell Cultures DSMZ under access number DSM ACC2832); b) blending such three cell lines; c) irradiating such three cell lines; d) adding adjuvants and excipients to the cell line mixtures. The procedure may also comprise in stage a) adding cell line Mel-XX4 (deposited at German Collection of Microorganisms and Cell Cultures DSMZ under access number DSM ACC2829).
[0019] In another object of the present invention, a procedure for preparing the composition is provided, which comprises the stages of:
a) thawing and culturing cell lines (a) Mel-XY1 (deposited at German Collection of Microorganisms and Cell Cultures DSMZ under access number DSM ACC2830), (b) Mel-XY2 (deposited at German Collection of Microorganisms and Cell Cultures DSMZ under access number DSM ACC2831), (c) Mel-XY3 (deposited at German Collection of Microorganisms and Cell Cultures DSMZ under access number DSM ACC2832), and Mel-XX4 (deposited at German Collection of Microorganisms and Cell Cultures DSMZ under access number DSM ACC2829); b) blending such cell lines; c) irradiating such cell lines; d) obtaining autologous dendritic cells; and e) co-culturing for some time the autologous dendritic cells with the irradiated cell lines of stage c).
[0025] In another aspect of the present invention, a method to induce an anti-tumor immune response in patients carrying a melanoma is provided, which comprises administering to a patient in need thereof an affective amount of a combination of cell lines (a) Mel-XY1 (deposited at German Collection of Microorganisms and Cell Cultures DSMZ under access number DSM ACC2830), (b) Mel-XY2 (deposited at German Collection of Microorganisms and Cell Cultures DSMZ under access number DSM ACC2831), and (c) Mel-XY3 (deposited at German Collection of Microorganisms and Cell Cultures DSMZ under access number DSM ACC2832), where such cell lines are incapable of proliferate. The administration may be done together adjuvants and/or immunomodulators.
[0026] In another aspect of the present invention, a method of inducing an anti-tumor immune response in patients carrying a melanoma is provided, which comprises administering to a patient in need thereof an effective amount of a combination of cell lines (a) Mel-XY1 (deposited at German Collection of Microorganisms and Cell Cultures DSMZ under access number DSM ACC2830), (b) Mel-XY2 (deposited at German Collection of Microorganisms and Cell Cultures DSMZ under access number DSM ACC2831), (c) Mel-XY3 (deposited at German Collection of Microorganisms and Cell Cultures DSMZ under access number DSM ACC2832), and (d) Mel-XX4 (deposited at German Collection of Microorganisms and Cell Cultures DSMZ under access number DSM ACC2829), where such cell lines are incapable of proliferating.
[0027] In another aspect of the present invention, a method of inducing an anti-tumor immune response in patients carrying a melanoma is provided, which comprises administering to a patient in need thereof an effective amount of a co-culture from between 6 and 72 hours of autologous dendritic cells, and a combination of cell lines (a) Mel-XY1 (deposited at German Collection of Microorganisms and Cell Cultures DSMZ under access number DSM ACC2830), (b) Mel-XY2 (deposited at German Collection of Microorganisms and Cell Cultures DSMZ under access number DSM ACC2831), (c) Mel-XY3 (deposited at German Collection of Microorganisms and Cell Cultures DSMZ under access number DSM ACC2832), and (d) Mel-XX4 (deposited at German Collection of Microorganisms and Cell Cultures DSMZ under access number DSM ACC2829), where such cell lines are incapable of proliferating.
DESCRIPTION OF THE DRAWINGS
[0028] FIG. 1 shows a representative example of the results of Gamma irradiation of the mixture of cell lines of la invention in reference to apoptosis induction and necrosis (Apo-Nec cells). Panel A shows non-irradiated cells, and panel B shows the cells after Gamma irradiation 70Gy, and stained with Anexin V-FITC and IP (propidium iodide). Early apoptotic cells are defined as Anexin V-FITC + /IP − , while necrotic cells were doubly positive.
[0029] FIG. 2 shows a Kaplan Meier graph of patients treated with the composition of the invention DC/Apo-Nec.
[0030] FIG. 3 shows in vitro e lymphocytes proliferation in response to autologous tumor cells presented by DC. Results are shown as mean±SD cpm (counts per minute) of triplicates. Lymphocytes with phytohemoaglutinin (PHA) incorporating more than 7×10 4 cpm were incubated as positive controls.
[0031] FIG. 4 shows tetramer staining for antigens Melan A/MART-1, and gp100. Panel A shows results obtained with PBMN samples from HLA-A*0201 patients participating in the test. *ND means: non-determined due to insufficient amount of CD8 + T cells in the samples post-application. Panel B shows the increase of CD8+HLA T lymphocytes/tetramer peptide+in PBMC from patient #2. Amounts represent percentage of CD8 + HLA/tetramer peptide + . HLA-A*0201 PBMC from healthy donors were stained as controls.
[0032] FIG. 5 shows intra-cytoplamic measurement of IL-10 and IL-12 in Apo-Nec cells of the invention. Panel A shows results of FACS from DCin, and panel B shows results of FACS from DC/Apo-Nec cells.
[0033] FIG. 6 shows antigen HMB45 and Mart-1 expression in line Mel-XY1 and in such cell line derivative clones. The three top panels correspond to the cell line, and the three lower panels correspond to the clones. Column 1 correspond to the cell line and control clones, column 2 correspond to the cell line HMB45 expression and the clones, respectively; and column 3 corresponds to the cell line Mart-1 expression and clones.
[0034] FIG. 7 shows a melanoma biopsy from patient #100. Panel A shows a low magnification image (25×), wherein Ag gp100 positive and negative tumor cells can be seen; panel B shows heterogeneous expression of gp100, wherein cells with high, moderate, and nil expression can be seen (400×); panel C shows heterogeneous Ag MART-1 expression, where a cell clone with high expression surrounded by negative cells can be seen (400×).
[0035] FIG. 8 shows a Kaplan-Meier graph of patients treated with the Apo-Nec composition of the invention.
[0036] FIG. 9 shows dermal metastases excised from patient #200, treated with the Apo/Nec composition of the invention, in addition to GM-CSF and BCG. Panel A shows macrophages in the necrotic area of the tumor (1), infiltrated with de lymphocytes in contact with tumor cells (2), and a viable tumor area (3). Panel B is a 100× detail of the area of strong tumor infiltration, panel C is a 400× detail of the same area, wherein infiltrating lymphocytes are observed, panel D shows a detail of the same metastasis wherein most of it is necrotized with macrophages charged with melanin (1), and a viable area(2) (25×).
[0037] FIG. 10 show computerized axial tomography images from patient #300, treated with Apo-Nec composition of the invention in addition to BCG. Panel A shows with an arrow the location of lung metastasis, and panel B shows an axial tomography image taken 5 months later.
DETAILED DESCRIPTION OF THE INVENTION
[0038] As regards this application, the terms “combination”, and “mixture” are interchangeable.
[0039] Where in the present invention reference is made to compositions which modify the immune system in mammals it must be understand that these compositions are also known by skilled in the art as vaccine compositions, cell based vaccines, or simply vaccines.
[0040] The four cell lines of the invention were deposited according the Budapest Treaty with the German Collection of Microorganisms and Cell Cultures DSMZ en Mar. 23, 2007 under the following access numbers: Mel-XY1 DSM ACC2830 cell line, Mel XY2 DSM ACC2831 line, Mel XY3 DSM ACC2832 line, and Mel XX4 DSM ACC2829 line.
[0041] The results of cell line characterization assays are shown in the following Table:
[0000]
TABLE 1
HUMAN MELANOMA TUMOR CELL MARKERS
OF THE INVENTION
MARKER
XY1
XY2
XY3
XX4
Gp100 (HMB45)
ND
ND
+
+
Gp100 (PCR)
+
+
+
+
Tyrosinase
+
+
+
+
(PCR)
MART-1 (PCR)
+
−
+
−
MAGE 1 (PCR)
ND
−
+
+
S100
+
+
+
+
Vimentin
ND
+
+
+
CEA
ND
+
+
ND
GD2
+
+
+
+
GD3
+
+
+
+
P53
+
+
+
+
MIA
+
+
+
+
MCP-1
−
+
+
+
TRP-2
+
+
ND
+
MDR1
−
ND
−
−
HLA class I
A02/23
A30/33
A02/
A24(9)/A33(19)
B18/B37
B18/B65
A23
B18/B65 (14)
B18
HLA class II
DR7/DR11
DR1/DR1
DR11
DR1/DR11
DR52/DR53
DR13
DR52
Tumorigenicity
+
+
+
+
in nude
mice
Growth in
++
++
++++
++
soft agar
colonies
[0042] From the MEL-XY1 cell line characterization appears that cells grow as a heterogeneous amelanotic cell monolayer in size and shape, where most are cubic or elongated in shape, and without extensions. They are slightly melanotic at high density. MEL-XY1 cells form great amount of colonies in semi-solid agar. MEL-XY1 cells are tumorigenic in athymic mice (nude), and do not generate metastasis.
[0043] From the MEL-XY2 cell line characterization appears that cells grow as a heterogeneous amelanotic cell monolayer in size. The cells are small in size and in less number, multinucleated and with prominent nucleoli. Cells with characteristic dendritic extensions in melanoma are also seen. By growing at high density, they may pile up and develop micro-tumors. MEL-XY2 cells are tumorigenic in athymic mice (nude), and do not generate metastases.
[0044] From the MEL-XY3 cell line characterization appears that cells grow in mono-layer. Cells are uniform, small, and partly rounded. By growing at high density, they may pile up and develop micro-tumors. MEL-XY3 cells form numerous colonies in semi-solid agar. MEL-XY3 cells are tumorigenic in athymic mice (nude), and do not generate metastases.
[0045] From the Mel-XX4 cell line characterization appears that such line grows in spindle-formed mono-layer at high density. At low density, it shows dendritic projections similar to melanocytes. Cells are melanotic, and some of them have multiple nuclei with prominent nucleolus. Population duplication time is of 172-173 hours, and they form colonies in soft agar assays.
[0046] When Mel-XX4 cell line of the invention was transplanted to nude mice (immuno-depressed) tumor cell lines were generated in vivo. Serial passages from the initial tumors demonstrated that 100% of transplanted animals developed tumors during the first month. Tumor growth was slowly, and at 84 days reached an average value of 372±63 mm 3 . Cell line Mel-XX4 of the invention is tumorigenic when injecting subcutaneously an amount of 3×10 6 cells.
[0047] From the analysis of modal chromosome number, the following appears: MEL-XY1 line of the invention shows a dispersion in chromosomal count (between 105 and 110), and thus a clear modal number did not stand out (male). MEL-XY2 line of the invention shows a bimodal tendency with chromosome numbers 89 and 91 (male). MEL-XY3 cell line of the present invention shows a modal number of (male). Most frequent number alterations were chromosome absence on pairs 2 and 6, and extra chromosomes on pairs 20 and 22. MEL-XY4 cell line of the invention shows a modal number of 57-58 (female sex).
[0048] Gamma radiation inducing apoptosis in the cell lines of the invention was studied. The application of 50 Gy radiation was enough to totally suppress clonogenic capacity in soft agar for each cell line of the invention. No significant differences were observed in the apoptosis/necrosis induction degree when cells were irradiated with 70, or 100 Gy. FIG. 1A showed that non-irradiated melanoma cells contained between 6-9% early apoptotic cells characterized by Anexin-V + /IP − coloration (bottom right hand panel). After radiation at 70 Gy and 72 hr culture, 45-53% of early apoptotic cells were obtained (see FIG. 1B , bottom right hand panel). Anexin-V and IP stained necrotic cells increased from 7.5% in non-irradiated cells to about 15% in irradiated cells (top left hand panels). Thus, in reference to the present patent application, irradiated melanoma cells of the invention are called Apo-Nec cells, and the composition comprising one or more of any of the Apo-Nec cell lines (Mel-XY1, Mel-XY2, Mel-XY3 and/or Mel-XX4) is known as Apo-Nec composition.
[0049] Cell irradiation allowed to obtain cells incapable of proliferate, useful for the manufacture of compositions such as Apo-Nec composition of the invention. It shall be evident for a skilled in the art that the Apo-Nec composition of the invention may comprise any of the lines of the invention or different combinations thereof. In a preferred embodiment, composition Apo-Nec of the invention comprises a mixture or combination of Mel-XY1, Mel-XY2, and Mel-XY3 cell lines. In another preferred embodiment, composition Apo-Nec of the invention comprises a mixture, or combination of Mel-XY1, Mel-XY2, Mel-XY3, and Mel-XX4 cell lines. The mixture of the preferred Apo-Nec cell linea of the invention provides a combination of multiple antigens inducing an excellent anti-tumor immune response.
[0050] Surprisingly, the combination of tumor antigens presented by the mixture of the four Apo-Nec cell lines of the invention induce a specific T cell immune response against the tumor, and allows to obtain more than 80% of patients free of disease, when treated with Apo-Nec composition of the invention (see FIG. 8 ).
[0051] The lines of the invention were also used to prepare de composition of the invention known as DC/Apo-Nec, which comprises at least one of the cell lines of the invention and autologous dendritic cells.
[0052] In a preferred embodiment, the cell lines are different combinations of lines Mel-XY1, Mel-XY2, Mel-XY3, and Mel-XX4. As an example, and without limitation, the combination may comprise a mixture of cell lines Mel-XY1, and Mel-XY2, or a mixture of lines Mel-XY1, Mel-XX4. In a preferred embodiment, the combination of cell lines comprises a mixture of cell lines Mel-XY1, Mel-XY2, Mel-XY3, and Mel-XX4; therefore, the four cells are present.
[0053] In a preferred embodiment, composition DC/Apo-Nec of the invention comprises a combination of irradiated cell lines Mel-XY1, Mel-XY2, Mel-XY3, Mel-XX4, and autologous dendritic cells.
[0054] The particular combination of the four cell lines of the invention provides a unique source of native antigens to charge dendritic cells, additionally providing antigens of clonogenic cells. It must be taken into account that the combination of the four irradiated cell lines of the invention not only provides a particular combination of native antigens, but also comprises a particular combination of cell population, wherein about 50% of apoptotic cells, and about 15% of necrotic cells are present. This combination of populations induces maturity of DC.
[0055] Stage I study with composition DC/Apo-Nec of the invention was performed in 16 melanoma patients which characteristics are shown in Table 2
[0000]
TABLE 2
characteristics of patients
Dose of
DC/Apo-
Clinical
PBMC
Nec
evolution
Clinical
(×10 9
(×10 6
(30/3/
DTH
Patient
Sex
Age
stage
Mts
cells)
cells)
Dose
07)
score
1
F
42
IV
LN
3.5
5
4
P (8 m)
4
2
F
57
III
ND
3.6
5
4
NED
8
(54 m+)
3
M
32
III
ND
3.3
5
4
NED
14.25
(35 m+)
4
F
17
III
ND
4.4
5
4
NED
9.5
(45 m+)
5
M
56
IV
L
5
10
4
P (4 m)
4
6
M
60
III
ND
1.5
3
4
NED
4.5
(37 m+)
7
M
27
IV
SC
4.2
10
2
WP
ND
(1 m)
8
M
26
III
ND
3.6
10
4
P (7 m)
10.5
9
F
42
III
ND
7.5
15
4
NED
5.6
(71 m+)
10
M
34
IV
LN
6.2
15
4
P
5.5
(11 m)
11
M
44
IV
L
4.7
15
4
P (4 m)
10
12
M
56
III
ND
8
15
4
NED
4.5
(25 m+)
13
M
47
IIC
ND
9.3
20
4
NED
6.5
(26 m+)
14
M
30
III
ND
7.5
20
4
NED
7.25
(39 m+)
15
M
52
IV
LN
6
20
4
P
3.75
(10 m)
16
F
57
IV
SC
8.2
20
4
P (6 m)
5.25
ND: Non detectable;
SC: subcutaneous;
L: lung
LN: lymph node
[0056] Average age was 42 years (ranging from 17 to 60 years). Five women and eleven men were treated. One of the patients had stage IIC AJCC melanoma, eight had stage III melanoma, and seven had stage IV melanoma. Patients #5 and #11 had been submitted to lung metastases surgery; patient #16 had subcutaneous metastases, and patients #1, #10, and #15 had received radiotherapy in the armpit area after surgery, due to rupture of the lymphatic node capsule. Cohorts of four patients were treated and washed with 5, 10, 15, or 20×10 6 dendritic cells (CDs) co-cultured with Apo-Nec cells (composition DC/Apo-Nec of the invention). Every patient received each two weeks a dose of the composition DC/Apo-Nec (0.3 ml) without adjuvants. Patient #7 was eliminated from de protocol after a second application due to a rapid progression of the disease after a sport trauma on the right thigh, and a non-controlled infection; this patient was not replaced.
[0057] Immature dendritic cells (DCin) showed the following pattern: 95.1±3.6% were CD14 − /CD11c+, and 70±6% were CD1a + . Purity was esteemed in about 60%.
[0058] About 3×10 6 DCs were obtained from 1×10 8 PBMC sown in medium free from serum.
[0059] When DCin obtained from patients, and the cells comprised in the composition DC/Apo-Nec of the invention were characterized it was found that 42.3%±13.7 of Dcin cells from patients (n=15) were able of fagociting Apo-Nec cells of the invention. Phagocytosis of Apo-Nec cells was assessed by electronic microscopy, observing whole Apo-Nec cells or parts of them within DCs in vacuoles.
[0060] The ability of the Apo-Nec cells of the invention to affect the maturation process of the monocyte derivative DC cells was examined trough measurements of specific DC cell markers by flow cytometry (FACS) (FACSCalibur, BD Biosciences, San Jose, Calif.). Phagocytosis of the Apo-Nec cells of the invention resulted in a DC cell mature phenotype compared to controls incubated with LPS. DC cell maturity was evidenced by the increase of CD83, CD80, CD86, HLA class I, and II and CD40 expression. After phagocytosis, a 75.2%±16 reduction in endocytosis FITC-Dx was found, compared to DCin.
[0061] The chemokine receptor (C-C motif) receptor 7 (CCR7) increased its expression in DCs after phagocytosis of Apo-Nec cells of the invention in all patients, and this was related to CD cell migration in vitro towards MIP-3β. DCin cells (9.6% CCR7+, MFI: 23.3) migrated towards MIP-1α but not towards MIP-3β; in contrast, DC/Apo-Nec cells (81.8% CCR7+, MFI: 41.2) clearly migrated towards MIP-3β, and not towards MIP-1α.
[0062] Except patient #6, which showed low PBMC yield, and thus the 10×10 6 DC/Apo-Nec cell dose could not be obtained, and doses of 3×10 6 cells per application had to be administered, all remaining patients received the expected dosage of the DC/Apo-Nec composition of the invention cohort 1: 5×10 6 , cohort 2: 10×10 6 , cohort 3: 15×10 6 , and cohort 4: 20×10 6 . The DC/Apo-Nec composition of the invention was well tolerated, and mean toxicity cases found were always of Degree 1. Weak local reactions and DTH were found in the application sites, consisting in erythema, and papule. None of the patients developed autoimmune disease manifestations (Table 3).
[0000]
TABLE 3
Toxicity associated to application of the DC/Apo-Nec
composition of the invention
Composition
Composition
Composition
Composition
Symptoms
5 × 10 6
10 × 10 6
15 × 10 6
20 × 10 6
Fatigue
1/4
1/3
0/4
0/4
Headache
1/4
0/3
0/4
0/4
Chills
1/4
0/3
0/4
0/4
Abdominal
0/4
0/3
0/4
1/4
cramps
Local
4/4
3/3
4/4
4/4
reaction
Asthenia
0/4
1/3
0/4
0/4
Nausea
0/4
0/3
0/4
1/4
Abdominal
0/4
0/3
0/4
1/4
pain
Vomiting
0/4
0/3
0/4
1/4
Anorexia
0/4
1/3
0/4
0/4
Diarrhea
0/4
0/3
0/4
1/4
Myalgia
1/4
0/3
1/4
0/4
[0063] After a mean follow-up of 41.5 months post-surgery (between 25 and 71 months), stage IIC patients showed no evidences of disease (NED); 7/8 (87.5%) of stage III patients were NED, and 7/7 of stage patients IV showed progression of the disease (see FIG. 2 ).
[0064] DTH reactions were assessed for each application to heterologous cells Apo-Nec of the invention and the intensity of the reaction was assessed, with the DTH score as described in the examples. Only 6/15 patients showed a slight DTH reaction before application against Apo-Nec cells of the invention. DTH assays disclosed that the application of Apo-Nec cells induce a specific reactivity in all patients, since the DTH score was significantly higher after the application of the second dose of the DC/Apo-Nec composition, compared to base reactions observed after the first application (Mann Whithney test P=0.029, n=15). DTH scores were higher in the NED patients than in those experiencing progression of the disease (P=0.28, Mann Wilcoxon Rank Sum test).
[0065] The increase of the amount of DC/Apo-Nec cells per application did not significantly increase DTH score.
[0066] No humoral response against living melanoma cells comprised in the composition of the invention was observed before and after the application, assessed through FACS analysis. Presence of reactive antibodies against Apo-Nec cells was also assessed in serum pre and post application, by the Western blot technique. In four patients (#3, #4, # and #16) only a tenuous band of melanoma protein (>200 kDa) was observed and detected in post-application serum, and which was not recognized in the breast cancer cell extracts used as non-specific control.
[0067] An autologous melanoma cell line was established for patient #1, and thus the likelihood of the application in such patient of the DC/Apo-Nec cells inducing an lymphocyte proliferation response against the own tumor cells could be assessed. Lymphocyte proliferation was assessed after 5 days lymphocyte incubation pre- and post-application with Apo-Nec#1 cells (irradiated tumor cells from patient #1 obtained as described in the examples). FIG. 3 shows that lymphocyte proliferation post-application as a response to DC/Apo-Nec#1 cells was higher compared to lymphocytes pre-application, which suggests that specific immunization to tumor antigens presented by Apo-Nec cells exists, which is also present in the patient #1 tumor after the application of DC/Apo-Nec cells.
[0068] Seven of the 15 patients enrolled in the study had haplotype HLA-A*0201 class I, and this allowed to study the restrictive HLA tumor-specific response in their own PBMC samples. Anti-gp100 response, and specific Melan A/MART-1 CD8+T cells induced by the CD/Apo-Nec composition were assessed through the specific link of HLA tetramers/peptides, and the secretion de IFN-γ measured by ELISpot, directly in the peripheral blood samples.
[0069] 15/7 patients, sufficient PBMC were obtained pre (7 days before the first application) and post (15 days after the fourth application) in order to analyze presence of specific CD8+T lymphocytes reactive to gp100, and Melan A/MART-1 by stain of tetramers. Results are shown in FIG. 4 A. Patients #2 and #6 increased significantly the frequency of gp100 and Melan A/MART-1 specific CD8+T cells after application above 1%, and they were still NED (53, and 36 months, respectively, after the surgery), while patients #5, # 8, and #16 reduced the pre-application tetramer coloration, and all of them progressed in the disease after the application ( FIG. 3 A). An example is shown in FIG. 4 B, with the results of patient #2. The percentage of CD8+T cells recognizing gp100, or Melan A/Mart-1 peptide increased after the application from 0.17 and 0.26 to 1.15, and 1.16, respectively. No reactivity was observed in an experiment performed in the same conditions with healthy positive HLA-A*0201 donors.
[0070] Release of IFN-γ was analyzed in an ELISpot of total PBMC pre and post-application after 24 hrs incubation with autologous DCs cells pulsed with gp100 or Melan A/MART-1, and using influenza peptides as control (flu 58-66 ). This assay was evaluated in 5/7 HLA-A*0201 patients. It was observed that two patients (#5 and #16) induced IFN-γ after the application of the DC/Apo-Nec composition of the invention, secreted by specific CD8+T cells for gp100, and Melan a/MART-1. In patients #5, and #16, frequencies of 7-3.5×10 −4 CD8+T cells secreting IFN-γ were induced. In patient #2, a great amount of specific CD8+T cells for gp100, and Melan A/MART-1 were found before and after the application. This patient is still free from disease, 54 months after surgery. Patients #8, and #15 showed a low amount on base point (pre-application) and no changes were observed after four applications with the DC/Apo-Nec composition of the invention.
[0071] Balance between IL-12 e IL-10 in the DC/Apo-Nec cells of the invention was quantified by FACS in differentes times after phagocytosis, and followed by 8 hours treatment with Brefeldin A in order to accumulate cytokines intra-cytoplasmically. As shown in FIG. 5 , only 6.1% of DCin produce IL-12, but after 32 hrs. From co-culture, 30.8% of DC/Apo-Nec cells was induced to produce IL-12. On the other hand, 81.6% of the DCin contained cytokines in the cytoplasm, and they were not modified after phagocytosis. Double positive cells producing IL-10 e IL-12 were 27.8% at 24 hours (see FIG. 5 ).
[0072] The DC/Apo-Nec composition of the invention was safe, and well tolerated by the patients.
[0073] The DC/Apo-Nec composition of the invention induced cell responses in patients, since the DTH reaction using Apo-Nec cells as immunogens increased in all patients after the second application, compared to base values.
[0074] 85% of patients (stage IIc, and III) treated with the DC/Apo-Nec composition of the invention are free of disease after an average follow-up of 41.5 months, when treated after surgery (see FIG. 2 ). The DC/Apo-Nec composition of the invention is useful per se for the treatment of patients with melanoma, and is also useful as adjuvant after radical treatments, since it stimulates an immune response in the patient, where the immune system deletes all residual tumor cells, protecting the patient against possible recurrences. More specifically, the DC/Apo-Nec composition of the invention is useful for treating patients in stages IIB, IIC and III, who contain less tumor mass, and it is useful as adjuvant after radical therapies for stage IV patients.
[0075] It is evident for a skilled in the art that the DC/Apo-Nec composition of the invention may be used in treating human melanoma; it may also be used as adjuvant together with other treatments, and as immune system stimulant, for example depending on the stage of the patient and the stage of the treatment.
[0076] Importantly, it must be pointed out that the combination of Apo-Nec cells of the invention induces maturity of autologous DC cells. The mixture or combination of Apo-Nec cells of the invention is a good source of melanoma antigens to charge dendritic cells. Note that dendritic cells only mature by contacting, and phagocyting the combination of Apo-Nec cells of the invention, without adding an extra stimulus such as, for example Interleukine 1, Tumor Necrosis Factor α, CD40 ligand, or Prostaglandin E, which are commonly used as a maturation cocktail. DCs phagocyting the Apo-Nec cells of the invention increase migration in vitro in response to chemokine MIP-3β, and intracellular production of IL-12. The DC/Apo-Nec dells of the invention are capable of presenting crossed native tumor antigens to specific CTL antigens.
[0077] As mentioned above, phagocytosis of Apo-Nec cells by DCin of each patient induced maturity of such DC.
[0078] On the other hand, the cell lines of the invention were analyzed for their clonogenic ability. MEL-XY3 cell line colonies of the invention in soft agar present an heterogeneous morphology, with low adhesion between cells. A low proportion of melanotic colonies is observed. MEL-XY1 cell line colonies of the invention in soft agar present a compact morphology, with high adhesion between the comprised cells. Melanotic colonies are seldom observed.
[0079] As a way of characterizing colonies, the melanoma antigen expression levels were compared, normalized to the expression of β-actin in the cell lines of the invention, and in such cell line colonies in soft agar. Clone characterization results are found in Table 4, and FIG. 6 .
[0000]
TABLE 4
Comparative study of antigen expression between cell lines
of the invention, and clonogenic lines of the invention.
Melanoma
Cell lines
differentiation
MEL-XY3
MEL-XY3
MEL-XY1
MEL-XY1
antigens
line
colonies
line
colonies
MART1
+++
+
+
+
MAGE1
+
ND
+
ND
NYESO-1
++++
+
+
+
GP100
+
++
+
+
TYR
+
ND
+
ND
TRP2
+*
+*
+*
+*
B-ACTIN
+
+
+
+
ND: non-determined
*Data not yet normalized
[0080] As may be observed, within the population, and each cell line of the invention a sub-population of de clonogenic cells exists, and these clonogenic cells are also included in the scope of the present invention. The presence of clonogenic cells may provide the patient with typical antigens of undifferentiated cells, also called stem cells.
[0081] The heterogeneity of melanoma tumors is high, therefore for immuno-therapy it is fundamental to use complex antigen mixtures provided by the mixture, or combination of cell lines and their sub-populations. As an example, FIG. 7 shows a primary melanoma biopsy evidencing the heterogeneity of such tumors compared to the expression of melanocytic differentiation antigens.
[0082] When patients were treated with the Apo-Nec composition of the invention together with BCG as adjuvant, and GM-CSF as immuno-modulator according to the scheme disclosed below in the examples, it was observed that 75% of patients (stages IIC and III) were free of disease with a maximum follow-up of 51 months (see FIG. 8 ), and toxicity was low, and only of degree 1.
[0083] Exemplary results from one selected protocol patient are shown. Patient #200 is female, Caucasian, 67 years old, appeared in November 2003. In June 2002, she was subjected to surgery on an increased dorsal nevum. Histology disclosed a cutaneous melanoma, Clark's level IV, Breslow's level 5.7 mm. In August 2002, some satellitoses were detected, which were excised. Patient was administrated Apo-Nec+BCG+GM-CSF, receiving 600 μg GM-CSF (per composition) and finished treatment with little toxicity. At the last clinical examination, a suspected node was detected on the back, which was excised, and the microscopic image is shown in FIG. 9 . Intensive lymphoid infiltration is observed, with viable tumor areas remaining, but also intensive tumor tissue necroses, and the presence of macrophages charged with melanin.
[0084] As an example, the results in a patient treated with the Apo-Nec composition of the invention+BCG+IFN-α are also shown. Patient #300 is male, 17 years old, who appeared with left inguinal adenopathy. Two months later, another left inguinal excision was performed, where 4/11 nodes with melanoma metastases were obtained. He received treatment with interleukin-2 in low doses.
[0085] 14 months after the second excision, recurrence was detected in left inguinal arch, and again a surgery was performed, where 5/7 nodes with melanoma metastases where isolated. The patient presented back pain. Computed axial tomography disclosed retroperitoneal adenopathies, and chemotherapy with Dartmouth scheme was performed. After finishing chemotherapy, he began treatment with Apo-Nec composition of the invention+BCG. 14 months after beginning treatment with the composition of the invention, a node was detected in the left inguinal area. He was subjected to surgery, and melanoma metastases were detected with large lymphoplasmocyte infiltration. The patient continued treatment with Apo-Nec composition+IFN-α. FIG. 10 shows the remission of a left lung node. Currently, the patient is disease-free.
[0086] The present invention discloses melanoma cell lines, which in combination express most melanoma-associated antigens, compositions comprising such irradiated lines, and compositions comprising autologous DC generated ex vivo, which have phagocyted a mixture of apoptotic/necrotic cells of the melanoma cell lines.
[0087] This invention is better illustrated according to the following examples, which must not be understood as a limitation imposed to its scope. On the contrary, it must be clearly understood that other embodiments, modifications, and equivalents may be referred, which after reading the present description, may be suggested to skilled in the art without leaving the spirit of the present invention and/or the scope of the attached claims.
Example 1
Obtaining, Establishment, and Maintenance of Cell Lines of the Invention
[0088] Mel-XY1: Line Mel-XY1 was obtained from a male Caucasian patient, from a lung metastasis secondary to a primary melanoma on the back. The patient died two years later due to brain metastases.
[0089] Mel-XY2: The patient from whom the line originated was 44 years old, and was a Caucasian male who presented ulcerated melanoma on the back (Clark's level III). Two years later, he developed simultaneous axillary adenopathies, and lung metastases. The axillary adenonopathies were excised, dissociated, and such cells gave rise to the cell line.
[0090] Mel-XY3: The patient was a Caucasian 43-year-old male, who had developed a primary arm melanoma. Two years later, axillary lymphatic node metastasis appeared. The patient received chemotherapy with DTIC, without apparent clinical response. The axillary metastases were excised, and the cells gave rise to cell line Mel-XY3.
[0091] Mel-XX4: It was obtained by surgery of an inguinal adenopathy in a white 33-year-old woman, where such adenopathy was diagnosed as melanoma metastasis. The primary tumor was unknown. Fifteen months later, the patient had a recurrence in the inguinal lymphatic node. The gross melanotic node was excised, cut into small pieces, the fat and connective tissue were removed, and was suspended in Dulbecco modified by Eagle's Medium (DMEM), mechanically separated by pressure on a nylon mesh, and the cell aggregates were treated enzimatically overnight at 37° C.
[0092] The cells were re-suspended in melanoma culture medium supplemented with 10% fetal bovine serum (FBS) (Natocor, Cordoba, Argentina), sown in 25 cm 2 culture flasks, and incubated at 37° C. with humidity, and a 5% CO 2 -95% atmosphere in air. After 24 hrs, the culture medium was removed in order to eliminate non-adhered cells.
[0093] The cell suspension was passed four times through anti-fibroblast micro-sphere columns (Miltenyi Biotec, Germany). The cells obtained were named Mel-XX4
[0094] Maintenance of the four cell lines of the invention (Mel-XY1, Mel-XY2, Mel-XY3, and Mel-XX4) was done through culture in melanoma medium DMEM: F12 nutritive mixture (1:1) supplemented with 2 mM glutamine, 20 nM sodium selenite, 100 μM ascorbic acid, 0.3 mg/ml galactose, 0.15 mg/ml sodium piruvate, and 5 μg/ml insulin), 100 IU/ml penicillin, 10 μg/ml streptomycin, in addition to 10% fetal bovine serum (FBS) (Natocor, Cordoba, Argentina) at a GMP laboratory of Centro de Investigaciones Oncológicas-FUCA.
[0095] Clones CTL (restricted HLA A*0201) specific for Melan A/MART-1 (M27: AAGIGILTV), and gp100 (G154: KTWGQYWQV) antigens were expanded in RPMI medium with 10% inactivated AB human serum, and antibiotics, in 14-days-cycles using 30 ng/ml antibody anti-CD3 (OKT-3, BD Biosciences), and series of 300 UI/ml IL-2 (Chiron BV, Amsterdam, Netherlands) every 3 days.
Example 2
Cell Line Characterization
Growth Kinetics In Vitro:
[0096] 10 4 cells were cultured by well in 24-well plates (Corning). Every 2-3 days, the cells were treated with EDTA (0.02%), harvested, and counted. The population duplication time was esteemed from the growth curve slope during the exponential phase.
[0097] Clonogenicity
[0098] Anchoring-independent cell growth was determined by the soft agar method (Hamburger, and Slamon, Science 197: 461, 1977). 3-10×10 3 cells were cultured in the upper layer. The plates were incubated for 21 days, and then fed each day with 50 μl culture medium. Colonies with over 36 cells were counted under the microscope.
[0099] Characterization of Melanoma Antigens by Immuno-Citochemistry (ICC) and FACS
[0100] For the ICC evaluation, the exponentially growing cells were treated with EDTA, centrifuged, fixed with formaldehyde, embedded in paraffin, and cut into fine sections. Normal tissue samples from the patient were used as control.
[0101] Tissues and cells were assayed with monoclonal antibodies (Mabs) against keratins, vimentin, and gp100/HMB (Biogenex), MART1/Melan-A (Dako), and with polyclonal antibodies anti-S100 (Biogenex).
[0102] Reactions were visualized with avidin-biotin complexes (Vectastain ABC). Endogenous peroxides were blocked with 0.6% H 2 O 2 .
[0103] Indirect immunofluorescence reactions were carried out by re-suspending EDTA-treated cells. After blocking with normal goat serum diluted 10%, the cells were incubated with primary antibodies, washed, incubated with secondary antibodies (FITC anti-mouse goat immunoglobulin (Dako), washed, fixed in 1% para-formaldehyde, and analyzed by FACS (FACS Vantage SE, Becton-Dickinson, USA). Primary antibodies were murine anti-p53 Mabs (DO-7, BD Pharmingen), 3F8 anti-GD2, R24 anti-GD3. In the case of p53, the cells were permeatized. Human leukocyte antigens (HLA) Class I, and Class II were typified by PCR-SSP.
[0104] Melanoma Associated Antigen Determination by RT-PCR:
[0105] Total RNAS was extracted with Trizol (Invitrogen). In order to initiate cADN synthesis, the appropriate primers were added to 1-3 μg RNA, and incubated with 200 U MMLV-RT enzyme (Promega), 25-40 U RNAsin (Promega), and 250-500 μM dNTPs (Invitrogen) for 5 min at 70° C., and then for 60 min at 42° C. cDNA aliquots (2-10 μl) were amplified with Taq DNA polymerase (Invitrogen), using specific pairs or primers.
[0106] Specific primers are shown below:
[0000]
Gp100
5′-GCTTGGTGTCTCAAGGCAACT-3′
(SEQ ID N o 1)
5′-CTCCAGGTAAGTATGAGTGAC-3′
(SEQ ID N o 2)
MART-1
5′-CAAGATGCCAAGAGAAGATGCTCACT-3′
(SEQ ID N o 3)
5′-GCTTGCATTTTTCCTACACCATTCCA-3′
(SEQ ID N o 4)
Tyrosinase
5′-TTGGCAGATTGTCTGTAGCC-3′
(SEQ ID N o 5)
5′-AGGCATTGTGCATGCTGCTT-3′
(SEQ ID N o 6)
5′-GTCTTTATGCAATGGAACGC-3′
(SEQ ID N o 7)
5′-GCTATCCCAGTAAGTGGACT-3′
(SEQ ID N o 8)
TRP-2
5′-GAGTGGTCCCTACATCCTACG-3′
(SEQ ID N o 9)
5′-GCGTCCTGGTCCTAATAATGT-3′
(SEQ ID N o 10)
MAGE-1
5′-GAGTCCTCAGGGAGCCTCC-3′
(SEQ ID N o 11)
5′-TTGCCGAAGATCTCAGGAAA-3′
(SEQ ID N o 12)
NY-ESO-1
5′-AGCCGCCTGCTTGAGTTCTACCTC-3″
(SEQ ID N o 13)
5′-AGGGAAAGCTGCTGGAGACAG-3′
(SEQ ID N o 14)
MDR-1
5′-TCCAAGAAGCCCTGGACAAAG-3′
(SEQ ID N o 15)
5′-TTGATGATGTCTCTCACTCTGTTCC-3′
(SEQ ID N o 16)
MIA
5′-CATGCATGCGGTCCTATGCCCAAGCTG-3′
(SEQ ID N o 17)
5′-GATAAGCTTTCACTGGCAGTAGAAATC-3′
(SEQ ID N o 18)
β-actin
5′-ATGTTTGAGACCTTCAACACCCC-3′
(SEQ ID N o 19)
5′-GCCATCTCTTGCTCGAAGTCCAG-3′
(SEQ ID N o 20)
[0107] Anti-sense primers are shown in the lower line.
[0108] For tyrosine detection, a 1/100 aliquot from the first PCR reaction with internal primers (nested PCR) was also amplified.
[0109] PCR products were analyzed in agarose gels, and stained with ethidium bromide; the size of the fragments was calculated by comparison with the rum sown with 100 by DNA PM markers (Promega).
[0110] Cytogenetic, and Cytomolecular Analysis:
[0111] Cells corresponding to the four lines of the invention were incubated for cytogenetic analysis in exponential growth colchicine (0.1 μg/ml) at 37° C. for 8-16 hrs, collected with a Trypsine-EDTA solution, and processed according to standard protocols. The G-band technique was used. Chromosome identification was done according to International System for Human Cytogenic Nomenclature (Mitelman, 1995 ISCN.: An International System for Human Cytogenetic Nomenclature, (ed. S Karger, Basel).
Example 3
Generation of Dendritic Cells (DC) from Monocytes, Characterization Thereof, and Charge with Apo-Nec Cells
[0112] The dendritic cells were obtained form buffy-coats or leukopheresis products from healthy donors. Peripheral mononuclear cells (PBMCs) were purified with a Fycoll-Hypaque density gradient. PBMCs were suspended in fresh AIM-V™ serum-free medium (Invitrogen), and were left adhering in culture flasks (TPP, Germany). After 2 hrs at 37° C., non-adherent cells were removed, and adhered monocytes were cultured for 5 days in AIM-V supplemented with 800 U/ml rhuGM-CSF and 50 ng/ml IL-4 (Peprotech, Mexico), thus obtaining CDin. Phenotype changes were analyzed by light microscope and FACS. To induce DCin controlled maturation 2 μg/ml LPS ( E. coli J5 lipopolysaccharides, Sigma, St. Louis, Calif.), and finally cells were cultured for 48 hrs.
[0113] DC cell phenotype characterization was performed when cells were in immature state (DCin), and after apoptotic/necrotic cell (Apo-Nec cells) phagocytosis assays through staining of 5×10 5 cells with antibodies marked with fluorochromes against CD14, CD11c, CD1a, HLA class II, CD80, CD86, CD83, CD40, HLA class I, and CCR7 antigens (BD Biosciences, San Jose, Calif.), through FACS analysis (Becton Dickinson, San Jose, Calif.). Appropriate iso-type controls were rat IgG2a PE, and mouse IgG1 and IgG2a (BD Biosciences, San Jose, Calif.). The expression of CD83 in DCs phagocyting Apo/Nec cells was also analyzed, employing non-marked monoclonal antibody anti-CD83 (IgG1), and the appropriate iso-type as control; for developing, an anti-mouse IgG1-PerCP (BD Biosciences, San Jose, Calif.) was used.
[0114] DC endocytosis capacity was assessed by incubating 1×10 6 DCs with 1 mg/ml conjugated Dextran with FITC (Dx-FITC) (Sigma, St Louis, Calif.) for 30 min at 37° C. After incubation, the cells were washed with PBS, and analyzed by FACS. Controls included DCs incubated with Dx-FITC for 30 min at 4° C. in order to inhibit the endocytosis process; on the other hand, basal incorporation basal was considered at time 0 of the assay. DX-FITC incorporation (endocytosis) was quantified by FACS.
[0115] Assessment of DC Cell Phagocytosis:
[0116] DCin cells were co-cultivated with Apo-Nec cells (prepared as shown above) in fresh AIM-V medium on different times. In some assays, DCs were stained red with PKH26, and the Apo-Nec cells were stained green with PKH67 (Sigma, St. Louis, Calif.). Analysis by FACS was performed after co-culture, and the percentage of DCs phagocyting Apo-Nec cells was defined as the percentage of double positive cells. Appropriate controls were performed for each color. The control of non-specific bond of Apo-Nec cells with DCs was performed by incubating cells at 4° C. for the same periods of time.
[0117] DCs In Vitro Migration:
[0118] DCs in vitro migration was assayed before and after co-culture with Apo-Nec cells, using 48-well chemotaxis chamber (AP 48 Neuroprobe Inc., Gaithersburg, Md.). 10 ng/ml de MIP-1α, or MIP-3β (Peprotech, Rocky Hill, N.J., USA) diluted in RPMI were placed in the bottom compartment. Basal migration was assayed by placing RPMI in the lower chamber. DCs were sown in the upper chamber (3×10 4 CDs/well) in RPMI. A 5 μm-pore poly-carbonate membrane was placed between the upper and the lower chamber (Neuroprobe, Inc., Bethesda, Md.). After 90 min at 37° C., cells of the upper side of the membrane were removed, and cells migrating adhered to the lower side of the membrane were stained with Giemsa 10% diluted in neutral water. Membranes were air-dried, mounted on a slide with Canada balsam, and the migrating runs were counted using a microscope. Five fields per well were analyzed with 40× magnification, and 3 wells/condition were analyzed. Statistical analysis was performed by Student's Test.
[0119] Electronic Microscopy:
[0120] The phagocytosis process was also studied by electronic microscopy. Co-culture samples were fixed with 2,5% glutaraldehyde in 0.1 M phosphate buffer, and the post-fixation staining with 1% osmium tetroxide was carried out, they were washed twice with distilled water, and counter-stained with 5% uranil acetate for 2 hr. After washing, and dehydration, the samples were embedded in resin (Durkupan). Ultra-thin sections were obtained (70-90 nm), mounted on copper meshes, and counter-stained with Reynold's lead citrate. Meshes were analyzed in a Zeiss 109 transmission electronic microscope. Alternatively, in order to obtain figures of the complete cells, thin sections (0.5 μm) were obtained in a ultra-microtome (Reichert-Jung), stained with 0.4% toluidine blue, 0.1 M carbonate buffer, mounted on Durkupan, and analyzed with light microscope (1000×). Images were obtained with a Sony Cybershot Digital digital camera (5 megapixels), and processed with Adobe photoshop 6.0 program.
[0121] In Vitro Cross Presentation Assay, IFN-γ Secretion:
[0122] 98% CD14+ monocytes were purified from HLA A*0201 donors using anti-CD14 micro-spheres (Miltenyi Biotec, Germany), and differenciated to DCin cells by 5 days culture as described above. DCin cells were incubated with Apo-Nec cells for 6, 12, 24, and 48 hrs, and exposed overnight to specific CTL MelanA/MART-1, or gp100 clones in ml AIMV medium. IFN-γ secretion to supernatant was determined in triplicate by the ELISA technique (OptEIA IFN-γ, Pharmingen BD Biosciences, San Diego, Calif.) according to the supplier's suggestions. A calibration curve was drawn for each experiment, and sample concentration was calculated using a log-log regression analysis, and using Cembal 2.2 software. Controls included: DCs plus 20 μg/ml MART-1 or gp100 peptides, HLA A*0201 + viable melanoma cell lines expressing MART-1, and gp100 antigens (positive controls) or DCs cells cultivated with non-specific peptides, and HLA A*0201 + viable melanoma cell lines not expressing the appropriate antigens (negative controls).
[0123] Measurement of Introcytoplasmic Cytokines IL-10 e IL-12:
[0124] DCs marked with PKH26 (red) were co-cultured with Apo-Nec cells marked with PKH67 on different times (6, 12, 24, and 48 hrs). Accumulated cytokine measurement was done by the intracellular immunofluorescence technique, after blocking the output thereof with Brefeldin A (8 hrs) post-culture (Golgi Plug, BD Biosciences, San Jose Calif.). The cells were permeatized with 0.05% saponin, and stained with anti-IL10 (rat isotype IgG2a)-APC, and anti-IL12 sub-unit p40-p70 (mouse isotype IgG1)-PerCp (BD Biosciences, San Jose, Calif.). Double stained PKH26/PKH67 population was selected for studies by FACS, and cytokines were assessed for such population in a four color experiment. Co-culture at 4° C. was used as control.
Example 4
Preparation of Compositions of the Invention, and Application Schemes
[0125] Apo-Nec Composition:
[0126] Irradiation of Cell Lines:
[0127] The four cell lines of the invention (Mel-XY1, Mel-XY2, Mel-XY3, and Mel-XX4) were irradiated with gamma radiation at 70Gy (Siemens, Instituto Alexander Fleming, Buenos Aires, Argentina), subsequently the cells were frozen (50% DMEM, 40% human albumin, and 10% DMSO) in liquid nitrogen until use.
[0128] The day of cell application, they were thawed, washed, and prepared in composition doses containing between 5-10×10 6 cells of each of the isolated cell lines of the invention, or combinations thereof, re-suspending them in DMEM medium.
[0129] 300 ul were injected intradermally.
[0130] DC/Apo-Nec Composition:
[0131] Preparation of Apoptotic/Necrotic Tumor Cells:
[0132] Irradiated and frozen cells (Mel-XY1, Mel-XY2, Mel-XY3 and Mel-XX4) as described above were thawed and sown in melanoma medium plus 10% fetal bovine serum until complete apoptotic process. After 72 hrs culture, the cells were detached from the bottom of the flasks, washed, counted, and re-suspended in fresh AIMV™ medium free of serum (therapeutic grade, GIBCO, Invitrogen Corporation, Grand Island, N.Y.). Apoptosis and necrosis was assayed by the Anexin-V FITC link technique, and incorporation of propidium iodide (IP) (Anexin-V apoptosis detection kit, BD Biosciences, San Jose, Calif.), and analyzed by FACS. Clonogenig assays in soft agar were performed in sextuplicate (1.5×10 4 cells/well) in order to analyze proliferation capability in irradiated cells, compared to non-irradiated control cells.
[0133] 5, 10, 15, o 20×10 6 DCs, according to each patient's dose, were co-cultured with Apo-Nec cells in AIMV medium for 48 hrs at 37° C. On application day, co-cultivated cells were centrifuged at 1200 rpm for 5 min, re-suspended in DMEM medium (300 μl), and injected intra-dermically in one of the four extremities with intact drainage of lymphatic nodes.
[0134] Quality controls, and sterility assays were done for all composition preparations.
Example 5
Patient Study Design, and Selection Criteria
[0135] Studies in patients were carried out to assess toxicity, viability, and immune response to treatment. The studies were approved by the Institutional Revision Council of Instituto Alexander Fleming, and by an ethics commission. Viability criteria were (a) cutaneous melanoma, confirmed by histology in stages IIB, IIC, III, or IV (AJCC); (b) patients with minimal or non-detectable disease (ND) after surgery, assessed Computed Axial Tomography, and lactate dehydrogenase (LDH) enzyme values. Patients with unknown primary melanoma could be included in the study; (c) age between 15, and 60 years; (d) life expectation >6 months; (e) yield (ECOG) 0, o 1; (f) patients of stage III preciously treated with IFN-α who had finished or interrupted treatment due to disease progression, toxicity, or any other clinical cause, or patients who had not initiated treatment with IFN-α six months prior to the surgery; (g) adequate venous access for the leukopheresis procedure, (h) laboratory election criteria were: hemoglobin >10 gr %; white blood cell count >4800/mm 3 , platelets >150,000/mm 3 ; total and direct bilirrubin, oxalacetic transaminases, glutamic-piruvic transaminase <1.5 times normal highest value; LDH 450 mU/ml; i) non-pregnancy, with serum β-HCG determined one week before each application in pre-menopausal women; (i) creatinine <1.4 mg %; (k) no chemotherapeutic, radiotherapy treatment, or biological treatment for the previous month; (k) no medication with corticosteroids, or non-steroid anti-inflammatory medication (AINEs); (1) no active brain metastasis; (m) normal ECG; (n) all patients had to sign informed consent.
[0136] Patient Assessment and Treatment Scheme:
[0137] Patient basic assessment was done within 35 days before the first application. Clinical evaluation included complete clinical history, physical exam, electrocardiogram (ECG), Computed Axial Tomography (thorax, abdomen, pelvis, and brain), determination of tumor stage, tumor size, and documentation of sites of disease, chemical blood test, and hematology. The selected patients were subjected to leukopheresis in order to obtain PBMC, to generate DCs.
[0138] Patients received 4 applications of DC/Apo-Nec with 2 weeks intervals. Inoculation was done intradermally (300 μl), and with each dose DTH test were assayed consisting in inoculation in the forearm of between 5, and 20×10 6 DC/Apo-Nec cells without adjuvant. Vital signs and DTH skin reactions were analyzed at 2, 24, and 48 hrs post-application. Patient status was investigated on day 70 by abdominal ultrasonography, and thorax X-rays, and the protocol was ended on day 75 with a clinical exam.
[0139] For the application of Apo/Nec cells of the invention, patients were injected intradermally (id) in one extremity with intact lymphatic nodes. Twenty (20) patients received a 400 μg rhGM-CSF dose (100 μg per day, four days). On the day of application, 0.1 ml hGM-CSF were mixed with Apo-Nec (16×10 6 irradiated cells in 0.3 ml), and BCG (1×10 6 colony forming units) in 0.05 ml. During the following 3 days, 0.1 ml rhGM-CSF were injected i.d. on the application site. Each patient received 4 applications separated by 3 weeks, then 1 composition every two months for a year, 1 composition every three months the second year, and continued afterwards with 1 composition every 6 months.
[0140] Statistical Analysis:
[0141] All adverse results were classified according to Common Toxicity Criteria for National Cancer Institute (NCI).
[0142] The assessable population was defined as all patients receiving the four applications. Since most patient data were not normally distributed, the total data were analyzed using the Wilcoxon's Rank Sum test. DTH values of the different groups receiving different amount of DCs/Apo-Nec were compared between each group with one variable ANOVA, and the Dunnett multiple comparison test. A P<0.05 value was considered significant.
[0143] Methods to Evaluate Immune Response of Treated Patients:
[0144] To evaluate patient immune response, serum was obtained on day 7 before application (pre-serum), and day 15 after finishing treatment (post-serum), and the samples were stored at −80° C. PBMC cells were purified by a Ficoll-Hypaque gradient, and subsequent centrifugation form leukopheresis (pre-application), or from 100 ml blood obtained 15 days after the last dose (post-application), PBMC were frozen in 50% DMEM, 40% human albumin, and 10% DMSO until use in immunologic assays. HLA-A*0201 HLA typification was determined after incubating patient samples with mouse anti-HLA*A0201 monoclonal antibodies conjugated with FITC (BD-Pharmingen, San Jose, Calif.).
[0145] DTH Reaction:
[0146] On each application day, a DTH test was done in the forearm with 2×10 5 Apo-Nec cells, and the reaction was evaluated at 2, 24, and 48 hrs post-application. DTH intensity value was established as follows: 0: erythema <0.5 cm; 1: macular erythema 0.5-1.0 cm; (2) macular erythema 1.0-2.0 cm; 3: macular erythema >2.0 cm, or papular erythema <1.5 cm; 4: papular erythema >1.5 cm. Store DTH corresponds to the sum of all individual DTH intensities/4.
[0147] Proliferation Assay:
[0148] Pre- and post-composition PBMC were obtained by a Ficoll-Hypaque density gradient, and stored frozen in liquid nitrogen until use. The cells were thawed for the assay, and incubated in AIM-V medium (Gibco, Grand Island, N.Y.) for 1 hr at 37° C. 5×10 5 cells were sown in 96-well plates in the presence or in absence of phyto-hemoaglutinin (PHA) (5 μg/ml) (Gibco, Grand Island, N.Y.), and incubated at ° C. for 72 hrs. During the last 16 hrs, the cells were pulsed with (3H)dThd (Amersham, 1 μCi/well), and after cell lysis, the DNA incorporated radioactivity was measured (Cell Harvester, Nunc, Rochester, N.Y.), with a liquid scintillation counter.
[0149] Determination of Cytokines:
[0150] Patient serum IL-10 and IL-12 concentrations were determined before the application (pre-application serum), and two weeks after the fourth application (post-application serum). Sera were frozen at −80° C. until ELISA assay (OptEIA IL-10 and IL-12, BD Biosciences, San Diego, Calif.) was performed. A calibration curve was drawn for each assay, and the sample concentration was calculated by log-log linear regression analysis using Cembal 2.2 software.
[0151] Measurement of IFN-γ by ELISpot Technique:
[0152] CD14 + cells were purified as stimulators from PBMC from HLA-A2 positive patients using micro-spheres covered by anti-CD14 (Miltenyi Biotec, Paris, France), cultivated 5 days in synthetic SYN-H medium (AbCys, Paris, France) with 100 ng/ml GM-CSF, and 20 ng/ml IL-4, and matured with 10 μg/ml LPS for additional 48 hrs. Mature DCs were pulsed for hr at 37° C. with 10 μg/ml of the appropriate peptide diluted in SYH-H medium, washed, and mixed with PBMC until reaching an relation E/T patients of 10:1, using a total of 10 5 CD8+ lymphocyte cells/well.
[0153] 96-well plates were covered with nitrocellulose (MAIPS 450; Millipore, Bedford, Mass.) overnight at 4° C. with 10 μg/ml human anti-IFN-γ mAb (Mabtech, Nacka, Sweden) in carbonate-bicarbonate buffer, pH 9.6, washed, and blocked with IMDM medium+10% AB human serum (Biowest, Nuaille, France) for 1 hr at 37° C. Effector cells were sown in 100 μL medium, and target cells were added until reaching an E/T relation of 10:1, at a total of 200 μL/well. After 24 hrs incubation, the wells were washed 5 times with 0.1% Tween-20 in PBS. Plates were incubated 2 hrs at room temperature with 1 μg/ml human biotinilated anti-IFN-γmouse mAb (Mabtech) in PBS/HSA (0.4 g/L). After several washings with 0.1% Tween-20 in PBS, 1:1000 alkaline phosphatase-streptavidine (Mabtech) in PBS/HSA was added, and incubated for 1 hr at room temperature. Then the plates were washed, and the 5-bromine-4-chlorine-3-indol phosphate/nitro-tetrazolium blue substrate was added for 30 minutes at room temperature (Mabtech). Development of color was quenched by washing the plates with water. After drying, the CD8+T cells secreting IFN-γ were counted, visualized by a color spot on the nitro-cellulose membrane, using the ELISpot automatic image system reader (AID, Strassberg, Germany).
[0154] Staining with HLA Tetramers/Peptides:
[0155] HLA-A0201 tetramers were used to identify clones of specific CD8+T lymphocytes for MART-1 (AAGIGILTV), or gp-100 (KTWGQYWQV) conjugated to PE (phycoerithrine), or APC (allo-phycocyanine) respectively. The staining procedure was done at 37° C. for 15 minutes, and immediately placed on ice. Then, the samples were incubated with anti-CD8 FITC (BD Biosciences, San Jose Calif.) at 4° C. for additional 40 minutes, and analyzed by FACS. Positive controls were done with specific CTL clones (restricted HLA A*0201) for MART-1 (M27: AAGIGILTV), and gp100 (G154: KTWGQYWQV) antigens expanded un 14 day-cycles in RPMI medium in the presence of anti-CD3 antibodies (OKT-3, BD Biosciences) at 30 ng/ml, and series of IL-2 (Chiron By) a 300 UI/ml each 3 days, plus 10% inactivated human AB serum, and antibiotics. Negative controls were performed PBMC samples from healthy HLA-A0201 donors.
[0156] Determination of Humoral Response:
[0157] Viable cells comprising Apo-Nec cells were mixed in equal en proportions, blocked with 10% rabbit serum for 30 min, and incubated with pre- and post-application serum, diluted 1/10 per 1 hr at 4° C. Then they were washed, and the cells were incubated with a human anti-immunoglobulin antibody (IgG+A+M) obtained in rabbits (DakoCytomation, Glostrup, DK) for 1 hr at 4° C. The cells were washed, fixed in para-formaldehyde at 1%, and were analyzed by FACS. Alternatively, cells were first permeatized with saponin at 0.05% (Sigma-Aldrich, Saint Louis, Mo.) in PBS in the blocking stage, and 0.05% saponin/PBS was added in each after the reaction stage. Normal serum was used as first antibody control.
[0158] Protein extracts were prepared from Apo-Nec cell lines of the invention. Cell pellets were frozen at −80° C., thawed, and treated for 20 min at 4° C. with lysis buffer (50 mM Tris-ClH, pH 7.5, 1% NP 4 O, 150 mM de NaCl, 5 mM de EDTA, and 1 mM PMSF). The suspension was homogenized with a Polytron (Brinkmann Instruments, USA), and was centrifuged for 40 min at 10,000 g. Supernatant was stored as aliquots frozen at −20° C. Protein concentration was measured according to the Lowry method. IIB-BR-G human breast carcinoma cell line protein extracts were likewise prepared.
[0159] Protein extracts (50 μg) were run in a SDS-PAGE 3%-12% gradient, and transferred to a nitro-cellulose membrane (0.45 μm pore, Sigma-Aldrich, Saint Louis, Mo., USA). After blocking with 3% skimmed bovine milk (Moliko, Argentina), they were incubated overnight at 4° C. with patient serum diluted 1/10. After several washings, the membranes were incubated with human anti-IgG+A+M antibodies obtained in goat, conjugated with horseradish peroxidase (HRP) (Zymed, San Francisco, Calif.), and developed with 4-Cl-naphthol plus H 2 O 2 .
[0160] Histopathologic Analysis of Melanoma Metastases:
[0161] Paraffin-embedded biopsies were used to analyze lymphoid cells, and DCs cell infiltration. Between three and five sections were stained with hematoxylin/eosin, or immuno-stained with anti-CD4 (1F6 clon), anti-CD8 (C8E—144b clon), anti-CD20 (L26 clon), anti-CD1a (010 clon) (DakoCytomation, Glostrup, DK), and anti-CD57 (NK1 clon, Zymed, San Francisco, Calif.) antibodies, and developed with ABC reactant, and diamino-benzidine (DAB), or Novared as substrate (Vectastain, Vector, Burlingame, Calif.). Reactions were conducted as control by omitting primary antibodies. Sections were analyzed with an Olympus BX40 microscope. | Cell lines, compositions comprising them for the treatment of melanomas, procedures to prepare the compositions, and treatment methods. More particularly, the invention relates to diverse human melanoma cell lines for the treatment of malignant diseases, wherein the cell lines are: (a) Mel-XY1 (deposited at German Collection of Microorganisms and Cell Cultures DSMZ under access number DSM ACC2830), (b) Mel-XY2 (deposited at German Collection of Microorganisms and Cell Cultures DSMZ under access number DSM ACC2831), (c) Mel-XY3 (deposited at German Collection of Microorganisms and Cell Cultures DSMZ under access number DSM ACC2832), (d) Mel-XX4 (deposited at German Collection of Microorganisms and Cell Cultures DSMZ under access number DSM ACC2829), or (e) sub-populations thereof. The cell lines may be irradiated, thus obtaining populations with apoptotic phenotype, and populations with necrotic phenotype of such lines. The compositions may comprise adjuvants and/or immuno-modifiers, and/or autologous dendritic cells. | 0 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a system for handling capsules, such as gelatin capsules. More particularly, the present invention relates to a system for conveniently opening empty capsules, filling the capsules with medicine or the like, and then re-closing the capsules.
2. Description of Related Art
Prior art capsule handling systems U.S. Pat. No. 326,578 (Merz), U.S. Pat. No. 422,365 (Bateson), U.S. Pat. No. 803,145 (Winchester), U.S. Pat. No. 899,761 (Remington), U.S. Pat. No. 1,155,023 (Winchester), U.S. Pat. No. 1,993,716 (Hanley et al.), U.S. Pat. No. 2,322,169 (Smith), U.S. Pat. No. 2,348,749 (Norelli), U.S. Pat. No. 2,742,749 (McGuire), U.S. Pat. No. 3,286,436 (Lakso), U.S. Pat. No. 3,552,095 (Inman) and U.S. Pat. No. 4,089,152 (Zanasi). Also, there is a known capsule handling system marketed by a company called Feton®.
SUMMARY OF THE INVENTION
An object of the present invention is to provide a relatively inexpensive system for handling different sized capsules.
Another object of the invention is to provide capsule handling systems that have interchangeable parts so that a compounding pharmacist can conveniently produce a variety of distinct filled capsules, on the order of a prescribing medical professional to meet the unique needs of patients. Being able to distinguish filled capsules from each other is an important safety consideration. With the present invention, the pharmacist has the ability to make one hundred distinct, different-looking filled capsules while only purchasing ten different types of empty capsules from a manufacturer.
Another object of the invention is to provide a capsule handling system that is uncomplicated and reliable.
Accordingly, the present invention relates to a system formed of a loader component and an opener/encapsulater component, with the loader component being used to simultaneously position and orient different sized capsules within the opener/encapsulater component.
The present invention also relates to a capsule handling system formed of: (1) an opener/encapsulater component for opening, filling and closing capsules; and (2) a loader component for positioning and orienting the capsules within the opener/encapsulater component; wherein the opener/encapsulater component has a pair of capsule receiving plates, each with a plurality of holes for receiving the capsules. Advantageously, at least one of the plates can be displaced to hold the bottom portions of the capsules. Another advantage of the present invention is that the plates can be removed and replaced by plates with different sized holes for handling different sized capsules.
The present invention also relates to a method including the steps of: using a loader component to position and orient capsules within an opener/encapsulater component; using the opener/encapsulater component to separate the top portions of the capsules from their bottom portions; using a second opener/encapsulater component to separate the top and bottom portions of second capsules; filling the bottom portions of the first capsules; and connecting the bottom portions of the first capsules to the top portions of the second capsules.
With the present invention, an operator can open a large number of capsules at the same time, simultaneously fill the bottom portions of the capsules, and then replace the top portions of the capsules onto their respective bottom portions.
A preferred embodiment of the invention is formed of two modular components: (1) an opener/encapsulater component; and (2) a loader component for loading capsules into the opener/encapsulater component such that all of the capsules are oriented in the same direction (bottom portions down). The loader component has two parallel plates, each with matching elongated slots. The plates are removably held within the loader component by a slidable retainer.
In operation, the loader component is supported on the opener/encapsulater component, and the capsules are positioned within the slots of the top plate, without regard to the orientation of the capsules. Initially, the capsules do not fall through the bottom plate because the slots of the bottom plate are not directly underneath the slots of the top plate. But then the top plate is pushed against the horizontally directed spring such that the top plate slots are located over the slots of the bottom plate. The capsules then fall through the bottom plate slots and into the opener/encapsulater component. In doing so, the top portions of the capsules are caught by the edges of the slots of the bottom plate, such that all the capsules fall into the opener/encapsulater component in the same direction, i.e., bottom portions first.
Advantageously, the retainer can be moved down and the plates can be removed and replaced by plates with slots sized for different sized capsules. Another important feature of the invention is that the plates of the loader component are machined, not stamped and die cut out of aluminum, as is the case with the known machine manufactured by Feton. The machined plates of the present invention more accurately flip (turn) the capsules. Machining the plates also improves interchangeability between two systems.
The opener/encapsulater component has a pair of receiver plates with matching holes for receiving the bottom portions of the capsules as they fall from the loader component. The capsule bottom portions are firmly held (pinched) within these plates by slightly displacing one of the plates with respect to the other. All of the top portions of the capsules are then removed from their respective bottom portions by lifting a support plate assembly off of the opener/encapsulater component. The top portions are held within the assembly by a removable keeper plate. The bottom portions are then filled with medicine or the like, and then the capsule top portions are placed back onto the bottom portions by replacing the assembly onto the housing of the opener/encapsulater component. To firmly re-connect the portions of the capsules, the holes of the receiver plates are realigned and the capsule bottoms are pushed upwardly by a movable push plate, whose lowermost position is selectively adjustable.
Like the plates of the loader, the receiver plates and the support plate of the opener/encapsulater component can be removed and replaced by plates with different sized holes. In this way, the capsule handling system can handle a variety of different sized capsules. Also, the receiver plates are machined. Since all of the plates of the preferred embodiment are machined, two capsule handling systems can be used together to produce a wide variety of distinct, filled capsules.
Other objects and features of the present invention will be apparent from the following detailed description and drawings which illustrate preferred embodiments of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an exploded, perspective view of a capsule handling system in accordance with the present invention;
FIG. 2 is a perspective view of the opener/encapsulater component of the system illustrated in FIG. 1;
FIG. 3 is a partially cut away perspective view of the loader component of the system illustrated in FIG. 1;
FIG. 4 is a partially cut away top view of the opener/encapsulater component of FIG. 2;
FIG. 5 is a side view of the opener/encapsulater component of FIG. 2;
FIG. 6 is a partial cross-sectional view taken along the line 6--6 of FIG. 5;
FIG. 7 is a partial cross-sectional view similar to FIG. 6, but with the door in an open position and with the support plate removed;
FIG. 8 is a partial cross-sectional view taken along the line 8--8 of FIG. 3;
FIG. 9 is a partial cross-sectional view similar to FIG. 6 but showing the use of the keeper plate;
FIG. 10 is a side view of a capsule;
FIG. 11 is a partial cross-sectional view taken along the line 11--11 of FIG. 3;
FIG. 12 is a schematic view of a capsule turning hole;
FIG. 13 is a side view of a tamper; and
FIG. 14 is a partial perspective view showing means for identifying plates.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
Referring now to the drawings, wherein like reference numerals indicate like elements, there is shown in FIG. 1 a capsule handling system constructed in accordance with the principles of the present invention and designated generally by reference numeral 10. The capsule handling system 10 is formed generally of an opener/encapsulater component 12 and a loader component 14.
The capsule handling system 10 is designed to handle up to one hundred conventional gelatin capsules 16, one of which is shown in FIG. 10. Each gelatin capsule 16 has a bottom portion 18 fitted into a top portion 20 with a friction fit. The diameter 22 of the top portion 20 is slightly greater than the diameter 24 of the bottom portion 18. Preferably, the capsule handling system 10 will accurately fill capsules 16 in sizes 00, 0, 1 and 3.
The opener/encapsulater component 12 (FIG. 2) has a housing formed of side walls 26, 28, a back wall 30 (FIG. 4), a door 32, and a bottom 34 (FIG. 5) supported on legs 36. Preferably, the walls 26, 28 and 30, and the door 32 are formed of lightweight aluminum, the bottom 34 is formed of plastic and the legs 36 are formed of an elastomeric material.
A support plate 38 (FIG. 2) is located on top of the walls 26, 28 and 30, and receiving plates 40, 42 are slidably received within the housing, underneath the support plate 38. Preferably, the plates 40, 42 are slidably supported on ledges 44 machined into each wall 26, 28.
The door 32 is hinged to the walls 26, 28 by a pin type hinge 46. The door 32 has connecting slots 48 at its top side corners. The door 32 is shown in its open position in FIG. 2. The door 32 is vertical in its closed position (FIGS. 4 and 5). When the door 32 is in its closed position, a grooved bearing means 50 (FIG. 6) pushes against the front edges of the plates 40, 42.
The door 32 is held in its closed position by connecting means formed of pins 52 (FIG. 2) and threaded knobs 54. The pins 52 fit within recesses 56 cut into the walls 26, 28 and are pivotally connected to the walls 26, 28 so as to be pivotally movable from a closed position to an open position. In FIG. 2, the pin 52 on the left is in its closed position and the pin 52 on the right is in its open position. To hold the door 32 in its closed position, as illustrated in FIG. 4, the knobs 54 are positioned in front of the slots 48 and then tightened (i.e., threaded toward the door 32).
The opener/encapsulater component 12 also has a push plate 58 (FIG. 2) loosely contained within the housing. The push plate 58 is in the shape of a square and is approximately the same size as the capsule receiving plates 40, 42. The front corners 60 (FIG. 4) of the push plate 58 are cut away to make room for the inner distal ends of the pins 52 when the pins 52 are in their open positions.
The push plate 58 has handgrips 62 at opposite sides thereof. The handgrips 62 extend out through opposite openings 64 (FIG. 2) in the walls 26, 28, and thereby are arranged to guide the plate 58 when the plate 58 is lifted vertically from a lower position to an upper capsule-closing position.
The push plate 58 rests upon support pins 66 (FIG. 2) in its lower position. These support pins 66 are threaded through the walls 26, 28 beneath the hole openings 64, so as to selectively determine the height of the push plate 58 in its lower position. Springs 68 press downwardly against the heads 69 of the threaded pins 66 to prevent the pins 66 from being inadvertently moved.
The support plate 38 fits on top of the walls 26, 28 and 30. The support plate 38 has four oblong position-indexing holes 70 which receive corresponding oblong indexing projections 72 extending upwardly from the walls 26, 28. The indexing projections 72 are integrally formed with the walls 26, 28.
Aluminum support slides 74 are fixed to the top of the support plate 38. Each support slide 74 has a ledge 76 which faces inwardly toward the center of the support plate 38. Each ledge 76 has opposite position-limiting ends 78, 80. Connecting knobs 82 are eccentrically pivotally connected to the support slides 74. The knobs 82 are shown in their closed positions in FIGS. 2, 4 and 5. To move the knobs 82 to their open positions, the knobs 82 are rotated 180° about vertical eccentric connecting pins 84. When the knobs 82 are in their open positions, they do not cover any portion of the ledges 76.
A keeper plate 86 (FIG. 1) can be placed over the support plate 38, with edges 88, 90 resting directly on the ledges 76 when the knobs 82 are in their open position. To hold the keeper plate 86 in this position, with the distance between the bottom of the keeper plate 86 and the top of the support plate 38 being equal to the height of the ledges 76, each knob 82 is rotated 180° about its respective pin 84, i.e., from its open position to its closed position.
The capsule receiving plates 40, 42 are shown in more detail in FIG. 4. Each receiver plate 40, 42 has one hundred holes 92, 94, respectively. For each plate 40, 42, the holes 92, 94 are formed in ten columns, with ten holes 92, 94 in each column. The spacings between the holes 92 are identical to the spacings between the holes 94, such that the holes 92, 94 of the two plates 40, 42 can be aligned (FIG. 7). However, the holes 92, 94 are not aligned when the door 32 is closed (FIG. 6). When the door 32 is closed, the bearing means 50 pushes the lower capsule receiving plate 42 toward the back wall 30 (i.e., to the left of FIG. 6). In this door-closed position, the holes 94 are slightly displaced with respect to the holes 92. When the door 32 is opened, the lower plate 42 can be moved outwardly (to the right of FIG. 6), allowing realignment of the holes 92, 94 (FIG. 7).
The loader component 14 (FIG. 3) is formed of a housing with side walls 96, 98, an upper plate 100, a lower plate 102, a base section 104, and a retainer 106 (FIG. 1) for maintaining the plates 100, 102 in the position illustrated in FIG. 1. The top plate 100 is biased toward the retainer 106 by a spring 108 (FIG. 11). The back edge of the top plate 100 can be manually pushed into a recess 110 (i.e., away from the retainer 106) against the compression force of the spring 108.
The top plate 100 has oblong holes 112 (FIG. 3) which are large enough to freely receive the capsules 16 in a horizontal position. There are fifty (five columns, ten holes 112 to a column) of the oblong holes 112 in the top plate 100. The lower plate 102 also has fifty (5×10) holes 114, with the spacings between the holes 114 being the same as the spacings between the holes 112. The distance between each ten-hole column of holes 114 is twice as wide as the distance between each column of holes 92 through the capsule receiving plate 40.
The holes 114 of the bottom plate 102 have a special configuration for turning (or flipping) the capsules 16. In particular, each hole 114 has a midsection width 116 (FIG. 12) which is greater than the widths 118 of its ends. The end widths 118 are slightly smaller than the diameter 22 of the top portion 20 of each capsule 16 and slightly greater than the diameter 24 of the capsule bottom portions 18. The midsection width 116 is greater than the top portion diameter 22. The length 117 of the midsection portion is greater than the diameter 22 of the capsule top portions 20. As a result, the capsules 16 all fall through the holes 114 bottom portions 18 first, as the wider top portions 20 are momentarily hung up on the edges of the holes 114, as illustrated in FIG. 8.
Preferably, the plate 102 is formed of rigid plastic and the holes 114 are formed by machining. This provides a very good flip rate. In the illustrated embodiment, 99-100% of the capsules 16 fall bottom portion 18 first through the holes 114. The Feton machine, in contrast, has a plate with holes that are die cut and stamped out of aluminum. The Feton machine has a 10-40% error rate in flipping capsules.
As illustrated in FIG. 3, the plates 100, 102 are slidably received within spaced apart grooves 120, 122. Thus, the plates 100, 102 can be removed from the loader component 14 and replaced with plates that are structurally identical to the plates 100, 102, except that they have holes for different sized capsules. The top groove 120 is coplanar with the recess 110 (FIG. 11), such that the back edge of the plate 100 can be slid into the recess 110.
The base section 104 (FIG. 3) has fifty (5×10) funnels 124 for receiving the capsules 16 as they fall through the holes 114 and for directing the capsules 16 into the holes 126 in the support plate 38. The funnels 124 are located directly underneath the holes 114. The distance between each column of ten funnels 124 is twice as wide as the distance between each column of ten funnel-shaped holes 126.
In operation, the loader component 14 is positioned on the ledges 76 in a first (e.g., left-most position) such that the left-most column of funnels 124 is located directly over the left-most column of holes 126, the next column of funnels 124 is located over the third column of holes 126, the third column of funnels 124 is located over the fifth column of holes 126, etc. In the first position, the left side wall 96 of the loader component 14 is in abutment with the left positioning ends 78 of the support slides 74, and the right side wall 98 is spaced apart from the right position limiting ends 80.
A handful of capsules 16 (more than fifty capsules 16) are then dropped or poured onto the top plate 100. Fifty of these capsules 16 will settle into the oblong holes 112, and any excess capsules 16 (i.e., capsules 16 which do not fit into the holes 112) may be poured off over the front edge 101 of the plate 100. At this point, both of the plates 100, 102 are in abutment with the retainer 106, and the fifty capsules 16 are lying on their sides on top of the bottom plate 102, with the capsules 16 being prevented from moving laterally by the peripheral edges of the holes 112. At this point, the orientation of the fifty capsules 16 is random. Some of the bottom portions 18 may be pointing toward the left of FIG. 3 and the rest of the bottom portions 18 may be pointing to the right of FIG. 3.
The operator then uses his thumbs to push the top plate 100 into the recess 110, against the bias force of the spring 108. When the back edge of the top plate 100 is fully inserted into the recess 110, each hole 112 is over the corresponding hole 114 of the bottom plate 102, such that the capsules 16 fall through the bottom holes 114. As the capsules 16 fall through the specially configured holes 114, the wider top portions 20 are momentarily caught between the edges of the holes 114 until the capsules 16 are moved to the center of the holes 114, such that all of the capsules 16 fall bottom portions 18 first through the plate 102, as illustrated in FIG. 8.
In this way, half of the holes 126 of the support plate 38 receive capsules 16, each bottom portion 18 first. The capsules 16 cannot fall all the way through the funnel-shaped holes 126 because the minimum diameter of each hole 126 is less than the top portion diameter 22 of each capsule 16. In FIG. 9, capsule 16' is an example of a capsule 16 that has just fallen into a hole 126. Any capsule 16 that inadvertently falls top portion 20 first into a hole 126 can be manually removed and properly reinserted into that hole 126 bottom portion 18 first.
The loader component 14 is then slid over along the ledges 76 to a second position with the right side wall 98 abutting against the right positioning ends 80, and the foregoing procedure is repeated to fill the remaining, alternating fifty holes 126 of the support plate 38. In the second position, the left-most column of funnels 124 is located directly over the second column of holes 126, the next-to-left column of funnels 124 is located over the fourth column of holes 126, the third column of funnels 124 is located over the sixth column of holes 126, etc.
After each of the one hundred holes 126 has received a capsule 16 bottom portion 18 first, the loader component 14 is lifted off of the opener/encapsulater component 12. Then, the keeper plate 86 is positioned above the support plate 38 with the edges 88, 90 resting on the ledges 76. The keeper plate 86 presses the top portions 20 of the capsules 16 down into the funnel-shaped holes 126, as illustrated in FIG. 9. The plate 86 is secured in place by rotating the knobs 82 over the top of the edges 88, 90 of the keeper plate 86.
The door 32 is then rotated upwardly about the hinge 46 to its closed position, and secured in place by rotating the knobs 54 down tight against the front of the door 32, with the pins 52 extending through the slots 48. When the door 32 is tightened in its closed position, the plates 40, 42 are held in place with their holes 92, 94 slightly out of alignment with each other. The bottom portions 18 of the capsules 16 are thereby pinched and held securely within the slightly misaligned holes 92, 94 (FIG. 6).
The support plate 38 with the keeper plate 86 secured thereon is then lifted off the top of the opener/encapsulater component 12. In doing so, the capsule top portions 20 stay between the support plate 38 and the keeper plate 86. This is because the capsule top portions 20 fit snugly within the holes 126.
The door 32 is then opened, allowing the holes 92, 94 to be realigned (FIG. 7). The capsule bottom portions 18 are then gently pushed down (by bouncing the opener/encapsulater component 12 or by means of a spatula (not shown)) until the top edges of the bottom portions 18 are aligned with the top surface of the capsule receiving plate 40, as shown in solid lines in FIG. 7. With the holes 92, 94 in alignment, the bottom portions 18 of the capsules 16 fall all the way down through the system until they reach the top of the push plate 58, which is in its lowermost position. The push plate 58, whose lowermost position is adjusted by the threaded depth adjustment pins 66, prevents the capsule bottom portions 18 from falling or being pushed any farther down through the plates 40, 42. A capsule bottom portion 18 which is ready for filling, with its open top edge even with the top surface of the plate 40 and with its bottom end resting on the push plate 58, is shown in solid lines in FIG. 7.
The bottom portions 18 are then filled with medicine or other material. Accurate filling is possible since the top edge of each capsule bottom portion 18 is located at the top surface of the plate 40. A tamper 130 (FIG. 13) with individual tamper projections 132 may be used for this procedure. Preferably, the spacings between the projections 132 are the same as the spacings between the holes 92. The tamper 130 has five projections 132 in a single row. In an alternative embodiment, the tamper may have five columns of five projections each, so as to tamp material into twenty five capsule bottom portions 18 at a time. A spatula (not illustrated) may also be used.
After all of the bottom portions 18 of the capsules 16 have been filled, the top portions 20 are returned by placing the support plate 38 back on top of the opener/encapsulater component 12 (i.e., the holes 70 are placed back over the projections 72). The operator then grabs the handgrips 62 and the support plate 38 and squeezes, causing the push plate 58 to move upwardly, such that the capsule bottom portions 18 are pressed back and locked by friction into the respective top portions 20. During this procedure, upward movement of the top portions 20 is resisted by the keeper plate 86. The support plate 38 can then be removed, the knobs 82 can be rotated to disassemble the keeper plate 86 from the plate 38, and the now filled and re-connected capsules 16 can then be pushed upwardly out through the holes 126 in the support plate 38, which completes the filling procedure.
An important feature of the present invention is that the capsule receiving plates 40, 42, the loader plates 100, 102, and the support plate 38 can all be removed and replaced by plates with identical structures except for different sized holes. The plates 40, 42 can be slid out of the housing after opening the door 32. New plates for different sized capsules can then be slid onto the ledges 44 and the position of the push plate 58 can be adjusted for the new size capsules. Preferably, the top surface of the push plate 58 would be set at a distance from the top surface of the capsule receiving plate 40 equal to the length of the bottom portions 18 of the new capsules. The depth adjustment screws 66 may have markings (not shown) such that the push plate 58 can be rapidly adjusted to predetermined positions for handling the different sized capsules.
To remove and replace the plates 100, 102, the retainer 106 (FIG. 1) is slid downwardly until pins 132 are in engagement with the tops of slots 134. The plates 100, 102 can then be slid out of the grooves 120, 122 and replaced by similarly structured plates with different sized holes. The support plate 38 can also be lifted off of the housing and replaced by a similarly structured support plate with funnel-shaped holes sized for the new capsules.
The plates 40, 42, 38, 100, 102 are all keyed to each other by visual indicia. In the example illustrated in the drawings, each plate 40, 42, 38, 100, 102 has a single notch 136, indicating that the plates 40, 42, 38, 100, 102 are designed for the largest capsules handled by the system. Plates for the next smaller size of capsules may have two notches 136' (FIG. 14), and plates for the next smaller size of capsules may have three notches, etc. A preferred keying system is as follows: 1 slot, size #3; 2 slots, size #1; 3 slots, size #0; 4 slots, size #00.
Also, the plates 40, 42 and 100, 102 are preferably color coded. In the illustrated embodiment, the plate 40 is formed of a gray tinted translucent plastic, and the plate 42 is formed of an opaque white plastic, the plate 100 is formed of black plastic, and the plate 102 is formed of opaque white plastic. This color coding scheme makes it easy to distinguish one plate from another.
Another important feature of the invention is that the plates 40, 42, 38, 100, 102 are accurately machined so as to be interchangeable with the plates 40, 42, 38, 100, 102 of another capsule handling system 10. By making the plates 40, 42, 38, 100, 102 interchangeable between different machines, it is possible for a pharmacist to take n number of distinct capsules and make n 2 new and distinct capsules from them by interchanging their top and bottom portions.
To interchange top and bottom capsule portions 20, 18, a loader component 14 is used to position and orient a first set of one hundred capsules 16 within a first opener/encapsulater component 12. Then, a second set of one hundred capsules 16 are positioned and oriented within a second opener/encapsulater component 12. The same loader component 14 may be used to load both opener/encapsulater components 12. Then, the top portions 20 of the two hundred capsules 16 are separated from their bottom portions 18, and the one hundred bottom portions 18 of the first set of capsules 16 are filled with medicine.
Then, the top portions 20 of the second set of capsules 16 are fitted onto the filled bottom portions 18 of the first capsule set. This is done by placing the support plate 38 of the second opener/encapsulater component 12 over the capsule receiving plate 40 of the first component 12, and squeezing the handgrips 62 of the first component 12 toward the support plate 38 of the second component 12. If the top and bottom portions of the first set of empty capsules are both red, and the top and bottom portions of the second set of empty capsules are both black, then the above-described procedure would produce one hundred red and black capsules.
Being able to interchange capsule portions with the present invention produces great cost savings. A pharmacist wanting to produce one hundred distinct types of capsules would only have to purchase ten types of empty capsules from a capsule manufacturer, and capsule manufacturers generally sell empty capsules in lots of at least one million capsules.
The above description and drawings are only illustrative of preferred embodiments which achieve the objects, features and advantages of the present invention, and it is not intended that the present invention should be limited thereto. Any modifications of the preferred embodiments which come within the spirit and scope of the following claims is to be considered part of the present invention. | A capsule handling system is formed of a loader component and an opener/encapsulater component. The system can handle different sized capsules, and has interchangeable parts so that a compounding pharmacist can conveniently produce a variety of distinct filled capsules, on the order of a prescribing medical professional to meet the unique needs of patients. | 8 |
BACKGROUND OF THE INVENTION
The outlet drains of bathtubs in beach homes, beach motels and/or beach hotels and the like tend to continually become clogged by sand when bathers fail to rinse their sandy feet/bodies and shower/bathe in tubs. Sand is washed from their bodies/feet, flows into and through the associated bathtub drain and accumulates in the bathtub outlet/trap resulting in slow drainage of water from the bathtub or total blockage thereof. It is not unusual, for example, to take a shower and stand in water accumulating in the bathtub because the flow from the shower head/outlet is faster than the outflow of the water from the bathtub drain. The adverse health problems are clearly apparent from such circumstances, not to mention the cost involved to have a plumber continuously and repetitiously clear such drains.
SUMMARY OF THE INVENTION
In keeping with the foregoing, a major object of the present invention is to provide a novel mechanism which preferably can be retro-fitted to a bathtub outlet for trapping sand, while at the same time providing a flow controller mechanism to regulate the flow of water through the bathtub outlet or completely cut-off the same.
In keeping with the foregoing, a novel sand trap and flow controller mechanism is provided in keeping with the present invention which includes an outer housing having an externally threaded peripheral wall, a lower annular shelf and a radially outwardly directed flange which can be threaded into the internally threaded outlet pipe of a conventional bathtub after, of course, the conventional flanged bathtub outlet has been removed therefrom.
An inner sand trap housing seats in the outer housing and is defined by an outer peripheral wall, an inner tubular peripheral wall and an annular wall therebetween. The latter three walls define a generally annular sand trap chamber into which sand flows and can accumulate while water can flow outwardly from the sand trap chamber over an uppermost peripheral edge of the inner tubular wall.
The sand trap and flow controller mechanism also includes a closure having a conical deflector which deflects water draining from the bathtub radially downwardly and outwardly so that sand entrained in the water will accumulate in the sand trap chamber and will not exit a discharge opening of the inner tubular wall.
In further keeping with the invention, the closure includes a pair of diametrically oppositely directed wings or lugs which each ride in a channel of the outer peripheral wall of the inner sand trap housing. As the closure is rotated, the wings or lugs ride in the channels upwardly or downwardly, depending upon the direction of rotation of the closure, and thus the rate of flow of water through the discharge opening can be regulated or completely stopped.
Accordingly, in keeping with the present invention sand is not only prevented from exiting into the outlet pipe or discharge pipe associated with conventional bathtubs, but the present sand trap and flow controller mechanism can be utilized either as original equipment or as a retro-fit mechanism. Moreover, the sand trap housing is readily removed by a direct upward pull and, thus, sand which has accumulated in the sand trap chamber can be quickly dumped, the sand trap chamber rinsed and the sand trap housing replaced for subsequent use in a very efficient and rapid manner.
With the above and other objects in view that will hereinafter appear, the nature of the invention will be more clearly understood by reference to the following detailed description, the appended claims and the several views illustrated in the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a fragmentary side elevational view with portions thereof broken away and shown in cross section of a conventional bathtub installation, and illustrates a conventional bathtub, an overflow pipe, an internally threaded drain pipe, and a conventional flanged fitting having a flange seated upon an internal surface of the tub and an exteriorly threaded peripheral wall threaded into internal threads of the drain pipe.
FIG. 2 is a fragmentary cross-sectional view of a novel sand trap and flow controller mechanism of the present invention, and illustrates the mechanism retro-fit into the tub outlet of FIG. 1 after the conventional tub drain outlet has been removed and discarded.
FIG. 3 is an exploded view of the sand trap and flow controller mechanism of the present invention, and illustrates an outer housing defining an outer chamber having an externally threaded peripheral wall and a radially outwardly directed upper flange, an inner housing defining a sand trap chamber, and a closure/flow controller member.
FIG. 4 is an axial cross-sectional view taken through the sand trap housing, and illustrates the closure member rotated into its closed position with an elastomeric valve sealed against an uppermost peripheral edge of a discharge tube or wall of the sand trap housing.
FIG. 5 is a top plan view of the inner sand trap housing, and illustrates diametrically oppositely directed lugs or wings of the closure member received in helical channels of an outer peripheral wall of the sand trap housing.
DESCRIPTION OF THE PREFERRED EMBODIMENT
A conventional bathtub B is illustrated in FIG. 1 of the drawings and includes an opening O in a bottom wall W which is aligned with a drain pipe or outlet pipe P having internal threads IT. A conventional drain fitting DF is defined by a peripheral wall PW having external threads ET which are threaded into the internal threads IT of the drain pipe P. An integral apertured cover plate CP permits drain water DW to flow therethrough in a manner indicated by the unnumbered headed arrows of FIG. 1. An integral flange F seats over the outlet O to provide an aesthetic appearance to the interior (unnumbered) of the bathtub B. A conventional overflow cover C is conventionally connected to the bathtub B and to an overflow pipe OP which is in turn connected by a T-fitting TF to the drain pipe P. A drain trap (not shown) is, of course, conventionally associated with the drain pipe P and the overflow pipe OP and sand entrained in the water will over time accumulate in the drain trap eventually slowing the flow of water from the bathtub B or completely preventing the flow of water outwardly therefrom. As noted heretofore, cleaning/air-blasting sand from such traps is a costly proposition, particularly when done repetitiously, as is often the case at beach hotels, motels, and the like.
A novel sand trap and flow controller mechanism of the present invention is fully illustrated in FIGS. 2 through 5 of the drawings and is generally designated by the reference numeral 10.
The sand trap and flow controller mechanism 10 is adapted for retro-fit assembly to the tub outlet O once the conventional drain fitting DF has been removed, as illustrated in FIG. 2, although the sand trap and flow controller mechanism 10 can be installed as original equipment by bathtub manufacturers for installations susceptible to sand accumulation in outlet drains.
The sand trap and flow controller mechanism 10 includes an outer housing 11, and inner housing or inner sand trap housing 12 and a flow controller or flow controller means 13 for opening and closing water flow through the overall sand trap and flow controller mechanism 10.
The outer housing 11 of the sand trap and flow controller mechanism 10 includes an outer peripheral wall 20 (FIGS. 2 and 3) having an external thread 21 which matches the internal thread IT of the drain pipe P. A lower radially inwardly directed flange 22 of the outer housing 11 defines means for supporting the inner sand trap housing 12 thereupon in the manner best illustrated in FIG. 2 of the drawings. The annular radially inwardly directed lower flange 22 includes two diametrically opposite openings 23 (FIG. 2) therein which function in a manner to be described more fully hereinafter.
An upper radially outwardly directed flange 24 overlies the opening O of the bathtub B (FIG. 2) when the sand trap and flow controller mechanism 10 has been assembled relative to the bathtub wall W and the drain pipe P.
The inner sand trap housing 12 includes an outer peripheral or cylindrical wall 30, a lower annular wall 31 and a central cylindrical wall or tube 32 having an uppermost peripheral edge 33 which is axially below an uppermost peripheral edge 34 of the outer peripheral wall 30, as is most evident in FIG. 2 of the drawings. The walls 30, 31, 32 define an inner annular sand trap chamber 35 in which sand entrained in water enters during flow therein, as indicated by the dash-dot arrows of FIG. 2. The heavier sand particles S will, of course, sink to the bottom of the sand trap chamber 35, while water W alone will exit therefrom over the peripheral edge 33 of the inner peripheral wall 32 and outwardly of a discharge opening or discharge end portion 36 thereof, as indicated by the dashed arrows of FIG. 2.
The bottom or lower annular wall 31 includes two diametrically opposite downwardly directed detents or projections 38 (FIGS. 2 and 4) which in the assembled condition of the sand trap and flow controller mechanism 10 seat in the diametrically opposite openings 23 of the lower flange 22 of the outer housing 11. The interengagement between the detents 38 and the openings 23 prevents relative rotation between the housings 11, 12 upon rotation of the flow controller mechanism 13, as will be more apparent hereinafter.
The outer peripheral wall 30 of the sand trap housing 12 carries on its inner surface (unnumbered) two diametrically opposite helically/spirally disposed channels 39 which function to guide the axial movement of the flow controller 13 upwardly and downwardly relative to the peripheral edge 33 of the inner peripheral wall 32 of the sand trap housing 12 to open (FIG. 2) and close (FIG. 4) the flow of water relative to the discharge opening 36.
The flow controller mechanism 13 includes a circular elastomeric or similar material valve or gasket 40 secured by a screw 41 which passes through an opening (unnumbered) of a flow controller plate 42. The screw 41 is threaded into an internal thread (not shown) of a knurled knob 43. The flow controller plate 42 includes a circular central plate portion 44 which is slightly larger than the diameter of the gasket or valve 40, a pair of diametrically opposite radially outwardly directed wings or lugs 45 and a radially downwardly and outwardly directed frusto-conical plate 46 defining means for deflecting water and sand radially outwardly and downwardly into the sand trap chamber 35, as is indicated by the dot-dashed arrows of FIG. 2. The wings or lugs 45 have terminal edges 48 which define a distance slightly greater than the distance between the channels 39. Thus, the wings 45 can be deflected or bowed slightly to snap each into its associated channel 39 after which the natural resilience of the wings 46 return the same into a common plane, as is illustrated in FIG. 4 of the drawings. Thus, as the knob 43 is grasped and rotated in either direction, the wings 45 are guided along the channels 39 to raise and lower the flow controller 13 between the full closed position shown in FIG. 4, the full open position shown in FIG. 2, or positions therebetween. During rotation of the flow controller 13, the inner sand trap housing 12 will not rotate relative to the outer housing 11 because of the interengagement of the bosses or detents 38 and the openings 23 (FIG. 2). However, when sufficient sand S accumulates in the sand trap chamber 35, the sand can be emptied by simply grasping the knurled knob 43 and lifting the sand trap housing 12 axially upwardly which permits the total withdrawal thereof from the interior of the outer housing 11. The sand S can then simply be dumped from the sand trap chamber 35 by inverting the housing 11, rinsing out the same and reinserting the sand trap housing 12 into the outer housing 11. During cleaning of the sand S from the sand trap chamber 35, the flow controller 13 can, of course, be removed by simply snapping the wings 45 outwardly of the channels 39, flushing the sand chamber 35 to rid the same of the sand S and again reinserting the wings 46 into the channels 39 in the manner heretofore described.
As can be most readily visualized in FIG. 2, all the sand S accumulated in the sand trap 35 of the sand trap and flow controller mechanism 10 will not flow into the outlet pipe or drain pipe P and, obviously, will not accumulate therein or in the associated trap (not shown). Whether as original equipment or as a retro-fit assembly, the sand trap and flow controller mechanism 10 prevents the adverse accumulation of sand associated with bathtub drains and automatically prevents health-associated problems and the costs involved in plumbing maintenance and/or repair.
All of the components of the sand trap and flow controller mechanism are made of quality materials, such as brass, except for the gasket 40, or equivalent polymeric/copolymeric material which is not adversely effected by water and will not or will not readily rust or deteriorate. The outer housing 11 is preferably made from brass or the flange 24 can be chromed to achieve an aesthetic appearance while the sand trap housing 12 can be formed from polymeric/copolymeric plastic material of relatively high strength and low wear. Except for the elastomeric or equivalent gasket 40, the flow controller 13 should match the flange 24 (brass or chrome, for example, for aesthetic purposes).
It is also indicated that the bathtub B of FIG. 1 has been illustrated rather simplistically, and the same could include a conventional flow controller, either manually operated directly in the area of the drain fitting DF or provided with an operative lever in the area of the overflow coupling C, as is conventional. However, the latter components can be removed and discarded when replaced by the retro-fitted sand trap and flow controller mechanism 10 of the present invention.
Although a preferred embodiment of the invention has been specifically illustrated and described herein, it is to be understood that minor variations may be made in the apparatus without departing from the spirit and scope of the invention, as defined the appended claims. | A sand trap and flow controller mechanism for a bathtub includes an outer housing defined by an externally threaded peripheral wall having an upper outwardly directed peripheral flange and a lower inwardly directed peripheral flange with a pair of diametrically opposite openings, an inner sand trap housing defined by an outer peripheral wall, an inner peripheral wall and an annular wall therebetween collectively defining a sand trap chamber, and a flow controller mechanism having diametrically oppositely directed wings which are received in channels for guiding a valve of the flow controller toward, in sealing engagement upon and away from an upper peripheral edge of the inner peripheral wall of the inner sand trap housing. | 4 |
CROSS-REFERENCE TO RELATED PATENT APPLICATION(S)
[0001] This patent application claims the benefit of and priority to U.S. Provisional Patent Application No. 61/786,825, filed on Mar. 15, 2013, the contents of which are hereby incorporated by reference in their entirety.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] The invention described herein was made in the performance of work under a NASA contract and by employees of the United States Government and is subject to the provisions of Public Law 96-517 (35 U.S.C. §202) and may be manufactured and used by or for the Government for governmental purposes without the payment of any royalties thereon or therefore. In accordance with 35 U.S.C. §202, the contractor elected not to retain title.
FIELD OF THE INVENTION
[0003] The present invention relates to a method of treating carbon nanotube(s) or graphene yarn(s) and sheet(s) to improve the transport and mechanical properties thereof, and specifically to a process of treating the material with sucrose to lock the carbon nanotubes or graphene sheets in alignment with one another.
BACKGROUND OF THE INVENTION
[0004] Various aerospace and terrestrial applications require lightweight materials with very high mechanical properties, particularly specific modulus and strength. Carbon nanotubes and graphene sheets have been found to be such materials. In addition, they have been found to have excellent electrical and thermal transport properties. However, translating the excellent properties, particularly mechanical and thermal transport, at the nanoscale level to bulk materials has proven to be a difficult challenge. In order for the nanotubes to be used in applications, they must be spun into yarn(s), sheet(s), and other macroscopic forms introducing relatively weak tube-to-tube and inter-bundle bonds. Also, the nanotubes tend to be entangled, and they therefore do not all contribute in load bearing. Weak coupling at tube and bundle interfaces also leads to mechanical and thermal transport that are much lower than would be expected from the carbon nanotube or graphene properties.
BRIEF SUMMARY OF THE INVENTION
[0005] One aspect of the present invention is a method of treating carbon nanotube/graphene yarn, sheet, tape or other macroscopic form. The material is soaked in a sucrose solution, and the sucrose solution is then chemically or thermally dehydrated to form a carbon binder. The soaking and subsequent reduction can be repeated numerous times to obtain the desired sucrose penetration and to form a binder of the desired thickness. Stretching of the carbon nanotube/graphene material during the sucrose infusion and dehydration process leads to locking in of alignment as the binder forms. Such alignment of the carbon nanotubes/graphene sheets leads to large enhancements of the mechanical properties as more of the nanotubes or graphene sheets contribute to load bearing. The strong tube-to-tube and bundle bonds introduced by the carbon binder also serve to enhance the overall mechanical and thermal transport properties of the material as these bonds form conduits for phonons.
[0006] These and other features, advantages, and objects of the present invention will be further understood and appreciated by those skilled in the art by reference to the following specification, claims, and appended drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] FIG. 1 is a schematic showing a process according to one aspect of the present invention;
[0008] FIG. 2 is a graph showing mechanical properties of carbon nanotube yarns that has been treated with either a sucrose/ethanol mixture or a sucrose/water mixture;
[0009] FIG. 3 is a graph showing mechanical properties of carbon nanotube yarns treated with a sucrose/ethanol/water mixture;
[0010] FIG. 4 is a graph showing mechanical properties of carbon nanotube yarns that have been treated with a sucrose mixture over several treatment cycles.
DETAILED DESCRIPTION OF EMBODIMENTS
[0011] For purposes of description herein, it is to be understood that the invention may assume various alternative step sequences, except where expressly specified to the contrary. It is also to be understood that the specific devices and processes illustrated in the attached drawings, and described in the following specification, are simply exemplary embodiments of the inventive concepts defined in the appended claims. Hence, specific dimensions and other physical characteristics relating to the embodiments disclosed herein are not to be considered as limiting, unless the claims expressly state otherwise.
[0012] The present invention relates to a process for treating carbon nanotube(s) and graphene yarn(s) and sheet(s) with sucrose to improve the mechanical properties of the tube(s), sheet(s), or yarn(s). Any combination of tube(s), sheet(s), yarn(s) can be simultaneously treated. With reference to FIG. 1 , carbon material in the form of nanotube or graphene yarn or sheet is initially provided at step 1 . The carbon material generally comprises a plurality of microscopic structures such as nanotubes, graphene sheets, or any combinations thereof that are interconnected to form a macroscopic yarn or sheet material. The sheet material can be woven or unwoven. Prior to treatment, the carbon material has a first specific modulus. At step 2 , the carbon nanotube(s) or graphene sheet(s) are aligned. Alignment is accomplished by stretching the carbon material by applying a force to the material. A sucrose solution is then applied to the carbon material at step 3 . The sucrose solution can be applied by soaking the carbon material, such as carbon yarn or sheet material, in a liquid sucrose solution. The liquid sucrose solution can comprise sucrose and a solvent, wherein the solvent can comprise one or more of water, ethanol, and water/ethanol mixtures. In one embodiment, the liquid sucrose solution is sucrose dissolved in water and ethanol. It will be recognized that various other solvents may also be utilized to dissolve the sucrose.
[0013] After the sucrose solution is applied, the carbon material is then dried, wherein water is removed from the solvent used in the sucrose solution, and the sucrose then dehydrated (dry process) or dehydration of the sucrose can be done without the drying step (wet process), as shown in step 4 . For the purposes of this application, dehydration is defined as the removal of hydroxyl groups from sucrose to form the amorphous carbon. The dehydration is carried out with acid. In some embodiments, the acid used is sulfuric acid. In some embodiments the acid can be concentrated sulfuric acid. Various chemical dehydration agents including, for example concentrated sulphuric acid (H 5 SO 4 ) (as well as heat treatment), can be used to treat and dehydrate the sucrose. After dehydration, the carbon material can be washed to remove any unreacted sucrose or dehydration agent(s), step 5 . Applying and dehydrating the sucrose solution while stretching the material (steps 2 to 5 ) can be repeated numerous times to form a binder of the desired thickness (arrows 6 and 7 ). In some embodiments, the desired thickness of the binder is a thickness that yields less than about 60% by weight of the resulting nanocomposite. In other embodiments, the binder thickness is less than about 50% by weight, less than about 40% by weight, less than about 30% by weight, less than about 20% by weight, less than about 10% by weight, less than about 5% by weight or less than about 1% by weight of the resulting nanocomposite. The material is preferably stretched in the same direction during the repeated soaking in the sucrose solution and dehydrating of the sucrose.
[0014] The process of applying the sucrose solution and dehydrating the sucrose forms a binder that locks the individual carbon nanotubes or graphene sheets and bundles of graphene sheets to one another. In various embodiments the carbon material can be made of nanotube(s), graphene sheet(s), bundles of graphene sheets or any combination of the foregoing. Stretching of the carbon material during the process of applying and dehydrating the sucrose aligns the individual carbon nanotubes or graphene sheets relative to one another, and the sucrose binder locks the microscopic structures in alignment. Such alignment of the carbon nanotubes or graphene sheets in the final material leads to large enhancements of the mechanical properties (e.g. specific modulus) as more of the carbon nanotubes or graphene sheets contribute to load bearing. The interlocking binder improves the interaction of the tubes and bundles, limiting slippage and thus enhancing load carrying capacity. Additionally, the bridges formed by the binder serve to enhance the phonon transport properties. In some embodiments the alignment of the microstructures is 100% in the load direction. In other embodiments the microstructure alignment can be about 90%, about 80%, about 70%, about 60%, about 50% or about 40% in the load direction.
[0015] Referring again to FIG. 1 , after drying the sucrose solution and dehydrating the remaining sucrose, the carbon material can be washed and subject to further processing. For example, the carbon material can be annealed or used as a platform for further chemical treatment of the yarns or sheets.
[0016] Various carbon composite structures can be formed utilizing the treated carbon material such as treated carbon yarns or sheets. For example, the treated carbon material can be dispersed in a matrix material (e.g. polymer resin) to form a carbon fiber structural material. The carbon fiber structural material can be a rigid composite structure. Numerous aerospace applications require lightweight structural materials with high specific modulus and strength. Examples of applications include, but are not limited to, structural materials for aerospace vehicles, materials for lightweight, mechanically robust consumer devices, and materials for space habitats.
[0017] Testing of the carbon yarn treated according to the present invention has shown a dramatic increase in mechanical properties. FIG. 2 is a graph showing the mechanical properties of carbon nanotube (“CNT”) yarns treated with a sucrose and ethanol mixture and of carbon nanotube (“CNT”) yarns treated with a sucrose and water mixture. The mixtures of FIG. 2 were a saturated solution of sucrose. As shown in FIG. 2 , the mechanical properties (modulus) of the yarns increase significantly after treatment with the sucrose and ethanol or the sucrose and water mixtures.
[0018] FIG. 3 is a graph showing the mechanical properties of carbon nanotube (“CNT”) yarns that have been treated with sucrose dissolved in an ethanol/water mixture. Again, the mechanical properties (modulus) of the yarns increase significantly after treatment with the sucrose with ethanol/water mixtures. From FIG. 4 ( 3 ), cycle 1 added ˜0.2 g/m of amorphous carbon to the yarn. Cycle 3 added a total of ˜0.5 g/m of amorphous carbon to the untreated yarn. These numbers were calculated from the tex values shown on the graph caption where tex is defined as g/m length of the CNT yarn
[0019] FIG. 3 also shows the results of both a wet process and a dry process utilizing a concentrated (98%) H 2 SO 4 solution. Drying requires heating to ˜110° C. to remove the water. Dehydration is carried out by dipping the dry treated material in concentrated sulfuric acid until the reaction is complete—no more fumes are formed so all the sucrose has reacted.
[0020] FIG. 4 is a graph showing the mechanical properties of CNT yarns treated over several cycles. Control yarns have no treatment. Sucrose yarns are always treated with a solution of sucrose so it would be sucrose mixture. Mixture concentrations are always saturated sugar solutions. Sucrose 1 and sucrose 4 are treated with the same sucrose mixture and only differ from each other by the number of sucrose mixture treatment cycles.
[0021] The carbon obtained from the dehydration of the sucrose serves to bind the CNTs/CNT bundles in the sheet or yarn to lock in alignment and enable better load transfer between the tubes and/or bundles leading to materials with greatly enhanced mechanical properties as shown in FIGS. 2-4 . FIGS. 2-4 show that a greater than 30% increase in tensile properties was realized for non-optimum starting materials.
[0022] It is to be understood that variations and modifications can be made on the aforementioned structure without departing from the concepts of the present invention, and further it is to be understood that such concepts are intended to be covered by the following claims unless these claims by their language expressly state otherwise.
[0023] All cited patents, patent applications, and other references are incorporated herein by reference in their entirety. However, if a term in the present application contradicts or conflicts with a term in the incorporated reference, the term from the present application takes precedence over the conflicting term from the incorporated reference.
[0024] All ranges disclosed herein are inclusive of the endpoints, and the endpoints are independently combinable with each other. Each range disclosed herein constitutes a disclosure of any point or sub-range lying within the disclosed range.
[0025] The use of the terms “a” and “an” and “the” and similar referents in the context of describing the invention (especially in the context of the following claims) are to be construed to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context. “Or” means “and/or.” As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items. As also used herein, the term “combinations thereof” includes combinations having at least one of the associated listed items, wherein the combination can further include additional, like non-listed items. Further, the terms “first,” “second,” and the like herein do not denote any order, quantity, or importance, but rather are used to distinguish one element from another. The modifier “about” used in connection with a quantity is inclusive of the stated value and has the meaning dictated by the context (e.g., it includes the degree of error associated with measurement of the particular quantity).
[0026] Reference throughout the specification to “another embodiment”, “an embodiment”, “some embodiments”, and so forth, means that a particular element (e.g., feature, structure, and/or characteristic) described in connection with the embodiment is included in at least one embodiment described herein, and can or cannot be present in other embodiments. In addition, it is to be understood that the described elements can be combined in any suitable manner in the various embodiments and are not limited to the specific combination in which they are discussed.
[0027] This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to make and use the invention. The patentable scope of the invention is defined by the claims, and can include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal language of the claims. | Consolidated carbon nanotube or graphene yarns and woven sheets are consolidated through the formation of a carbon binder formed from the dehydration of sucrose. The resulting materials on a macro-scale are lightweight and of a high specific modulus and/or strength. Sucrose is relatively inexpensive and readily available, and the process is therefore cost-effective. | 2 |
TECHNICAL FIELD
The invention relates to a thermally bonded nonwoven fabric having improved thermal and chemical stability. The invention further relates to uses of this nonwoven fabric.
PRIOR ART
Melt-bondable fibers and nonwoven fabrics produced therefrom are known from EP 0 340 982 B1. Melt-bondable fibers are dual-component fibers composed of a first, at least partially crystalline, polymer component and a second component, adhering to the surface of the first component, containing a compatible blend of polymers comprising at least one amorphous polymer and at least one polymer which is at least partially crystalline. The melting temperature of the second component is at least 30° C. below that of the first component, but is at least equal to or greater than 130° C. In addition, the weight ratio of the amorphous polymer of the second component to the at least partially crystalline polymer of the second component is in the range of 15:85 and 90:10, and has a value such that binding of dual-component fibers to a similar dual-component fiber is prevented, and the first component forms the core and the second component forms the sheath for a dual-component fiber spun in the form of a sheath-core configuration. This dual-component fiber is mixed with conventional polyester fibers and thermally bonded to produce a nonwoven fabric, which is processed into an abrasive fleece by application of abrasive particles.
Heat-bondable conjugate fibers are known from JP 07-034326 which have a sheath-core configuration, and have a core made of a polyester containing polyethylene terephthalate (PET) as the main component, and have a sheath that is produced from a copolymerized polyester or a side-by-side conjugate fiber composed of polyethylene terephthalate and a copolymerized polyester. The copolymerized polyester represents the lower-melting component, and contains butylene terephthalate units and butylene isophthalate units as repeating structural units. A nonwoven fabric produced from these dual-component fibers is designed to have excellent thermal resistance and fatigue resistance against pressure stress, so that it may be used as an alternative material for polyurethane seat coverings, primarily in the automotive sector.
Thermally bonded nonwoven fabrics may also be produced from a mixture of drawn and undrawn PET fibers. However, these nonwoven fabrics require bonding under heat and pressure in a calender. The bonding capability of the undrawn amorphous PET fibers is based not on a melting process, but, rather, on the crystallization process for PET, which begins above 90° C. provided that crystallizable fractions are still present. Such nonwoven fabrics have high chemical and thermal stability. However, the production process permits little flexibility. Thus, for undrawn PET fibers, for example, it is not possible to activate the bonding capability multiple times, since this requires a process that is irreversible below the melting temperature. In addition, bonding of nonwoven fabrics having weights per unit area >150 g/m 2 with undrawn PET fibers is difficult, since in the calendering process the external heat cannot penetrate sufficiently into the nonwoven web. A more or less pronounced gradient always occurs.
DESCRIPTION OF THE INVENTION
The object of the invention is to provide a thermally bonded nonwoven fabric having improved thermal stability properties, in particular the shrinkage tendency of the nonwoven fabrics obtained. In addition, the chemical stability is increased compared to fibers containing copolymers of monomer mixtures such as isophthalic acid/terephthalic acid.
The object is achieved according to the invention by use of a thermoplastically bonded nonwoven fabric containing a low-shrinkage dual-component core-sheath fiber. The low-shrinkage dual-component core-sheath fiber is composed of a crystalline polyester core and a crystalline polyester sheath which has a melting point at least 10° C. lower than the core, and has a hot-air shrinkage of less than 10%, preferably less than 5%, at 170° C. At temperature stresses of 150° C. (1 h), a corresponding nonwoven fabric exhibits a thermal dimensional change (shrinkage and curl) of less than 2%. In the context of the invention, the term “crystalline” means a polyester polymer having a heat of fusion (DSC) of >40 joule/g and a width of the melting peak (DSC) preferably occurring at <40° C. at 10° C./min.
The sheath of the low-shrinkage dual-component fiber is preferably composed of a homogeneous polyester polymer, produced from a monomer pair, of which greater than 95% is formed from a single polymer pair. In the case of the polyester described in the claims, this means that >95% of the polymer is composed of a single dicarboxylic acid and a single dialcohol.
The mass ratio of the core-sheath component is typically 50:50, but for specialty applications may vary between 90:10 and 10:90.
A nonwoven fabric is particularly preferred in which the sheath of the dual-component core-sheath fiber is composed of polybutylene terephthalate (PBT), polytrimethylene terephthalate (PTT), or polyethylene terephthalate (PET).
Further preferred is a nonwoven fabric in which the core of the low-shrinkage dual-component core-sheath fiber is composed of polyethylene terephthalate or polyethylene naphthalate (PEN).
The nonwoven fabric according to the invention may contain additional fibers besides the low-shrinkage dual-component core-sheath fiber, depending on the particular use. It is preferred to use 0 to 90% by weight of monofil standard polyester fibers, for example, together with the low-shrinkage dual-component fiber.
The nonwoven fabric according to the invention is preferably composed of low-shrinkage dual-component core-sheath fibers having a titer in the range between 0.1 and 15 dtex. The nonwoven fabric according to the invention has a weight per unit area between 20 and 500 g/m 2 . For a weight per unit area of 150-190 g/m 2 , for example, the nonwoven fabric according to the invention achieves a bending stiffness of greater than 1 Nmm transverse to the machine direction, as determined in accordance with ISO 2493.
The method for producing the thermally bonded nonwoven fabric is characterized in that the fibers are laid out to produce a nonwoven fabric, thermally bonded, and immediately compressed if necessary. In the method, the fibers of the nonwoven fabric according to the invention are placed in a thermal fusion oven which allows uniform temperature equilibration of the binding fibers. The low-shrinkage dual-component core-sheath fibers are preferably laid out wet in a paper layout process and dried, or laid out dry using a carding or airlaid process and then bonded at temperatures of 200 to 270° C., and optionally compressed using a calender or press tool at rolling temperatures below the melting point of the sheath polymer, preferably <170° C. This compression is preferably carried out immediately after the bonding process in the dryer, when the fibers are still hot. However, the structure of the fibers also allows subsequent heat treatment, since the bonding process may be activated multiple times.
The thermally bonded nonwoven fabrics obtained have shrinkage and curl values in the range of <2%, preferably <1%.
The nonwoven fabrics according to the invention are suitable as a liquid filter medium, membrane support fleece, gas filter medium, battery separator, or nonwoven fabric for the surface of composite materials on account of their high thermal stability, low shrinkage tendency, and stability with regard to chemical aging. This is particularly true for use as an oil filter medium in motor vehicle engines.
Brief Description of the Drawings
The invention is explained in greater detail below with reference to the figures, which show the following:
FIG. 1 shows a diagram illustrating the maximum tensile forces for nonwoven fabrics A and B in the form of an index, after storage in air and in oil, relative to the respective new state (DIN 53508 and DIN 53521);
FIG. 2 shows a diagram illustrating the maximum tensile force elongation for nonwoven fabrics A and B after storage at 150° C. in air and in oil, relative to the respective new state (DIN 53508 and DIN 53521);
FIG. 3 shows a diagram illustrating the maximum tensile forces for nonwoven fabrics A and B at various temperatures in the form of an index, relative to the respective new state (DIN EN 29073-03);
FIG. 4 shows an electromicrograph of a membrane support fleece bonded with undrawn polyester fibers (nonwoven fabric E; comparative example);
FIG. 5 shows an electromicrograph of a membrane support fleece which according to the invention is composed of 100% low-shrinkage PET/PBT dual-component fiber (nonwoven fabric F);
FIG. 6 shows a DSC curve for a dual-component fiber A containing crystalline sheath polymer (in this case PET/PBT; according to the invention); and
FIG. 7 shows a DSC curve for a dual-component fiber B containing amorphous sheath polymer (in this case PET/coPET; prior art).
TEST METHODS
Bending Stiffness
The bending stiffness was determined in Nmm in accordance with ISO 2493.
Thermal Dimensional Change (Shrinkage)
The sample (DIN A4-size sample) was provided with marks 200 mm apart in the longitudinal and transverse directions. The samples were stored for 1 hour at 150° C. in a circulating air oven and then cooled for 20 minutes at room temperature, after which the dimensional change was determined. This value was expressed as a percentage of the starting value for the longitudinal and transverse directions. The algebraic signs preceding the percentage value indicate whether the dimensional change is positive (+) or negative (−). The mean value was determined from at least six individual values (measurements).
Thermal Dimensional Change (Curl)
The sample (DIN A4-size sample) was provided with marks at which the thickness was determined in accordance with ISO 9073/2. The samples were stored for 1 hour at 150° C. in a circulating air oven and then cooled for 20 minutes at room temperature, after which the thickness was redetermined at the marks (ISO 9073/2). The curl (B), expressed as a percentage, was calculated as follows:
B (%)=(Thickness after storage×100/Thickness before storage)−100
The mean value was determined from at least six individual values (measurements).
Testing of Hot-Air Shrinkage
Twenty individual fibers were tested. The fiber was provided with a pretensioning weight as described below. The free end of the fiber was placed in the clamp of a clamping plate. The length of the clamped fiber was determined (L 1 ). The fiber, freely suspended without weight, was then temperature-equilibrated for 10 minutes at 17° C. in a circulating air drying oven. After cooling for at least 20 minutes at room temperature the same weight from the determination of L 1 was suspended from the fiber again, and the new length (L 2 ) after the shrinkage process was determined.
The percentage of hot-air shrinkage was calculated from the following expression:
HS (%)=(Σ L 1 −ΣL 2 )*100/Σ L 1
TABLE 1
Size of pretensioning weight
Pretensioning weight
Titer (dtex)
(mg)
≦1.20
100
>1.20
100
≦1.60
>1.60
150
≦2.40
>2.40
200
≦3.60
>3.60
250
≦5.40
>5.40
350
≦8.00
>8.00
500
≦12.00
>12.00
700
≦16.00
>16.00
1000
≦24.00
>24.00
1500
≦36.00
In the freely suspended state the fiber should have an uncurled appearance. If the curl was too great, the next heavier weight was selected.
Heat of Fusion (DSC)
The sample was weighed in a DSC apparatus from Mettler Toledo and heated from 0° C. to 300° C. using a temperature program of 10° C./min. The area beneath the endothermic melting peak obtained, in conjunction with the original fiber weight and the associated masses of the sheath or core component, represents the heat of fusion of the respective component in J/g.
EXAMPLE 1
Nonwoven fabric A represents a dry-laid, carded, and thermally bonded nonwoven fabric having a weight per unit area of 190 g/m 2 . This nonwoven fabric was composed of 75% low-shrinkage PET/PBT dual-component fiber having a sheath melting point of 225° C. and a core-to-sheath ratio of 50:50, and up to 25% conventional PET fibers. The thickness was 0.9 mm, and the air permeability was 850 L/m 2 s at 200 Pa. 140 g/m 2 of the fibers were carded by combing using a cross-layer, and the remaining 50 g/m 2 were carded in a longitudinal layout. The nonwoven fabric was bonded in a thermal fusion oven at approximately 240° C., and was calibrated to the target thickness using an outlet press tool.
COMPARATIVE EXAMPLE
Nonwoven fabric B was produced analogously as for nonwoven fabric A. The differences consisted in use of conventional PET/CoPET dual-component fibers having a sheath melting point of approximately 200° C., and reduction of the oven temperature to 230° C. The resulting weight per unit area, thickness, and air permeability were comparable.
The advantages of nonwoven fabric A according to the invention compared to nonwoven fabric B are as follows:
The width of the nonwoven fabric after the dryer decreased by only about 9% for nonwoven fabric A, whereas a loss in width of approximately 21% occurred for nonwoven fabric B. The transverse bending stiffness for nonwoven fabric was 15% greater. The increase in thickness after storage at 150° C. (thermal dimensional change) for nonwoven fabric A was 1.5%, and for nonwoven fabric B, 4.7%. The thermal and chemical stability for storage at 150° C. in air and in oil was much better for nonwoven fabric A ( FIGS. 1 and 2 ). The diagrams clearly show greater destruction of nonwoven fabric B when stored in motor oil. In particular, the brittleness in FIG. 3 indicates a problem with the chemical stability of nonwoven fabric B in oil. The maximum tensile forces at various temperatures show a much more favorable progression for nonwoven fabric A ( FIG. 3 ).
EXAMPLE 2
Nonwoven fabrics C and D represent wet-laid, dried, and thermally bonded nonwoven fabrics having a weight per unit area of 198 g/m 2 and 182 g/m 2 , respectively. These nonwoven fabrics were composed of 72% low-shrinkage PET/PBT dual-component fiber having a sheath melting point of 225° C. and a core-to-sheath ratio of 50:50, and up to 28% conventional PET fibers. The fibers were present as dispersible short-cut fibers. The fibers were deposited on a screen belt in the paper-laying process, dried, and thermally bonded in a second dryer. The exceptional properties of these nonwoven fabrics consisted in the very good mechanical test values and excellent shrinkage characteristics (Table 2). In this case a comparison could not be made to nonwoven fabrics composed of conventional dual-component fibers having a CoPET sheath, since on account of the high shrinkage values it has not been possible heretofore to use such fibers on this nonwoven fabric apparatus; i.e., the fibers exhibited reductions in width of at least 20%. The wet nonwoven fabrics according to the invention exhibited reductions in width of approximately 3%.
TABLE 2
Test values for nonwoven fabrics C and D
Nonwoven
Nonwoven
fabric C
fabric D
Weight per unit area
198
g/m 2
182
g/m 2
Thickness
1.10
mm
0.99
mm
Air permeability
714
L/m 2 s
796
L/m 2 s
Maximum longitudinal tensile force
536
N/5 cm
446
N/5 cm
Maximum transverse tensile force
358
N/5 cm
329
N/5 cm
Longitudinal bending stiffness
2.5
Nmm
1.9
Nmm
Transverse bending stiffness
2.1
Nmm
1.6
Nmm
Longitudinal shrinkage at
0.0%
0.3%
150° C., 1 h
Transverse shrinkage at
0.0%
0.0%
150° C., 1 h
Curl at 150° C., 1 h
0.7%
1.5%
The low-shrinkage dual-component fibers according to the invention offer advantages, in particular for use in the wet-laying process employing separate dryers for water removal and for thermal fusion, since in contrast to undrawn binding fibers these fibers may be activated multiple times, i.e., are not completely reacted upon the first drying process.
Nonwoven fabrics A, C, D according to the invention are particularly suited for use as motor oil filter media in motor vehicles.
EXAMPLE 3
For use as membrane support fleeces, calendered PET nonwoven fabrics (comparative example; nonwoven fabric E) composed of a mixture of drawn and undrawn monofil PET fibers represent prior art. As a result of the calendering process, there is a risk of surface sealing in particular for heavy nonwoven fabrics having weights per unit area >150 g/m 2 , since for good bonding of the nonwoven fabric high rolling temperatures or slow production speeds are required in order to conduct the necessary heat to the interior of the nonwoven fabric. Sealed surfaces entail the risk of film formation, which in turn results in poor membrane adhesion and lower flow rates (comparative nonwoven fabric E). FIGS. 4 and 5 demonstrate the difference in surfaces for a conventional nonwoven fabric (comparative example; nonwoven fabric E; FIG. 4 ) and for a nonwoven fabric according to the invention (nonwoven fabric F; FIG. 5 ).
The complete absence of surface sealing for nonwoven fabric F ( FIG. 5 ) is also shown in a comparison of test values for the two nonwoven fabrics. The air permeability of nonwoven fabric F increased by an order of magnitude, whereas the other test values were comparable (Table 3).
TABLE 3
Test values for nonwoven fabrics E and F
Nonwoven
Nonwoven
fabric E
fabric F
Weight per unit area
190
g/m 2
190
g/m 2
Thickness
0.26
mm
0.25
mm
Air permeability (200 Pa)
5
L/m 2 s
41
L/m 2 s
Maximum longitudinal tensile force
520
N/5 cm
514
N/5 cm
Maximum transverse tensile force
470
N/5 cm
560
N/5 cm
Use of conventional dual-component fibers containing copolymers in the sheath has not become established in this application area due to the high shrinkage values and the associated weight fluctuations, in addition to the frequent denial of food safety authorization for sheath polymers. The nonwoven fabrics according to the invention, composed of the corresponding dual-component fibers, overcome both drawbacks, since they are low-shrinkage and pose no difficulties in food safety authorization because they are composed of homopolymers.
EXAMPLE 4
To further demonstrate the differences in the nonwoven fabrics according to the invention compared to conventional nonwoven fabrics containing dual-component fibers having sheaths based on copolymers, FIGS. 6 and 7 show a comparison of differential scanning calorimetry (DSC) curves for fibers containing crystalline sheath polymer (fiber A; in this case PBT) to DSC curves for conventional dual-component fibers (fiber B; in this case CoPET). The analysis of the heats of fusion of the lower-melting component showed that the sheath for fiber B has a much lower heat of fusion, in J/g, than fiber A.
The heat of fusion is a direct measure of the crystalline fractions in the polymer. The core-to-sheath ratios in both fibers were 1:1, resulting in the following heats of fusion for the fiber sheaths:
Fiber A
63 J/g
Fiber B
29 J/g
Here as well, the core of both fibers, which in each case is composed of PET, may be used as a measurement reference. The values obtained for the heat of fusion are comparable (59 J/g versus 54 J/g).
Independent of the measured values, in a comparison of the DSC curves the low peak height and the wider peak base are characteristic of fiber sheaths based on copolymers (in this case CoPET). The melting point as well as the crystallinity, i.e., the tendency of the polymers to crystallize, are reduced by incorporation of comonomers such as isophthalic acid into polyethylene terephthalate.
The nonwoven fabrics according to the invention are therefore based on fibers of the fiber A type. | The invention relates to a thermally bound non-woven material containing a low-shrinkage dual-component core-sheath fiber consisting of a crystalline polyester core and a crystalline polyester sheath which has a melting point at least 10° C. lower than the core, the heat-shrinkage characteristic of said fiber being less than 10% at 170° C. | 3 |
BACKGROUND OF THE DISCLOSURE
The present disclosure is directed to a system for reducing water scaling in a system with flowing water. Water normally obtained from practically every source is loaded with dissolved salts which form scale deposits under certain circumstances. The collection of water scale is more or less related to the amount of hardness in the water. Water becomes hard as the dissolved salt content increases. The most common sources of hard water are water accumulated in lakes or from artesian wells. Typically, lake water carries a higher level of hardness in the water, but artesian water is not exempt from the problem. The problem derives from dissolved salts and mostly calcium salts carried in the water. As the water flows over limestone formations, it will carry away a part of the limestone in the form of dissolved rock salts which are most commonly CaCO 2 . Not only are calcium salts commonly encountered, magnesium salts also occur. All of the various salts encountered in water flow in nature create the risk of dissolving the salts into the flowing stream, accumulating in a lake, and ultimately forming water scale deposits when flowing in a metal pipe. The extreme of this is seen in the Dead Sea and the great Salt Lake in Utah. There, the water flows into a basin and cannot escape except through evaporation. The lakes become highly mineralized and are therefore so laden with salt accumulation that they are, for all practical purposes, poisonous to plant life. When that water is used, obviously for purposes other than cooking or drinking, the water tends to leave a deposit which builds up so that flowing water engenders the risk of scaling. The problem of scaling varies with the region which depends on the geology of the region. In the Panhandle of Texas, flowing water carries a very large amount of dissolved minerals in it. It is not uncommon for the water minerals to accumulate on the metal surfaces of pipes downstream from the water source and ultimately reduce the effective cross-sectional area of the pipes. The tendency to come out of solution and form a deposit is dependent on many factors including concentration, water temperature, flow velocity, turbulence, and the roughness of the surface. Even where the surface is extremely smooth when initially installed, once a thin layer of deposited scale is formed, the growth can increase rapidly as the scale builds up. As a generalization, this requires expensive steps to remove and clear the passage. It is especially a problem in equipment where the volume of highly mineralized water is significant. That problem is most often seen in systems where there is recirculation such as cooling systems or heating systems using water. Untreated water and even water which has been treated in an economical way will nevertheless build up large amounts of scale. It is probably a very chronic problem in closed flow loops in heating and air conditioning systems. There is also a great difficulty in stationary border plants and the like.
In solution, the dissolved salts are best considered in an ionic state. Thus, the limestone rock deposits may have some calcium CaCO 2 along with other salts. When dissolved, the ionic disassociation simply scatters, in a random distribution in the stream of water, the constituents. Accordingly, a flowing stream of water will include any number of cations and anions flowing in the stream. The cations and anions are the material ultimately forming a deposit downstream which is characterized by the more common ions in the stream. It is not uncommon to build up a scale deposit which becomes hard over time as the dissolved minerals are plated onto a surface which will hold and accumulate the deposits. Therefore, this prompts the accumulation of substantial amounts of deposited material so that the hardness restricts flow, interferes with heat transfer, and is a cumulative detrimental problem.
SUMMARY
In this systems an apparatus is installed in the flowing water which functions as a pipe, thereby making up part of the plumbing system. The pipe component is made of metal. In this aspect, the first metal is the metal in contact with the flowing water. The pipe supports, on the interior, a second metal which is spaced from the first metal, thereby defining first and second metal surfaces where the two metal surfaces are different in electrochemical activity. The electrochemical activity of metals range from one extreme for platinum, gold and silver to the other extreme for aluminum. Ranking of the metals is believed well known in this aspect. In a flowing water stream, the two metals define separated metal surfaces. The flowing water, in cooperation with the different metals, forms an electrolytic cell. The potential difference between the two metals is well known from the table of relative activities of the various metals. This creates a current flow between the two metals. The, current flow is from metal to metal, hence, across the flowing water. The current flow generally is resisted by the water because water is a relatively good insulator (referring to pure water). The impurities in the water, however, and especially the dissolved minerals, provide ionic carriers for charge interchange between the metal surfaces. This charge interchange is accomplished by migration between the two metal surfaces. The ionic current flow is significant in that the dissolved minerals tend to collect at the metal surfaces. There will be a preference at one surface or the other dependent on the electrolytic activity of the two metals with respect to each other. There will be a tendency of ions to be neutralized. This neutralization results in formation of a soft deposit in the region. In other words, the current transfer mechanism changes the binding forces involved in depositing the dissolved mineral ions at one of the metal surfaces so that plating is accomplished, yet with a reduction in hardness.
Consider a worse case description. A water system installed in the Texas Panhandle for transfer of water accumulated from rain runoff is extremely mineralized and can form deposits in metal pipes which have a hardness approaching that of sheet rock. It also has a consistency in color approximating that of sheet rock. Vigorous effort is required to clean the pipe. The present apparatus sets out a system in which a softer form of scaling occurs, and just as importantly, the scaling which does occur is localized easily on the surface of the present invention.
This system incorporates a bimetal cell which is self-powered. By that, no electrical power is required from the exterior. It makes its own electrical current, and that current is defused as it flows through the water between the two metal surfaces so that the defused flow forms a defused distribution of deposits on one of the metal surfaces. The deposits are cumulative. However, deposits have reduced hardness and are mechanically removed more readily. The present apparatus, when installed in a flowing stream, reduces the mineral hardness downstream. The deposits resultant from hard water are likewise reduced downstream. This is true in a variety of circumstances. For instance, the downstream device may be a water recirculation system for transfer of heat. In that system, there will be a cooler region and a hotter region. One example of this is a cooling system for an air conditioning plant. Another example of this is a boiler system where the water is heated in a nest of pipes in a boiler to convert into steam and is recycled by condensing the spent steam. Of course, where steam is lost, there will be a modest flow of water added to make up the total feed. Suffice it to say, many other examples can be identified in which water scale is a serious problem, and especially serious in a closed flow loop of the type just mentioned. The present invention sets forth a mechanism which significantly changes the plating mechanism and also reduces the amount of scale accumulated downstream.
The present apparatus is therefore summarized as a fitting which is installed to be electrochemically active in a flowing water stream. The water is delivered into and out of the fitting by an installed elongate sleeve having an inside metal surface, that being the first metal. There is a radially spaced metal surface on the interior that is electrically insulated from the first metal surface. The second metal surface in conjunction with the first defines an electrolytic cell. Water is directed through the cell and sets up current flow through the metal components. The system also incorporates a set of fittings which enable it to be assembled in a plumbing system and disassembled for easy servicing.
BRIEF DESCRIPTION OF THE DRAWINGS
So that the manner in which the above recited features, advantages and objects of the present invention are attained and can be understood in detail, more particular description of the invention, briefly summarized above, may be had by reference to embodiments thereof which are illustrated in the appended drawings.
The only drawing shows, in sectional view, an external housing having the form of a pipe and defining a first metal surface on the interior in conjunction with a supported coil formed of a second metal which is electrically isolated in the housing so that water flows through and between the two metal surfaces.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Attention is now directed to the only drawing where the numeral 10 identifies the apparatus of the present disclosure. The description will begin with the external shape and construction which brings out features enabling connection in a system. The term system refers to a water flow system. It is typically water delivered under pressure where the water carries various levels of hardness as a result of flowing over terrain laden with limestone and similar minerals. Such rock formations are dissolved by the flowing water and are carried in the water to define the water hardness which can vary from negligible to extreme. As a first aspect, the exterior elongate member has the form of a pipe of fixed length and diameter. The diameter can vary in proportion to the length, but for household systems, it is suggested that the pipe have a flow capacity equal to that of 1 inch pipe, operating at perhaps 100 psi, obviously increased by several fold for over design and safety. The device 10 typically measures between 12 and 24 inches in length. It can be increased in length, diameter and weight for commercial situations. From the left, a pipe thread 12 is incorporated to enable easy connection with a union or other fitting upstream. Flow will be assumed to be from left to right although the construction of the device enables its operation with flow from either end. The threaded end portion connects with a neck 14 which defines the throughput permitted by the device. An enlargement 16 enables the larger diameter tubular member 20 . The thickness of the wall remains substantially the same while the transition 16 steps out the diameter so that certain equipment can be included in the interior. Moreover, this diameter is sufficiently large so that there is no loss in volumetric throughput. The device is intended to provide 100% flow capacity. It is especially important to avoid defining a narrow neck restriction. The right side of the tubular member 20 terminates at a transition 17 to a neck 14 ′ with a pipe thread 12 ′.
The present apparatus supports at the left end a cylindrical insert sleeve 22 which is formed of PTFE or other plastic materials. It is an electrical insulator. The outer cylindrical shell 20 is formed of two similar portions or halves which are joined together by a union 24 . The union 24 is constructed of any suitable material. Preferably it includes a metal coupling so that the left hand half is connected to the right hand half. The union provides electrical continuity and structural support. The outer cylindrical member 20 is formed of a metal or an alloy of sufficient strength to provide the structure desired. The inside face, however, is coated. The coating is sufficiently uniform and thick so that it provides an overlay of at least as many microns so that an impervious metal layer is provided on the interior. This metal layer comprises the first metal. That metal will be discussed in detail below at which time a description of the electromotive series will be given. The electromotive series is defined at page F-102 of the 57th Edition of the CRC Handbook of Chemistry and Physics. That definition states that the electromotive series comprises a list of metals arranged in the decreasing order of their tendency to pass into ionic form by losing electrons. Typically. hydrogen is included in that series to serve as a reference point although it is not practically a metal. The other metals are in the periodic table. Accordingly, the member 20 is coated on the interior. That coating defines the first metal. That metal coating includes the coupling 24 at the location where it is exposed to water.
The resilient insulator sleeve 22 and insulator sleeve 22 ′ serves as a support for the second metal. In physical structure, the second metal has the form of a coil spring 25 . The coil spring is inserted on the interior. The coil spring preferably has a resilient metal core. Typically the coil spring is formed of wire stock. The wire is springy in the sense that spring steel has that characteristic. Indeed, it is wound so that the coil spring 25 fits between the enlargements at 16 . This enables the coil spring to rest on the insulator sleeve 22 . It is therefore electrically isolated and not in contact with any other metal. The coil 25 is formed of at least one metal. As noted, it is formed by winding from rod stock to define the coil spring. The rod stock enables construction of a resilient coil spring with a defined amount of springiness. Since no load is placed on it, a low cost steel such as 1010 or 1020 steel will suffice. Obviously, other material with comparable resiliency and elasticity can also be identified.
The coil spring 25 is coated with an external metal coating. The entire exterior is preferably coated to a depth of many microns and comprises a second metal. The second metal operates in conjunction with the first metal, i.e., the metal on the sleeve 20 . The metal coating on the coil spring is selected from the electromotive series so that an appropriate difference can be obtained from the second metal. The potential difference between the two metals is important to the operation of the device. The second metal (placed on the coil spring 25 ) is attached by electroplating or other appropriate chemical deposition techniques. This enables the second metal to have a high quality surface and sufficient thickness to assure that it is only a single metal which is exposed to the water, not the metal which makes up the coil spring. Again, the coil spring can be made of a single metal if desired but cost savings are normally obtained by making the spring 25 out of an inexpensive steel and then coating it with the second metal. That typically is cheaper than attempting to fabricate a coil out of a single metal, i.e., copper. Focus is now directed to the surface area of the first and second metals. Looking solely at the surface of the enlarged tubular member 20 , it has an aggregate length represented by the symbol L and a diameter D. Surface area is given by the relationship L×D×pi. The second metal (on the coil spring 25 ) has an area also given by the relationship just noted but the respective diameters are quite different; therefore, the respective lengths must also be different. Consider an easy example for purposes of illustration. Assume that the ID of the member 20 is 1.000 inches and the length is precisely 20 inches of exposed area (this ignores the area under the plastic insulator). Accordingly, with a length of 20 inches and ID of 1.000, the coil spring must have a diameter and length which will vary inversely. If, for instance, the coil stock has a diameter of 0.1000, then the length must be 200 inches. This requires that the pitch of the coil be such that the turns of the coil will enable the coil to fit within the 20 inch length just noted while yet providing the aggregate surface area. So to speak, the coil is designed for a rod stock (hence, diameter) selected so that the number of turns will reasonably fit in the length for the first metal, or 20 inches in this example. To provide matching surfaces between the first and second metals, and using the dimensions given as an example, the coil has to be wound with a lead to compress the spring into the requisite number of turns to enable 200 inches of rod stock to be confined within about 20 inches.
It will be understood that some portion of the first metal surface (the inside face of the enlarged portion 20 ) and the second metal surface (the outside face of the coil spring 25 ) is ineffective in the insulator 22 . This depends on the area of contact by the insulator 22 and insulator 22 ′. Where the insulator is snug against the first metal then the insulator may well take that contacted portion of metal out of operation. There is a loss of area to the detriment of current flow between the first and second metals. This is less of a problem for the coil which is contacted only at a line of contact on the outer face of the coil turns. Again, it is not that there is a complete loss of effectiveness; it is simply that the electrical insulator prompts current to flow around the insulator between the two metals.
One of the metal surfaces will be more active than the other in accordance with the electromotive activity for the two metals. As an example, silver can be selected as one of the surfaces and the other can be zinc, copper, nickel and so on. The difference between the two determines the potential difference of the system to provide current flow. Moreover, this current flow prompts a coating on the two surfaces. The current interacts ionically with the dissolved mineral salts in the system and produces a plating at one of the two metal surfaces. Because of the current flow, the plating is accomplished with reduced binding forces so that the dissolved salts in the water are much softer when it plates out as a result of encountering the current flow. Absent the current flow, the scale deposits on the interior of the pipe can be extremely hard and can be removed only by strong abrasion or perhaps exposure to strong acids.
As a generalization, using the present apparatus, a soft powdery accumulation collects on one or the other metal surface. As a generalization, it prefers one surface over the other. One of the two metal surfaces will collect more of the material. Interestingly, the downstream plumbing system will also collect scale deposits but they are additionally reduced in hardness compared to that without the present invention. In general terms, the scale collected at all locations is easier to remove, and seems to have reduced binding or adhesive forces by at least 50%, and typically 75% or so. The binding forces in the deposits not only make the bond weaker, but the invention reduces the amount of scale deposits. Because of that, the plumbing system is easier to clean. It is especially easier to clean at the apparatus 10 which can be easily removed and quickly dusted to knock loose the accumulated scale. In ordinary circumstances without this invention, the scale can be very hard so that it will not be dislodged merely by dusting. Rather, it requires a wire brush or the like for removal.
An important aspect of this invention derives from the relationship of the two surface areas. One surface area will attract more of the deposits than the other. Ideally, that metal surface is increased by about 25% over the other surface area that attracts fewer scale deposits. It is conjectured that the scale deposits are attracted to the relative polarity surfaces dependent on the charge of the ionic salts in solution and taking into account the relative electrochemical activity of the two metals. Accordingly, it is generally desirable that one of the two surfaces be about 25% larger than the other because it will collect more scale, and as the scale accumulates, that reduces somewhat the effective surface area. To be sure, the reduction of effective surface area is significantly less with this approach than without, and it is conjectured this is because the accumulated scale, using this system, is soft, light and almost feathery to the touch. Such generalizations are hard to quantify but they are distinctly easier deposits to collect and remove by contrast with deposits from an unprotected pipe. Literally those deposits can be as hard as sheet rock.
Going now to the proportionate areas, the optimum is to make one of the two metal surfaces about 25% greater than the other. Going back to the two ratios, with a 1:1 ratio, the system is given by the relationship D 1 L 1 =D 2 L 2 . This modified form enhances the DL product on one side or the other by 25%. With this suggested enhanced ratio for one metal, the system will then accumulate on that metal a very substantial amount of scale which is easily removed.
For convenience, the apparatus 10 is illustrated with threads 12 and 12 ′ but it can also be connected with a quick disconnect fitting at both ends. If desired, the coil can be sized so that it is smaller in maximum diameter than the narrow neck 14 and narrow neck 14 ′ thereby enabling the coil to be easily pulled from the interior. This mounting contemplates positioning the coil so that it is supported only on the insulative mounting sleeves and sized so that it can easily be pulled by finger engagement from the interior, cleaned and restored all in the matter of two or three minutes. Installation is then accomplished easily by simply inserting the coil back to the illustrated position.
While the foregoing is directed to the preferred embodiment, the scope thereof is determined by the claims which follow. | Water having dissolved salts therein causing scaling is treated by flowing through a passage in an elongate tubular member. The tubular member has a first metal inside surface exposed to the water. A second metal surface is positioned therein and the two surfaces have areas of 1:1 up to about 125% with the second metal being different from the first metal. The metal surfaces are electrically insulated from each other so that current flow between the two is through the water. | 2 |
This is a Continuation of application Ser. No. 11/878,883 filed Jul. 27, 2007, now U.S. Pat. No. 7,886,596 which claims the benefit of Japanese Patent Application No. 2006-216505 filed Aug. 9, 2006; Japanese Patent Application No. 2006-249404 filed Sep. 14, 2006; and Japanese Patent Application No. 2007-119281 filed Apr. 27, 2007. The disclosures o the prior applications are hereby incorporated by reference herein in their entirety.
BACKGROUND
1. Technical Field
The present invention relates to an inertial sensor such as an acceleration sensor and a gyro sensor and a method for manufacturing it, and is particularly preferred for in-vehicle navigation devices.
2. Related Art
In-car navigation devices are popularly spread out. When detecting a current position of a vehicle via such device, two methods are combined: a method for positioning a vehicle by using a so-called global positioning system (GPS), and a method for autonomously positioning the moving direction and distance of a vehicle. In order to autonomously position the moving direction and distance of a vehicle, an inertial sensor such as a gyro sensor (an angular velocity sensor) for detecting acceleration or angular velocity yielded by a moving vehicle are mounted in car navigation devices.
When acceleration or angular velocity is detected by using an inertial sensor, the detection axis of the sensor needs to be coincided with a direction to be detected. For example, the detection axis of a gyro sensor needs to be installed upward along the vertical direction.
In recent years, downsizing in-car navigation devices have been advanced. A casing main body (hereinafter, referred to as “an navigation body”), has been developed as to be installed into a center console between a driver seat and a passenger seat, though it was conventionally installed under a seat or inside a trunk.
FIGS. 15A and 15B show a navigation body installed in a center console. FIG. 15A is the whole perspective view. FIG. 15B shows a gyro sensor mounted in the navigation body.
When a navigation body 100 is installed in a center console 102 as shown in FIG. 15A , the surface of a display 101 and an operation panel (not shown) are preferably directed to a driver's viewing direction because of his/her visibility of the display 101 and operability of the operation panel. That is, the navigation body 100 is preferably installed tilted obliquely upward from the horizontal direction in the center console 102 . When the navigation body 100 is installed tilted obliquely upward in the center console 102 , however, as shown in FIG. 15B , the detection axis G of a gyro sensor 104 is slanted by angle (a tilt angle) θ from the vertical direction V. Here, the gyro sensor 104 is mounted on a printed board 103 in the navigation body 100 that is installed with also tilted by the angle θ. Due to this tilt, errors occur in angular velocity detected by the gyro sensor 104 .
In ordinal car navigation devices, such detection errors of the gyro sensor 104 due to the installation angle of the navigation body 100 are corrected by software arithmetic processing. The software arithmetic processing, however, is insufficient. For example, the software arithmetic processing cannot correct detection errors when the tilt angle θ of the navigation body 100 is 30° or more.
In order to avoid such insufficiency, an inertial sensor is required that can correctly perform a detection even when a car navigation device is installed tilted. Various kinds of sensors are proposed to satisfy the requirement.
For example, a first example of related art discloses an angular velocity sensor in which a detection axis is tilted by an angular velocity detection element inside the sensor being slanted from a holder without changing the shape of or mounting method of the sensor.
Further, a second example of related art discloses a sensor device provided with a detection element detecting a direction and magnitude of a physical quantity having a constant directional property and a fixture for fixing and supporting the detection element. In the device, the detection element is fixed to the fixture and tilted by a predetermined reduced angle in a reducing direction. The reducing direction reduces an predicted angular difference between the direction of the detection axis, serving as the reference for detecting the magnitude and the direction of the physical quantity, and a direction of the physical quantity actually applied to the detection element during detecting.
A third example of related art discloses a supporting structure in which the angle of a vibrator in a package is set by a support connecting the vibrator to a support substrate and an adhesive bonding the support substrate and a package substrate so as to direct the detection axis of the vibrator in a desired direction.
Here, WO03/100350 is the first example, JP-A-2003-227844 is the second example, and JP-A-2005-249428 is the third example of related art.
The sensors disclosed in the first and second examples, however, may deteriorate detection performance due to acoustic leakages or unwanted vibration modes of the quartz crystal resonator yielded from a fixture since the quartz crystal resonator serving as a detection element is directly fixed to the fixture.
In addition, the sensors disclosed in the first and second examples, a specialized tool is required for every fixing angle since the detection element in itself needs to be fixed tilted. As a result, production costs soar. The reason for requiring the specialized tool is as follows. In each sensor, the detection element is irradiated with a laser to adjust the sensor after fixing the detection element to the fixture. Thus, one of focal points of the laser differs from others every one of fixing angles when changing the fixing angle, resulting in that the same tool is not shared.
Further, in the second example, a slit is formed in a detection element in itself for fixing it tilted. This process causes a high cost of a detection element, increasing total production costs.
Furthermore, in the first and second examples the angle of a detection axis cannot be set to any angle when a sensor is mounted on a mount board since a detection element is set tilted within a sensor.
Further, a support (bonding wire) connecting a vibrating element (vibrator) to a support substrate shown in the third example significantly affects occurrence of acoustic leakages and unwanted vibration modes from the vibrating element, sometimes deteriorating detection performance of the sensor. In addition, changing the angle with using the adhesive causes large variations in production, resulting in a setting angle being inaccurate.
Further directly fixing an element to a fixture in the first and second examples also causes occurrence of acoustic leakages and unwanted vibration modes from the vibrating element, resulting in a setting angle being inaccurate.
Taking the above into consideration, the inventors pay attention to a method that a sensor device in which a sensor element is fixed by a conventional bonding method is bonded to a lead frame and molded. The method can suppress the occurrence of acoustic leakages and unwanted vibration modes since the sensor element is fixed by the conventional bonding method, control a setting angle corresponding to a detection axis, by which the sensor responds to movements, with the shape of the lead frame, and further secure mechanical strength as molded.
However, in the method, the sensor device including the sensor is tilted with respect to a mount surface corresponding to the detection axis by which the sensor responds to movements, by controlling the shape of the lead frame. Thus, when a sensor device is formed by using a related art molding method in which the outline of the molded one follows the outline of the sensor device, the outline of the sensor device is not parallel with the mount surface. This outline may worsen workability in mounting processes.
SUMMARY
An advantage of the invention is to provide an inertial sensor that can set a detection axis at a predetermined angle without deteriorating detection performance of a detection element.
Another advantage of the invention is to provide a method for manufacturing an inertial sensor device that can accurately set the detection axis of the sensor when the device is fixed on a mount surface having a predetermined tilt angle, and can set a predetermined angle that the detection axis of the sensor makes with respect to a bottom surface and an upper surface of a molded package, improving workability.
An inertial sensor according to a first aspect of the invention includes a detection element detecting an amount of a physical quantity in a detection axis direction, a plurality of support members having flexibility and supporting nearly a center of the detection element, and a package substrate housing the detection element and the plurality of support members. In a case when an X-axis is defined as an extending direction of the plurality of support members, a Y-axis is perpendicular to the X-axis in a plane including the detection element, and a Z-axis is perpendicular to the X-axis and the Y-axis, one of load components in a direction of the Y-axis of the detection member applied to the plurality of support members is nearly equal to other among the plurality of support members, and one of load components in a direction of the Z-axis is nearly equal to the other among the plurality of support members.
This structure can render the setting condition of mechanical resonance frequency of each support member robust to the change of force caused by acceleration since an effect due to the acceleration is equally applied to each support member. That is, the following trouble can be prevented. The resonance frequency of the support member varies to an unexpected value. In addition, the resulting frequency approaches near the driven vibration of the inertial sensor during a process in which the driven frequency of the inertial sensor varies with a temperature change. The driven vibration frequency of the inertial sensor is coupled with (attracted to) the resonance frequency of the support member. As a result, the output signal of the inertial sensor jumps.
In this case, the detection element may have a detection axis that detects an angular velocity and coincides with the direction of the Z-axis that makes an angle of θ with respect to a vertical direction, and a resulting load combined by the component in the direction of the Y-axis of the load and the component in the direction of the Z-axis of the load may be at least a load component based on gravity acceleration.
This structure can render the setting condition of mechanical resonance frequency of each support member robust to the change of force caused by acceleration since an effect due to the acceleration is equally applied to each support member even when the inertial sensor is set tilted. That is, the following trouble can be prevented. The resonance frequency of the support member varies to an unexpected value. In addition, the resulting frequency approaches near the driven vibration of the inertial sensor during a process in which the driven frequency of the inertial sensor varies with a temperature change. The driven vibration frequency of the inertial sensor is coupled with (attracted to) the resonance frequency of the support member. As a result, the output signal of the inertial sensor jumps.
In addition, the driven frequency of the inertial sensor can be inspected while the inertial sensor is tilted. As a result, the inspection process can be simplified.
Further, this structure has an advantage in that the resonance frequency of the support member is robust to acceleration of a vehicle during its movement.
In this case, the Z-axis may make the angle of θ with respect to the vertical direction by tilting the inertial sensor around a longitudinal direction of the sensor.
This structure can reduce the height of an inertial sensor device when the inertial sensor is built into an inertial sensor device as the sensor is tilted.
An inertial sensor device according to a second aspect of the invention includes the inertial sensor of the first aspect of the invention, a plurality of lead terminals electrically coupled to the inertial sensor, and a molded package including the inertial sensor.
This structure can render the setting condition of mechanical resonance frequency of each support member robust to the change of force caused by acceleration since an effect due to the acceleration is equally applied to each support member. That is, the following trouble can be prevented. The resonance frequency of the support member varies to an unexpected value. In addition, the resulting frequency approaches near the driven vibration of the inertial sensor during a process in which the driven frequency of the inertial sensor varies with a temperature change. The driven vibration frequency of the inertial sensor is coupled with (attracted to) the resonance frequency of the support member. As a result, the output signal of the inertial sensor jumps.
In this case, the molded package may include a first lead terminal extending toward a direction of a bottom surface of the molded package from a first part of the molded package, and a second lead terminal longer than the first lead terminal, the second lead terminal extending toward the direction of the bottom surface of the molded package from a second part facing the first part. The second lead terminal may include a plurality of bending parts facing the molded package.
This structure can prevent the inertial sensor from being floated by a coated solder along the second lead terminal when the inertial sensor is mounted to a mount board.
A method for manufacturing an inertial sensor device according to a third aspect of the invention is the method that molds a lead frame and a sensor device with resin. The lead frame includes a plurality of lead terminals electrically connecting a mount board. The sensor device includes a sensor that responds to a movement with respect to a detection axis and is directed by a shape of the lead frame at a setting angle. The method includes: bonding the sensor device to the lead frame; overlapping a lower die having a first surface in which a concave part is formed and an upper die having a second surface in which a second concave part is formed so that the first surface and the second surface meet each other with the lead frame interposed between the lower die and the upper die to house the sensor device in a cavity formed by the first concave part and the second concave part, after the bonding; and injecting resin into the cavity. The first concave part has a first bottom surface and the second concave part has a second bottom part, and after the overlapping, the first bottom surface and the second bottom surface are tilted with respect to a main surface of the lead frame and are in parallel with each other.
This method can form a molded package that has an outline in parallel with the mount board and includes the sensor device adjusted to the setting angle with respect to the mount board corresponding to the detection axis responding to the movement. As a result, the inertial sensor device can be manufactured that has improved workability in mounting the device.
In the method, the first bottom surface and the second bottom surface may be tilted by the setting angle with respect to the main surface of the lead frame.
Using the dies can form the molded package of the inertial sensor device so that the bottom surface of the sensor device makes an angle with respect to the bottom surface of the inertial sensor device and the normal line of the bottom surface of the inertial sensor device makes a predetermined angle with respect to the detection axis.
As a result, the inertial sensor device can be manufactured that allows the detection axis of the sensor to be accurately set even if the inertial sensor device is fixed to a tilted surface by setting an angle that the normal line of the bottom surface of the inertial sensor device makes with respect to the detection axis equal to an angle that the normal line of the surface of the tilted mount board on which the inertial sensor device is mounted makes with respect to the vertical direction.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be described with reference to the accompanying drawings, wherein like numbers reference like elements.
FIGS. 1A and 1B are schematic views illustrating the structure of a gyro sensor device according to a first embodiment of the invention.
FIG. 1A is the top view.
FIG. 1B is the side view.
FIG. 2A shows a mounting example of the gyro sensor device of the first embodiment.
FIG. 2B shows a mounting example of a gyro sensor device.
FIGS. 3A to 3D are schematic views illustrating a lead terminal unit used in the gyro sensor device of the first embodiment.
FIG. 4 is a flowchart illustrating manufacturing steps of the gyro sensor device.
FIG. 5 is a schematic view illustrating the structure of a gyro sensor device according to a second embodiment of the invention.
FIG. 6 is a schematic view illustrating a tool for wire bonding according to the second embodiment.
FIG. 7 is a schematic view illustrating the structure of a gyro sensor device according to a third embodiment of the invention.
FIG. 8 is a sectional view illustrating an internal structure of a gyro sensor 10 .
FIGS. 9A to 9C are schematic views illustrating the structure of a support substrate included in the gyro sensor 10 .
FIG. 10A is a plan view schematically illustrating a quartz crystal resonator element 11 .
FIG. 10B is a plan view illustrating a vibration of the detection vibration mode of the quartz crystal resonator element 11 .
FIG. 11A is a plan view illustrating wires 13 and a tilt direction where the present invention is not applied.
FIG. 11B is a side view illustrating a gyro sensor device, in which the quartz crystal resonator element 11 is placed on the wires 13 shown in FIG. 11A , installed tilted.
FIG. 11C shows the relationship between the resonance frequency of the wire 13 of the gyro sensor device shown in FIG. 11B and the resonance frequency of the quartz crystal resonator element 11 .
FIG. 12A is a plan view illustrating the wires 13 and a tilt direction where the present invention is applied.
FIG. 12B is a side view illustrating a gyro sensor device, in which the quartz crystal resonator element 11 is placed on the wires 13 shown in FIG. 12A , installed tilted.
FIG. 12C shows the relationship between the resonance frequency of the wire 13 of the gyro sensor device shown in FIG. 12B and the resonance frequency of the quartz crystal resonator element 11 .
FIG. 13 is a schematic view illustrating the structure of a lower die of a molding die.
FIG. 14 is a schematic view illustrating the whole structure of the molding die.
FIGS. 15A and 15B show a navigation body installed in a center console.
FIG. 15A is the whole perspective view.
FIG. 15B shows a gyro sensor mounted in the navigation body.
DESCRIPTION OF EXEMPLARY EMBODIMENTS
Embodiments of the present invention will now be described below.
In the embodiments, a gyro sensor will be described as an example of an inertial sensor of the invention.
FIGS. 1A and 1B are schematic views illustrating the structure of a gyro sensor device of a first embodiment of the invention. FIG. 1A is the top view. FIG. 1B is the side view.
In a gyro sensor device 1 shown in FIGS. 1A and 1B , a gyro sensor 10 is sealed with a resin part 2 , formed by a molding compound such as resin, so that the angular velocity detection axis G (detection axis G) of the gyro sensor 10 is tilted by an angle θ with respect to the perpendicular line V of the upper surface of the gyro sensor device 1 . From both the long sides of the resin part 2 , a plurality of lead terminals extends outside.
Here, the upper surface and a mounting side surface (the other surface opposite to the upper surface) of the gyro sensor device 1 are in parallel with each other. The lead terminals 3 are electrically connected to the gyro sensor 10 inside the resin part 2 . The lead terminals 3 exposed from the resin part 2 at a position close to its bottom surface are bent inside at bending parts 4 a and 4 b to form electrode terminals on the bottom surface of the resin part 2 . In contrast, other lead terminals 3 exposed from the resin part 2 at a position far from its bottom surface also bent to form electrode terminals on the bottom surface of the resin part 2 . In this case, they are bent inside at bending parts 4 c, 4 d, and 4 e since the length of a lead part of each lead terminal 3 exposed from the resin part 2 is long.
FIG. 2A shows a mounting example of the above gyro sensor device of the first embodiment. As shown in FIG. 2A , by connecting each lead terminal 3 of the gyro sensor device 1 of the embodiment to a pattern electrode 52 with a solder 53 , the gyro sensor device 1 can be mounted so that its detection axis G is tilted by the angle θ with respect to the perpendicular line (the vertical direction) of the mount surface of a mount board 51 .
The reason why the lead terminal 3 exposed from the position far from the bottom surface of the gyro sensor device 1 is provided with the bending parts 4 c, 4 d , and 4 e is as follows.
For example, as shown in FIG. 2B , if the bending part 4 d is not formed between the bending parts 4 c and 4 e of the lead terminal 3 , the amount of the solder 53 coated on it is larger than that of the lead terminal 3 having a short lead part from the bending parts 4 a to 4 b. This imbalance causes a large difference in surface tension of the solder 53 at both sides, and the lead terminal having the short lead part may float from the mount surface 51 . That is, errors may occur in a tilt angle since the gyro sensor device 1 is fixed slanted.
Therefore, in the gyro sensor device 1 , the bending parts 4 c, 4 d, and 4 e are formed in the lead terminal 3 having a long lead part from the bending parts 4 c to 4 e to limit the solder amount coated along it. This structure can limit the solder amount coated along the lead terminal having the long lead part. As a result, the occurrence of errors in the tilt angle of the gyro sensor device 1 fixed to the mount board 51 .
Particularly, setting the height position of the lead terminal having the long lead part equal to that of the lead terminal having the short lead part is more preferable since the solder amount coated along each lead terminal 3 makes equal.
In addition, even if the solder coats the lead terminal 3 having the long lead part beyond the bending part 4 d upward, the surface of the lead terminal 3 coated by the solder does not face any pattern electrode 52 . Thus, surface tension causing the gyro sensor device 1 to be tilted does not occur in this case.
Here, the gyro sensor device 1 has the upper surface and the mounting side surface that are in parallel with each other. This structure allows the gyro sensor device 1 to be moved in the vertical direction to the mount board 51 and to be mounted on it after suctioning the upper surface of the gyro sensor device 1 by using a parts-mounting device.
In this case, the gyro sensor device 1 is pushed to the mount board 51 while a force is equally applied to the lead terminals 3 or uniformly applied to the bottom surface of the resin part 2 upon mounting it to the mount board 51 . As a result, the parallelism between the mount surface of the mount board 51 and the upper surface of the gyro sensor device 1 is kept high. That is, the gyro sensor device 1 is mounted to the mount board 51 without errors in the angle θ that the detection axis G makes with respect to the perpendicular line of the mount surface of the mount board 51 .
In the embodiment, the gyro sensor 10 is tilted around its longitudinal direction so as to provide an angle that the Z-axis makes with respect to the vertical direction to be θ. This structure can reduce the height of the device when the gyro sensor 10 is built into the gyro sensor device 1 .
Next, a method for bonding the lead terminals and the gyro sensor in the gyro sensor device of the embodiment will be described.
FIG. 3A shows the structure of a lead terminal unit used in the gyro sensor device 1 of the embodiment. FIG. 3B is a top view illustrating a state in which the gyro sensor 10 is bonded to the lead terminal unit. FIG. 3C is a backside view illustrating the state in which the gyro sensor 10 is bonded to the lead terminal unit. FIG. 3D illustrates a setback when the gyro sensor 10 is bonded to the lead terminals 3 .
As shown in FIG. 3A , the lead terminal unit 61 , used in the gyro sensor device 1 of the embodiment, includes the plurality of lead terminals 3 and a die pad 5 . In the embodiment, the lead terminals 3 and the frame 63 are connected with suspending leads 62 to prevent the lead terminals 3 from being bent when the gyro sensor 10 and the lead terminals 3 are connected.
The die pad 5 provided on the upper surface of the lead terminal unit 61 and the gyro sensor 10 are mechanically connected with an adhesive interposed therebetween, for example. They may be electrically connected by using a conductive adhesive as the adhesive. In addition, each lead terminal 3 of the lead terminal unit 61 is electrically connected to respective electrodes 8 provided on the bottom surface of the gyro sensor 10 with a bonding wire or a conductive adhesive or the like.
Here, if the suspending leads 62 for the lead terminals 3 are not provided, the gyro sensor 10 sometimes rotates around the die pad as an axis due to the bending of the lead terminals 3 as shown in FIG. 3D when the gyro sensor 10 is mounted to the lead terminal unit 61 . As a result, the gyro sensor 10 cannot be mounted to the lead terminals 3 with high accuracy, possibly errors occurring in the tilt angle of the gyro sensor 10 . In contrast, the gyro sensor device 1 of the embodiment can suppress the rotation of the gyro sensor 10 since the bending of the lead terminals 3 are suppressed by fixing the lead terminals 3 with the suspending leads 62 .
As a result, the accuracy of the tilt angle of the gyro sensor device 1 of the embodiment can be enhanced. As shown in FIG. 3A , the lead terminal unit 61 includes three suspending terminals 62 fixing the distal parts of the lead terminals 3 . The suspending lead 62 for fixing the distal part of the lead terminal 3 may be diagonally provided at least two positions with respect to the die pad 5 . This arrangement can suppress the rotation of the gyro sensor 10 in the diagonal direction. Here, the suspending leads 62 are cut off after the resin part 2 is formed.
Next, a method of manufacturing the gyro sensor device of the first embodiment will be described.
FIG. 4 is a flowchart illustrating manufacturing steps of the gyro sensor device.
First, in step S 1 , an adhesive (nonconductive adhesive or epoxy based adhesive) is applied to the die pad 5 or the gyro sensor 10 , and then the gyro sensor 10 is placed on the die pad 5 to adhere.
Next, in step S 2 , a wire bonding is performed by forming wires between the lead terminals 3 and the electrode terminals 8 provided on the bottom surface of the gyro sensor 10 by a wire bonding method.
Next, in step S 3 , molding is performed in which the gyro sensor 10 is molded with a resin. The molding is performed by a so-called transfer molding method, in which the lead terminals 3 are set and sandwiched between an upper and lower dies each of which have a cavity so that the gyro sensor 10 is housed in the cavity, and then the cavity is filled with the resin. In this case, the lead terminals 3 exposed from the die are extended to have an original shape. In addition, a number of patterns of the lead terminals 3 are formed so as to mount a plurality of gyro sensors 10 .
In this step, the upper and lower dies are heated and kept at a predetermined temperature in accordance with the characteristics of the resin, and then the lead terminals 3 , on which the gyro sensor 10 is bonded with wires, are positioned and placed on the lower die by using the positioning pins of the lower die as a positioning reference, for example. Next, a resin tablet is put into a plunger pot of the lower die. Then, the upper die is placed on the lower die so as to sandwich the lead terminals 3 therebetween. Subsequently, the upper and lower dies are uniformly clamped by applying a predetermined pressure. As a result, the gyro sensor 10 is housed inside each cavity of the upper and lower dies.
Next, the resin tablet inside the plunger pot is pre-heated at a predetermined temperature to be melted. The melted resin is injected into the cavity from the gates of the upper and lower dies by operating the plunger with a predetermined phase, velocity, and temperature. After the cavity is filled with the melted resin, a fixed time is kept to form the resin. After the resin is formed, the upper die is removed from the lower die by releasing the clamping of the dies. Then, a remaining cull produced by the resin overflowing around the cavity is removed. Next, the lead terminals 3 with molded resin are taken out from the lower die, and then dried in an oven at a predetermined temperature for a given period.
Next, in step S 4 , the ends of the lead terminals 3 and the suspending leads between the leads are cut off by stamping or the like so as to make the molded part as an individual piece. Subsequently, in step S 5 , a terminal plating is performed in which the lead terminals exposed from the molded part are plated with bonding metal such as tin (Sn) and solder. Then, the bending parts 4 a and 4 c are bent into a predetermined shape by fixing the lead terminals between the bending part 4 a and the resin part 2 as well as the bending part 4 c and the resin part 2 . Next, in step S 6 , the bending parts 4 b and 4 d are bent by fixing the lead terminals between the bending part 4 b and the resin part 2 as well as the bending part 4 d and the resin part 2 , achieving the gyro sensor device 1 .
The terminal plating may be carried out before or after the lead terminals and suspending leads are cut off.
Finally, in step S 7 , necessary inspection such as characteristics inspection and outer appearance inspection is carried out, ending the manufacturing steps of the gyro sensor device 1 of the embodiment.
As described above, the method for manufacturing the gyro sensor device 1 of the embodiment, in which the detection axis of the gyro sensor 10 and the upper surface of the resin part 2 are set at a desired angle, with high productivity can be provided.
Next, a die used for molding in the above method for manufacturing the gyro sensor device 1 will be described with reference to the drawings.
FIG. 13 is a plan view illustrating a lower die 110 A, which constitutes a molding die with an upper die. FIG. 14 is a sectional view illustrating a whole structure of a molding die 110 , the sectional view being taken along the line a-a in FIG. 13 where an upper die 110 B is set to the lower die 110 A with the lead terminals 3 interposed therebetween.
The molding die 110 includes the upper die 110 B and the lower die 110 A. In order to easily explain the structure of a resin injection path or the like in the molding die 110 , the structure of the lower die 110 A will be described with reference to FIG. 13 .
The lower die 110 A includes a lower die body 120 , made of metal or the like, in which a plurality of concave parts (cavities) are formed and each cavity is connected in series by communicating with a linking path (e.g. gate), also a concave part.
The lower die 110 A is provided with a plunger pot 115 , in which a plunger (not shown) is set, inside a concave part formed in the lower die body 120 in a cylindrical shape. The plunger pot 115 has an opening at a part of its sidewall. From the opening, a runner 116 A having a groove shape extends and connects to a cavity 111 A as a first cavity, a concave part having a rectangular parallelepiped shape. Near a side, opposite to the part connecting the plunger pot 115 , of the cavity 111 A, a cavity 112 as a second cavity is disposed. The cavities 111 A and 112 are connected by communicating with a gate 113 A having a grove shape. In addition, from a side, opposite to the part connecting the cavity 111 A, of the cavity 112 , a gate 114 extends. The gate 114 is communicated and connected with the next cavity in the same manner, but this is not shown in FIG. 13 . As described above, the plunger pot 115 , the cavity 111 A, and the cavity 112 are connected in series by communicating with the runner 116 A, the gate 113 A, and the gate 114 , respectively. Likewise, the cavity 112 afterward, the necessary number of cavities are connected in series by communicating with the necessary number of gates.
Here, a rectangular area shown by the two-dot chain line in the FIG. 13 illustrates a lead frame placing position 3 a upon resin molding.
In contrast, the upper die 110 B is provided with a plunger pot, a plurality of cavities, and a plurality of runners and gates both of which communicate with the plunger pot and the cavities on the surface meeting the lower die 110 A. They are formed in the same shape openings at the same positions corresponding to those in the lower die 110 A. Upon overlapping and fixing the upper die 110 B and the lower die 110 A, the plunger pot 115 , a space of a container shape, cavities, runners, and gates are formed. The runners and gates connect and communicate with the plunger pot 115 and cavities in series for serving as a communication path of resin.
Next, with reference to the FIG. 14 , the molding die 110 including the upper die 110 B and the lower die 110 A will be described in a condition where the lead terminals 3 , on which the gyro sensor 10 serving as a sensor device is mounted, are molded. Particularly, the cross sectional shape of the cavity of the molding die 110 will be mainly described in details.
As shown in FIG. 14 , a concave bottom part 161 A of the cavity 111 A, the concave part formed in the lower die body 120 of the lower die 110 A, is formed so as to be tilted by the angle θ with respect to a parallel line 170 , parallel with the lead terminal 3 when the lead terminals 3 are placed on the lower die 110 A. The bottom surface of the gyro sensor device 1 is formed corresponding to the concave bottom part 161 A. Therefore, the gyro sensor device 1 is formed in which the relation between the normal line of the gyro sensor device 1 achieved by molding with the lower die 110 A and the detection axis G of the gyro sensor 10 is set as a desired angle θ.
Likewise, a concave bottom part 161 B of the cavity 111 B, the concave part formed in an upper die body 130 of the upper die 110 B shown in FIG. 14 , is formed so as to be tilted by the angle θ with respect to a parallel line 270 , parallel with the lead terminal 3 when the upper die 110 B is overlapped and fixed on the lower die 110 A on which the lead terminal 3 is placed. The upper surface of the gyro sensor device 1 is formed corresponding to the concave bottom part 161 B. Therefore, the gyro sensor device 1 is formed in which the relation between the normal line of the upper surface of the gyro sensor device 1 achieved by molding with the upper die 110 B and the detection axis G of the gyro sensor 10 is set as the desired angle θ.
Upon fixing (clamping) the lower die 110 A and the upper die 110 B with the lead terminal 3 on which the gyro sensor 10 is mounted interposed therebetween, a cavity for molding the sensor device 10 is formed by the cavity 111 A of the lower die 110 A and the cavity 111 B of the upper die 110 B.
In addition, a runner is formed by the runner 116 A of the lower die 110 A and the runner 116 B of the upper die 110 B. The runner serves as an injection path of melted resin when the resin is injected into the cavity from the plunger pot (not shown).
Further, a gate is formed by the gate 113 A of the lower die 110 A and the gate 113 B of the upper die 110 B. The gate serves as an injection path of the resin from the cavity to the next cavity.
In the embodiment, the runner 116 B and the gate 113 B of the upper die 110 B are formed larger than the runner 116 A and the gate 113 A of the lower die 110 A in the thickness direction, respectively. As a result, resin flows in the upper die 110 B stronger than in the lower die 110 A. This structure prevents a bonding part such as bonding wires and gold balls of the gyro sensor 10 from being strongly hit by the melted resin when the resin is injected. The structure is not limited to this. The runners and gates may be disposed only in the upper die 110 B for skirting the bonding part of the gyro sensor 10 .
Here, the sidewall of the cavities 111 A and 111 B are formed inward so as to be perpendicular or make an acute angle with respect to the surface contacting the lead terminals 3 .
As described above, in the method for manufacturing the gyro sensor device 1 of the embodiment, the cavity 111 A having the concave bottom part 161 A is formed in the lower die body 120 of the lower die 110 A. The concave bottom part 161 A is formed so as to be tilted by the angle θ with respect to the parallel line 170 , parallel with the lead terminal 3 when the lead terminal 3 is placed on the lower die 110 A. In addition, the cavity 111 B is formed in the upper die body 130 of the upper die 110 B. The cavity 111 B is the concave part formed so as to be tilted by the angle θ with respect to the parallel line 270 , parallel with the lead terminal 3 when the upper die 110 B is overlapped and fixed on the lower die 110 A on which the lead terminal 3 is placed. Then, the lower die 110 A and the upper die 110 B are fixed by sandwiching the lead terminals 3 therebetween so that the gyro sensor 10 is housed in the cavity 111 A and the cavity 110 B. Subsequently, melted molding resin is injected into the cavities 111 A and 111 B to form the gyro sensor device 1 .
The method can manufacture the molded package (resin part 2 ) having the bottom surface formed corresponding to the concave bottom part 161 A of the lower die 110 A, and the upper surface formed corresponding to the concave bottom part 161 B of the upper die 110 B. As a result, a gyro sensor device can be provided in which the detection axis G of a sensor makes a desired angle with respect to the bottom surface of the gyro sensor device. The gyro sensor device includes the sensor responding to a movement with respect to the given detection axis G, the gyro sensor 10 housing the sensor, the lead part to make electrically conduction between the terminal of the gyro sensor 10 and a mount board, and a molded package to fix the gyro sensor 10 .
In addition, the bottom surface and the upper surface of the gyro sensor device can be formed in parallel with each other. The bottom surface and the upper surface of the gyro sensor device make a desired angle with respect to the detection axis G of the gyro sensor. Thus, the gyro sensor device can be picked up in the same manner of typical chip-type electronic parts by a chip mounter, for example, when the gyro sensor is mounted to a mount board or the like. Further, typical part trays and hoop shaped packaging materials (taping materials) can be used for packaging the gyro sensor device without preparing trays and hoop shaped packaging materials having a special shape. As a result, a gyro sensor device can be manufactured that can be mounted with high productivity.
In the embodiment, the runner 116 B and the gate 113 B of the upper die 110 B are formed larger than the runner 116 A and the gate 113 A of the lower die 110 A in the thickness direction, respectively.
Because of the structure, melted resin flows in the upper die 110 B stronger than in the lower die 110 A when the resin is injected into each cavity. Thus, stress applied to the bonding part such as bonding wires and gold balls of the gyro sensor 10 placed in the lower die 110 A by the resin can be reduced. As a result, the occurrence of bonding wire breakage and open defects in bonding parts can be suppressed.
In addition, in the embodiment, the sidewalls of the cavity 111 A of the lower die 110 A and the cavity 111 B of the upper die 110 B are formed inward so as to be perpendicular or make an acute angle with respect to the surface contacting the lead terminals 3 . This structure enhances removability in releasing the lower die 110 A and the upper die 110 B from the clamping state, enabling the workability to be improved.
FIG. 5 is a schematic view illustrating the structure of a gyro sensor device according to a second embodiment of the invention.
In a gyro sensor device 20 shown in FIG. 5 , the gyro sensor 10 is sealed with the resin part 2 so that the detection axis G of the gyro sensor 10 is tilted by the angle θ with respect to the perpendicular line of a mount surface on which the gyro sensor device 20 is mounted.
In this case, also, the lead terminal 3 extends outside from both the long sides of the resin part 2 in a plurality of numbers. The gyro sensor 10 is tilted by the angle θ with respect to the upper surface of the gyro sensor device 1 by supporting with the lead terminal 3 , bent at the bending parts 6 e, 6 f, and 6 g in the resin part 2 . In the structure, the length between the bending parts 6 a and 6 b is nearly equal to the length between the bending parts 6 c and 6 d. This structure can prevent the occurrence of errors in the tilt angle of the gyro sensor device 20 when it is mounted to the mount board 51 .
Next, a method of manufacturing the gyro sensor device of the second embodiment will be briefly described.
In this case, first, the lead terminal 3 is stamped so that the bending parts 6 e and 6 g are formed as projected from and the bonding part 6 f are formed as depressed from one surface thereof. On the surface, the gyro sensor 10 is mounted. Next, an adhesive (nonconductive adhesive or epoxy based adhesive) 53 is applied to the die pad 5 or the gyro sensor 10 , and then the gyro sensor 10 is placed on the die pad 5 to adhere.
Then, the following is carried out by wire bonding: a gold ball 9 b is provided on the lead terminal 3 , and then a wire 9 a is formed from the gold ball 9 b, as a starting point, to the electrode terminal 8 , as an ending point, on the bottom surface of the gyro sensor 10 , for example. In this regard, the gold ball may be provided on the electrode terminal 8 , and the starting and ending points are exchanged. In wire bonding, a tool 81 shown in FIG. 6 is used. The tool 81 has a shape into which the upper surface of each of a plurality of gyro sensors 10 can be set corresponding to the lead terminal 3 . Here, a bottom surface 80 of the tool 81 makes the angle θ with respect to the lead terminal 3 . Therefore, the bottom surface of the gyro sensor 10 and the bottom surface 80 of the tool 8 are nearly in parallel with each other when the gyro sensor 10 is set in the tool 81 . In wire bonding, placing the tool 81 so that the bottom surface 80 is faced downward and nearly horizontally results in the bottom surface of the gyro sensor 10 being nearly horizontally. As a result, the wire bonding is accurately conducted.
Next, the gyro sensor 10 is molded with resin. In this case, the lead terminals 3 exposed from the molded package are extended to have an original shape. Then, the ends 6 h and 6 i of the lead terminals 3 , and between the lead terminals 3 are cut off. Next, the lead bending parts 6 b and 6 d are bent by fixing the lead terminal 3 between the lead bending part 6 b and the resin part 2 as well as the lead bonding part 6 d and the resin part 2 . Next, the lead bending parts 6 a and 6 c are bent by fixing the lead terminal 3 between the lead bending part 6 a and the resin part 2 as well as the lead bonding part 6 c and the resin part 2 .
As described above, a method for manufacturing the gyro sensor device 20 , in which the detection axis G of the gyro sensor and the upper surface of the resin part 2 are set at a desired angle (the angle θ that the detection axis G makes with respect to the vertical direction of a mount surface on which the gyro sensor device 20 is mounted), with high productivity can be provided. Here, the upper surface of the gyro sensor device 20 and the surface on which the gyro sensor device 20 is mounted are in parallel with each other.
FIG. 7 is a schematic view illustrating the structure of a gyro sensor device according to a third embodiment of the invention.
In a gyro sensor device 30 shown in FIG. 7 , the gyro sensor 10 is sealed with the resin part 2 so that the gyro sensor 10 is tilted by the angle θ with respect to the vertical direction of a mount surface on which the gyro sensor device 30 is mounted.
In this case, also, the lead terminal 3 extends outside from both the long sides of the resin part 2 in a plurality of numbers. The gyro sensor 10 is tilted by the angle θ with respect to the upper surface of the gyro sensor device 30 by supporting with the lead terminal 3 , bent in a step shape at the bending parts 7 e, 7 f, 7 g, 7 h, 7 i, 7 j , 7 k and 7 l in the resin part 2 . In the structure, the length between the bending parts 7 a and 7 b is nearly equal to the length between the bending parts 7 c and 7 d. This structure can prevent the occurrence of errors in the tilt angle of the gyro sensor device 30 when it is mounted to the mount board 51 .
In addition, the gyro sensor 10 can be placed in parallel with the upper surface of the gyro sensor device 30 by placing the gyro sensor 10 parallel on the upper step of the lead terminal 3 . That is, the detection axis G of the gyro sensor 10 can coincide with the vertical direction or make the desired angle θ with respect to the detection axis G by only changing the position of the step for placing the gyro sensor 10 .
Next, a method of manufacturing the gyro sensor device of the third embodiment will be described.
In this case, the lead terminal 3 is stamped so that the bending parts 7 e , 7 g, 7 j and 7 l are formed as projected from and the bonding part 7 f, 7 h, 7 i and 7 k are formed as depressed from one surface thereof. On the surface, the gyro sensor 10 is mounted. Here, the lead terminal 3 is linked in a plurality of numbers (not shown) to have a shape allowing the bottom of a plurality of gyro sensors 10 to be set in it.
Solder paste is coated on the electrode terminal 8 on the bottom surface of the gyro sensor 10 , or near the bending part 7 g or 7 i of the lead terminal 3 . The solder paste is heated at a temperature of the melting point or more, and cooled down to normal temperature to mechanically and electrically connect the electrode terminal 8 to the lead terminal 3 .
Next, the gyro sensor 10 is molded with resin. In this case, the lead terminals 3 exposed from the molded package are extended to have an original shape. Then, the end of the lead terminal 3 and suspending leads are cut off. Next, the bending parts 7 b and 7 d are bent by fixing the lead terminal 3 between the bending part 7 b and the resin part 2 as well as the bonding part 7 d and the resin part 2 . Next, the bending parts 7 a and 7 c are bent by fixing the lead terminal 3 between the bending part 7 a and the resin part 2 as well as the bonding part 7 c and the resin part 2 . As described above, a method for manufacturing the gyro sensor device 30 with high productivity can be provided.
Next, the gyro sensor 10 mounted in the gyro sensor device of the above embodiments will be described.
FIG. 8 is a cross sectional view illustrating the internal structure of the gyro sensor 10 . FIGS. 9A to 9C are schematic views illustrating the structure of a support substrate provided in the gyro sensor 10 .
As shown in FIG. 8 , the gyro sensor 10 includes a quartz crystal resonator element 11 as a detection element to detect angular velocity. As shown in FIGS. 9A and 9B , the quartz crystal resonator element 11 is mechanically and electrically connected to a support substrate 12 with wires 13 , supporting member having flexibility. The support substrate 12 is connected to the bottom surface inside a ceramics package 17 with an adhesive 14 . In addition, at the center of the support substrate 12 , an opening 12 a is formed. Through the opening 12 a, the wires 13 are provided from the back surface to the upper surface side of the support substrate 12 . On the upper surface of the ceramics package 17 , a lid 16 made of metal is bonded with a sealing member 19 such as low melting point metal. This structure allows the inside of the ceramics package 17 to be vacuum sealed. A glass lid also can be used as the lid 16 . In this case, low melting point glass is used as the sealing member 19 , for example. The electrode terminal 8 is formed from the external bottom surface to the sidewall of the ceramics package 17 . The electrode terminal 8 is connected to the quartz crystal resonator element 11 through an internal conductive member (not shown) formed in the ceramics package 17 .
Here, at least two, provided parallel at the center, out of six wires 13 shown in FIG. 8 serve as a support member mainly supporting the quartz crystal resonator element 11 .
FIG. 10A is a plan view schematically illustrating the quartz crystal resonator element 11 of the embodiments. FIG. 10B is a plan view illustrating a vibration of the detection vibration mode of the quartz crystal resonator element 11 .
The quartz crystal resonator element 11 shown in FIGS. 10A and 10B is provided with a base 31 , a pair of detection vibration arms 32 a and 32 b protruded from the base 31 , a pair of connection parts 33 protruded from the base 31 , and driven vibration elements 34 a, 34 b, 34 c, and 34 d provided at ends of the connection parts 33 . Each main surface of the driven vibration elements 34 a, 34 b, 34 c, and 34 d includes an elongate groove. Each transverse section of the driven vibration elements 34 a, 34 b , 34 c, and 34 d shows a nearly H-shape. In addition, an exciting electrode (or driving electrode) 36 is formed in each groove. At each end of the driven vibration elements 34 a, 34 b, 34 c, and 34 d, respective wide-width parts or weight parts 38 a, 38 b, 38 c, and 38 d are provided. Each main surface of the detection vibration elements 32 a and 32 b includes an elongate groove. Each transverse section of the detection vibration elements 32 a and 34 b shows a nearly H-shape. In each groove, a detection electrode 37 is formed. At the end of the detection vibration element 32 a, a weight part 35 a is provided while at the end of the detection vibration element 32 b, a weight part 35 b is provided.
FIG. 10A shows the vibration of a driven mode. In the driven mode, each of the driven vibration element 34 a, 34 b, 34 c, and 34 d performs a flexural vibration around a root part 39 to the connection part 33 as shown by an arrow A. In the state, the quartz crystal resonator element 11 is rotated around a rotation axis G, nearly perpendicular to the quartz crystal resonator element 11 , at an angular velocity ω. As shown in FIG. 10B , a resulting Coriolis force F is applied to the weight parts 38 a, 38 b , 38 c, and 38 d in a direction perpendicular to both the direction A of the flexure vibration and the rotation axis G. As a result, the connection part 33 performs a flexural vibration around a root part 33 a to the base 31 as show by an arrow B. As a counteraction to the vibration, each of the detection vibration elements 32 a and 32 b performs a flexural vibration around a root part 40 to the base 31 as show by an arrow C. The flexural vibration shown by the arrow C generates a piezoelectric phenomenon, changing the potential of the detection electrode 37 . The potential change is detected by a detection circuit (not shown) to obtain the angular velocity ω around the detection axis (rotation axis) G. The detection efficiency can be increased if the crystal axis direction of the Z-axis of the quartz crystal resonator element 11 is aligned to the rotation axis G as a result of setting the crystal axis direction of +X/−X axis of the quartz crystal resonator element 11 as the arrow A direction.
The detection element that employs the quartz crystal resonator element 11 and is structured as described above can achieve the gyro sensor having a height lower than that employing a tuning fork quartz crystal resonator, the rotation axis coinciding with the extending direction of the detection vibration element, i.e. the tuning fork quartz crystal resonator, since the direction of the rotation axis G coincides with the thickness direction of the quartz crystal resonator element 11 .
Here, as shown in FIG. 8 , three axes are defined as follows: the extending direction of the wire 13 , the support member included in the gyro sensor 10 , is the X-axis; an axis perpendicular to the X-axis in the plane in which the quartz crystal resonator element 11 is placed is the Y-axis; and an axis perpendicular to both the X-axis and Y-axis is the Z-axis. Assuming that the tilt direction of the gyro sensor 10 is set to coincide with the X-axis direction as shown in FIGS. 11A and 11B . In this case, a frequency difference occurs between the resonance frequencies of wires 13 a and 13 b shown in FIGS. 11A and 11B , possibly resulting in the operational conditions of the gyro sensor 10 being unstable.
That is, when the detection axis G is tilted so as to have the angle θ by setting a side adjacent to the wire 13 a higher than a side adjacent to the wire 13 b as shown in FIG. 11B , with respect to the direction of the X-axis component of the gravity acceleration, the extending direction of the wire 13 a is opposite to the extending direction of the wire 13 b. Therefore, the wires 13 a and 13 b are differently influenced by the acceleration (difference in the direction of inertial force). For example, the following are defined as shown in FIG. 11C : the resonance frequency of the quartz crystal resonator element 11 is fref, and the resonance frequency of each of the wires 13 a and 13 b is f0 when the quartz crystal resonator 11 is placed horizontally. In the tilted state, tensile force is produced in the wire 13 a, while compressive force is produced in the wire 13 b by the influence of the X-axis component of the gravity acceleration, resulting in the resonance frequency fa of the wire 13 a being higher and the resonance frequency fb of the wire 13 b being lower. As a result, the resonance frequencies of the wires 13 a and 13 b may greatly differ in each other. If the resonance frequencies of the wires 13 a and 13 b greatly differ in each other, the coupling of resonance energy is likely to occur due to a close approach to the resonance frequency of the quartz crystal resonator element 11 , and the mounted condition of the quartz crystal resonator element 11 is likely to be unstable.
In the first embodiment, the gyro sensor 10 is mounted in the gyro sensor device 1 so that the tilt direction of the gyro sensor 10 (the quartz crystal resonator element 11 ) coincides with the Y-axis direction as shown in FIGS. 12A and 12B . That is, when the wires 13 a and 13 b are disposed so that their tilt directions are symmetric with respect to the center axis, the acceleration equally influences both the wires 13 a and 13 b when the acceleration is applied in the Y-axis direction. As a result, the frequency difference hardly occurs between the resonance frequencies of the wires 13 a and 13 b as shown in FIG. 12C . This structure brings, for example, an advantage of easy controlling a frequency adjustment or the like. In addition, the wire 13 is less influenced by the acceleration since the extending direction of the wires 13 a and 13 b does not coincide with the acceleration direction (the Y-axis direction). Therefore, the variation amount of each resonance frequency of the wires 13 a and 13 b can be lessened as shown in FIG. 12C , bringing an advantage in that the coupling of resonance energy hardly occurs.
Further, when the tilt directions of the wires 13 a and 13 b are set symmetrically with respect to the center axis as shown in FIG. 12A , and the extending directions of the wires 13 a and 13 b are perpendicular to the tilt direction, the changing characteristics of each resonance frequency of the wires 13 a and 13 b are nearly equal even though the direction of the acceleration in the Y-axis direction is opposite (shown as G) as the sensor is placed horizontally. This structure allows the gyro sensor of the embodiments to be mounted horizontally, for example.
The gyro sensor device including the gyro sensor 10 structured as described above can suppress adverse influences, given by the changing characteristic of the resonance frequencies of the wires 13 a and 13 b, to the gyro sensor device with respect to the acceleration in the traveling direction of a vehicle, since the gyro sensor device is installed in the vehicle so that the Y-axis direction coincides with the acceleration direction of the vehicle.
The wire 13 may be one that is made of quartz, integrated to the base 31 of the quartz crystal resonator element 11 , and shaped in a reed.
The entire disclosure of Japanese Patent Application Nos: 2006-216505, filed Aug. 9, 2006 and 2006-249404, filed Sep. 9, 2006 are expressly incorporated by reference herein. | An inertial sensor, comprises a detection element detecting an amount of a physical quantity in a detection axis direction, a plurality of support members having flexibility and supporting nearly a center of the detection element, and a package substrate housing the detection element and the plurality of support members. In a case when an X-axis is defined as an extending direction of the plurality of support members, a Y-axis is perpendicular to the X-axis in a plane including the detection element, and a Z-axis is perpendicular to the X-axis and the Y-axis, one of load components in a direction of the Y-axis of the detection member applied to the plurality of support members is nearly equal to other among the plurality of support members, and one of load components in a direction of the Z-axis is nearly equal to the other among the plurality of support members. | 7 |
FIELD OF THE INVENTION
The present invention relates generally to data communication, and more particularly, to data communication with transmission diversity using Multiple Input Multiple Output (MIMO) Orthogonal Frequency Division Multiplexing (OFDM) in multiple antenna channels.
BACKGROUND OF THE INVENTION
In wireless communication systems, antenna diversity plays an important role in increasing the system link robustness. OFDM is used as a modulation technique for transmitting digital data using radio frequency signals (RF). In OFDM, a radio signal is divided into multiple sub-signals that are transmitted simultaneously at different frequencies to a receiver. Each sub-signal travels within its own unique frequency range (sub-channel), which is modulated by the data. OFDM distributes the data over multiple channels, spaced apart at different frequencies.
OFDM modulation is typically performed using a transform such as Fast Fourier Transform (FFT) process wherein bits of data are encoded in the frequency-domain onto sub-channels. As such, in the transmitter, an Inverse FFT (IFFT) is performed on the set of frequency channels to generate a time-domain OFDM symbol for transmission over a communication channel. The IFFT process converts the frequency-domain phase and amplitude data for each sub-channel into a block of time-domain samples which are converted to an analogue modulating signal for an RF modulator. In the receiver, the OFDM signals are processed by performing an FFT process on each symbol to convert the time-domain data into frequency-domain data, and the data is then decoded by examining the phase and amplitude of the sub-channels. Therefore, at the receiver the reverse process of the transmitter is implemented. Further, transmit antenna diversity schemes are used to improve the OFDM system reliability. Such transmit diversity schemes in OFDM systems are encoded in the frequency-domain as described.
MIMO has been selected as the basis for the high speed wireless local area network (WLAN) standards by the IEEE standardization group. FIG. 1 shows a MIMO system splits the data before convolutional encoding. The system in FIG. 1 includes a OFDM MIMO transmitter 100 implementing WLAN, comprising a source of data bits 102 , a spatial parser 104 , and multiple data stream processing paths 106 . Each data stream processing path 106 comprises: a channel encoder & puncturer 108 , a frequency interleaver 110 , a constellation mapper 112 , an IFFT function 114 , a guard-band insertion GI window 116 and an RF modulator 118 .
The system diagram in FIG. 1 represents a MIMO OFDM structure for 20 MHz channelization, and uses two independent convolutional-code encoders for the two data paths. Further, two IEEE 802.11a interleavers are used independently, each interleaver 110 corresponding to each encoder. An interleaver 110 in FIG. 1 provides an optimal design for single antenna systems by fully exploring the frequency diversity. However, for multiple antenna systems, this design does not explore the spatial diversity brought in by the multiple antennas. Thus, there is a need for an interleaver design to fully explore the diversity of the MIMO OFDM systems.
BRIEF SUMMARY OF THE INVENTION
The present invention provides an improved interleaver design to fully explore the diversity of the MIMO OFDM systems. An interleaver according to the present invention provides higher diversity gain than usual. Such an interleaver provides column swap and bit circulation for multiple forward error code encoder MIMO OFDM systems. Accordingly, in one embodiment the present invention provides a system and method for wireless data communication, implementing the steps of: parsing a bit stream into multiple spatial data streams; interleaving the bits in each spatial data stream by performing bit circulation to increase diversity of the wireless system; and transmitting the bits of each spatial data stream. The steps of interleaving the bits in each spatial data stream further include the steps of performing column swapping.
In one example, the steps of interleaving the bits include the steps of splitting the bits in each data stream into multiple groups corresponding to subcarriers in a transmission symbol, performing a column swap operation on the subcarriers, circulating the bits among the groups, and combining the bits for the different data streams to form a new bit sequence for transmission.
In another embodiment, the steps of interleaving the bits in each spatial data stream further includes the steps of performing column swapping within an interleaving array of that spatial data stream, to increase diversity of the wireless system. The steps of interleaving the bits can further include the steps of splitting the bits in each data stream into multiple groups corresponding to subcarriers in a transmission symbol, performing column swapping within an interleaving array of that spatial data stream, circulating the bits among the groups, and combining the bits for the different data streams to form a new bit sequence for transmission. The steps of interleaving the bits in each spatial data stream includes the steps of, before circulation, performing a first interleaving permutation for column swapping wherein the stream data bits are written in by row, read out by column.
These and other features, aspects and advantages of the present invention will become understood with reference to the following description, appended claims and accompanying figures.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a block diagram of a MIMO OFDM transmitter.
FIG. 2 shows an example block diagram of an embodiment of a MIMO OFDM transmitter according to an embodiment of the present invention.
FIG. 3 shows an example block diagram of details of interleaving in FIG. 2
FIGS. 4A-C show example simulation results in a 20 MHz channel using a transmitter according to FIG. 2 .
DETAILED DESCRIPTION OF THE INVENTION
In one embodiment, the present invention provides an improved method interleaving for a MIMO system that implements the IEEE WLAN standard. The interleaving method improves exploration of the diversity of an MIMO OFDM system, providing higher diversity gain than usual.
FIG. 2 shows a block diagram of an example OFDM MIMO transmitter 200 of a MIMO system, wherein the transmitter 200 implements an embodiment of the improved interleaving method according to the present invention. The transmitter 200 comprises: a source of data bits 202 , a bitwise spatial parser 204 , and multiple data stream processing paths 206 (e.g., two paths for two antennas 203 ). Each data stream processing path 206 corresponds to a transmit antenna 203 , and comprises: a channel encoder & puncturer 208 , a frequency interleaver 210 , a constellation mapper 212 , an IFFT function 214 , a guard-band insertion GI window 216 and an RF modulator 218 . Each data stream processing path 206 further includes a bit circulation function 211 , connected between the interleaver 210 and the constellation mapper 212 , described further below.
FIG. 2 further shows a receiver 150 corresponding to the transmitter 200 , forming a MIMO system. The receiver 150 includes a bit de-circulation unit 151 that performs the reverse operation of bit circulation unit 211 , and deinterleavers 152 that perform the reverse operation of the interleavers 210 in the transmitter 200 .
In this embodiment, the interleavers 210 provide column swap and the bit circulation unit 211 provides bit circulation for bits circulation/rotation among different spatial streams to incorporate the spatial diversity into one data stream.
FIG. 3 shows an example block diagram of an embodiment of interleaving by column swap (i.e., column skip) and bit circulation using the interleaver 210 and the bit circulation unit 211 , respectively. In this embodiment, the interleaving method incorporates a column skip operation, as follows. In each interleaver 210 , in a first permutation 210 a , the bits are written in by row, read out by column. This includes a column skip operation. After the data bits are written in block, instead of reading out the bits from column 0 1 2 3 . . . , the bits from columns 0, k, 1, k+1, 2, k+2, . . . or k, 0, k+1, 1, k+2, 2, . . . , are read out, where k is a number selected as the column-skip (i.e., columns swap operation 310 b ).
In the following example, k is set to 8, which is the middle column of the block interleaver. On both transmit (Tx) data path streams the write-in input bit indices are:
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
The read-out bits indices are:
0 16 32
8 24 40
1 17 33
9 25 42
7 23 39
15 31 47
In a second permutation 210 c , PAM (Pulse Amplitude Modulation) order rotation as described in IEEE 802.11a standard is performed. PAM is a one dimensional modulation with the change of amplitude. A QAM modulation can be viewed as two PAM modulations. One is in-phase (I), the other is quadrature (Q).
The bit circulation unit 211 includes, for each data stream path 206 : a splitter 220 , a bit circulator 222 , and a combiner 224 . In the bit circulation unit 211 of FIG. 3 , in each splitter 220 the output bits of the corresponding IEEE 802.11a interleaver 210 are split into two groups. One group (Group 1) corresponds to the bits in the odd index subcarriers in an OFDM symbol. The other group (Group 2) corresponds to the bits in the even index subcarriers in an OFDM symbol. For example, in a BPSK modulated OFDM system, each subcarrier carries 1 bit and the bit-splitting will look like the following:
Group 1: 1 3 5 7 9 . . . 47
Group 2: 2 4 6 8 10 . . . 48
Further, in a 64 QAM modulated OFDM system, where each subcarrier carries 6 bits, the bit-splitting will look like the following:
Group 1: 1 2 3 4 5 6; 13 14 15 16 17 18; . . .
277
278 279 280 281 282
Group 2: 7 8 9 10 11 12; 19 20 21 22 23 24; . . . 283 284
285 286 287 288
The bit circulator 222 for each data stream processing path 206 exchanges the bits in Group 2 for the first spatial stream with Group 1 for the second spatial stream. The combiner 224 for each data stream processing path 206 combines the bits for different spatial streams to form a new bit sequence for transmission. In another example, the bits in group 2 of both streams are exchanged as well.
Simulation has been conducted to verify the performance of the interleaving method of FIG. 3 for 20 MHz channelization. Simulation results verify the improved performance of a MIMO system implementing an interleaving method described above (e.g., FIGS. 2-3 for 20 MHz channelization). The coding and modulation set (MCS) for an example simulation is listed in Table 1 below. MCS14 uses 64 QAM, rate 3/4 convolutional code (133, 171). (IEEE 802.11 document #11-04-0889-02-000n, “TGn Sync Proposal Technical Specification,” January 2005, incorporated herein by reference.)
TABLE 1
Symbol
Number of spatial streams
Modulation
Coding rate
MCS14
2
64-QAM
3/4
MCS13
2
64-QAM
2/3
MCS11
2
16-QAM
1/2
FIGS. 4A-C shows example simulation results. All simulation settings and parameters are the same as in Table 1 above.
Specifically FIG. 4A shows an example of the performance improvement with column swap and bit circulation. The simulations were conducted under IEEE 802.11n Channel model B. MCS11/13/14 were simulated. The example curves 401 a , 401 b and 401 c correspond to MCS11, MCS 13 and MCS14 simulations, respectively, and represent the Packet Error Rate (PER) vs. SNR performance with the column swap and bit circulation operation of the present invention. The curves 402 a , 402 b , and 402 c also correspond to MCS11, MCS 13 and MCS14 simulations, respectively, and represent the PER vs. SNR performance of the system without the column swap and bit circulation operation. The curves in FIG. 4A illustrate that for different MCS modes, the performance improvement according to an embodiment of the present invention ranges from 0.5 to 1 dB at PER level of 10 −2 .
FIG. 4B shows another example of the performance improvement with column swap and bit circulation. The simulations were conducted under IEEE 802.11n Channel model D. MCS11/13/14 were simulated. The example curves 403 a , 403 b and 403 c correspond to MCS11, MCS 13 and MCS14 simulations, respectively, and represent the Packet Error Rate (PER) vs. SNR performance with the column swap and bit circulation operation of the present invention. The curves 404 a , 404 b , and 404 c also correspond to MCS11, MCS 13 and MCS14 simulations, respectively, and represent the PER vs. SNR performance of the system without the column swap and bit circulation operation. The curves in FIG. 4B illustrate that for different MCS modes, the performance improvement according to an embodiment of the present invention ranges from 0.5 to 1 dB at PER level of 10 −2 .
FIG. 4C shows another example of the performance improvement with column swap and bit circulation. The simulations were conducted under IEEE 802.11n Channel model E. MCS11/13/14 were simulated. The example curves 405 a , 405 b and 405 c correspond to MCS11, MCS 13 and MCS14 simulations, respectively, and represent the Packet Error Rate (PER) vs. SNR performance with the column swap and bit circulation operation of the present invention. The curves 406 a , 406 b , and 406 c also correspond to MCS11, MCS 13 and MCS14 simulations, respectively, and represent the PER vs. SNR performance of the system without the column swap and bit circulation operation. The curves in FIG. 4C illustrate that for different MCS modes, the performance improvement according to an embodiment of the present invention ranges from 0.5 to 1 dB at PER level of 10 −2 .
The above example interleaving implementations according to the present invention provide e.g. about 0.5 to 1 dB gain over usual interleaving methods. Although the description herein is based on two data streams in a two-antenna system, as those skilled in the art will recognize, the present invention is not limited to a specific number of transmission data streams and transmission antennas. With N transmission data streams, each stream can be split into N sub-streams for bit circulation. The optimal flip method would depend on N, but using the same principle as described in the examples above. The optimal swap number also depends on N, but using the same principle as described in the examples above.
The present invention has been described in considerable detail with reference to certain preferred versions thereof; however, other versions are possible. Therefore, the spirit and scope of the appended claims should not be limited to the description of the preferred versions contained herein. | An improved interleaver design to fully explore the diversity of the MIMO OFDM systems provides higher diversity gain than usual. A method for wireless data communication using such interleaver design implements parsing a bit stream into multiple spatial data streams, interleaving the bits in each spatial data stream by performing bit circulation and column swapping to increase diversity of the wireless system, and transmitting the bits of each spatial data stream. | 7 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a noise shielding apparatus for preventing the noise generated in the operation of a washing machine (washer) from being discharged to the outside through a lower area of the washer, thereby causing the same to operate in a noise-free state.
2. Description of the Prior Art
Generally, a washer, as illustrated in FIG. 6, comprises: a housing body 3, a wash tub 1 disposed in the housing 3 for receiving laundry and washing water; a driving unit 2 for driving (rotating) the washing tub 1 or an agitator (not shown); a body for forming an external appearance thereof while encompassing the washing tub 1 and the driving unit 2; a lid 4 for closing a top area of the washer; a base 5 for comprising a lower area of the washer and for supporting the washing tub 1, the driving unit and the housing body 3.
Meanwhile, the washer thus described inevitably creates noise due to operation of the driving unit 2 and the like, whilst the noise is not discharged through the top area and sides thereof due to the shielding function of the housing body 3, the lid 4 and the like but discharged mainly through the lower area thereof.
Accordingly, in order to prevent the noise from being discharged through the lower area of a conventional washer, the base has been disposed with a sliding type sound insulation plate 6.
In other words, the base 5 is disposed with upper and lower guide plates 5a and 5b whereby the insulation plate 6 is guided by the guide plates 5a and 5b to thereby be connected to the base 5.
Protruding fasteners 6a formed on frontal area of the insulation plate 6 is fastened to a fastening grooves 5c formed on the base 5.
Numeral 5d in the drawing is reinforceing member for preventing deformation of the base 5.
FIG. 7 is a perspective view for illustrating in detail the base 5 and the insulation plate 6 in FIG. 6.
According to FIG. 7, the base 5 has a rectangular shape of a predetermined height with the upper guide plates 5a and lower guide plates 5b formed therein.
A plurality of reinforcing members 5d are also formed therein in order to prevent the deformation of the base 5 and the fastening groove 5c is formed on the frontal area of the base 5.
The sound insulation plate 6 is formed with the protruding fastener 6a in its front area, and if the plate 6a is inserted between the upper guide plates of the base 5 and the lower guide plates 5b, the protruding fasteners 6a of the insulation plate 6 are insertedly fastened into the fastening grooves 5c of the base 5.
However, because the sound insulation apparatus 6 thus described is horizontally slid against the plates 5a and 5b to thereby be fastened into the base 5, as a result, there is a disadvantage in that the insulating plate 6 may become caught in the guide plates 5a and 5b during its insertion into the base, thereby making it difficult for the plate 6 to be inserted. Consequently, noise generated by the driving unit 2 through an opening (made for smoothness of sliding operation of the insulation plate) between the base 5 and the insulation plate 6 is discharged to the outside, thereby resulting in a problem of decreasing the sound shielding effect.
SUMMARY OF THE INVENTION
The present invention has been disclosed to solve the aforementioned problems, and it is an object of the present invention to provide a noise shielding apparatus of a washer for causing a sound shielding plate to be smoothly connected to a base of the washer and, at the same time, for preventing a gap from being formed between the sound shielding plate and a connecting unit of the base, thereby avoiding the noise from being discharged to the outside.
In order to achieve the aforesaid object of the present invention, the noise shielding apparatus according to the present invention, wherein a sound shielding plate is disposed in the washer housing for preventing operational noise of the washer from being discharged to the outside through a lower area thereof. One edge of the plate is connected to housing to enable the plate to be swung up and down. A securing device secures the plate in an upward position in which it closes off a lower portion of the housing.
BRIEF DESCRIPTION OF THE DRAWINGS
For a better understanding of the nature and objects of the invention, reference should be made to the following detailed description taken in conjunction with the accompanying drawings in which:
FIG. 1 is a side view of a washer broken at one side thereof where a noise shielding apparatus according to the present invention is applied;
FIG. 2 is a perspective exploded view for illustrating structure of one embodiment of the noise shielding apparatus of a washer according to the present invention;
FIG. 3 is a sectional view taken along line a--a in FIG. 2 in a state where the shielding plate illustrated in FIG. 2 is in an operative position.
FIG. 4 is a side sectional view for explaining how to insert and remove the noise shielding apparatus of a washer according to the present invention;
FIG. 5 is a perspective exploded view for illustrating another embodiment of the noise shielding apparatus according to the present invention;
FIG. 6 is a side view of a washer broken at its side for illustrating structure of a conventional noise shielding apparatus; and
FIG. 7 is a perspective view for illustrating in detail the structure of the noise shielding apparatus shown in FIG. 6.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
Hereinafter, preferred embodiments of the present invention will be described in detail with reference to the accompaning drawings.
FIG. 1 is a side view of a washer broken at one side thereof where the noise shielding apparatus of a washer according to the present invention is applied.
According to FIG. 1, a connector in the form of a groove 54 is formed at a rear side (right side on the drawing) of a base 50 and more than one downwardly open fastening groove 52 is formed in the underside of a front side of the base (left side on the drawing).
At an entrance side of the fastening groove 52 there is formed a fixing pin 62a.
A sound shielding plate 60 is inserted in its rear into the groove 54 formed in the base, and more than one upstanding fastening protruder 62 is formed on a frontal upper side thereof to thereby be connected to the fastening grooves 52 formed in the base 50.
Furthermore, a downwardly open groove-shaped handle 64 is formed at a front side of an underside of the sound shielding plate 60. Alternatively, if the handle is to be releasable, it can be formed as a protrusion on a bottom of the plate 64.
Meanwhile, as illustrated in the FIG. 1, the sound shielding plate 60 is connected to the base 50, so that the PG,8 facade thereof cannot be exposed to the outside.
Numeral 51 in the drawing is a reinforcing rib, and the washing tub 1, driving unit 2, body 3 and lid 4 are omitted in explanation as the same are of the same structure as the conventional one described earlier herein.
According to FIG. 2, the reinforcing ribs 51 are formed on a topside of the base 50.
A hole 70 is formed centrally in the base 50, to form a stop wall 72 against which the shielding plate may abut from below.
FIG. 3 is a sectional view of a--a line at a state where the shielding plate 60 illustrated in FIG. 2 and the base 50 are connected.
According to FIG. 4, if the plate 60 is to be connected to the base 50, as illustrated in solid lines the rear side or edge of the sound shielding plate 60 is pushed into the groove 54 to form a connection which enables the plate 60 to be swung upwardly in direction "a". The rear edge of the plate is curved and in engagement with a correspondingly curved surface of the groove to facilitate such swinging movement.
When the plate 60 is swung upward, the protrusions 62 enter the grooves 52 of the base 50.
At this time, the fixing pin 62a formed at an entrance side of each fastening groove 52 is resilient and is retracted inwardly by the fastening protruder 62 and thereafter snaps back to an original position.
Meanwhile, as seen from the foregoing, when the sound shielding plate 60 is connected to the base 50, side walls 74 formed on either side of the base 50 to define a plate-receiving chamber are closely adhered to respective edges of the plate 60.
Accordingly, there is generated no gap between the plate 60 and the base 50 to thereby prevent the driving noise of the washer from being discharged to the outside.
In order to separate the plate 60 from the base 50, the handle 64 formed underneath the plate 60 is utilized, so that the plate 60 is pulled downward for separation of the plate from the base 50 (in the "b" direction).
When the plate 62 is pulled downward, the fixing piece 62a formed at the entrance side of the fastening groove 52 is retracted, thereby separating the fastening protruder 62 from the groove 52, enabling the protrusion 62 to exit. Then, each fixing piece 62a returns to the original position by way of its resilience.
At the same time, when the plate 60 is pulled down and then drawn to the front (to the left in the drawing), the plate 60 is released from the groove 54 of the base 50 to thereby separate the plate from the base completely.
FIG. 5 is a perspective view of another embodiment of the noise shielding apparatus according to the present invention.
According to FIG. 5, the converter formed in the rear side of the base 50A comprises at least two upper guide plates 56a and one lower guide plate 56b.
Accordingly, when the plate 60 is connected to the base 50A, the plate 60 is inserted into a space between the upper guide plate 56a and the lower guide plates 56b, and then, when the plate 60 is swung upward, the plate and the base become secured as illustrated in the embodiment of FIGS. 1 through FIG. 4.
Of course, the plate 60 can be separated from the base 50 in the same manner as in FIGS. 1-4.
As seen from the foregoing, the noise shielding apparatus of a washer according to the present invention has solved a problem of upper and lower guide plates of the base interfering with movement of the sound shielding plate, so that the sound shielding plate can be easily separated and assembled.
Furthermore, because the sound shielding plate is closely adhered to walls 72, 74 the base, the same can achieve an effect of excellent noise shielding.
The foregoing description and drawings are illustrative and are not to be taken as limiting. Still other variations and modifications are passible without departing from the spirit and scope of the present invention.
Still furthermore, even though the base has been disclosed in a usual example but the same can be proposed in various shapes without departing from the scope of the present invention. | A clothes washer comprises a housing in which a washing tub is disposed. A noise shielding plate extends across the bottom of the housing. A first edge of the shielding plate is removably connected in a groove of the housing to permit the plate to be swung up and down within a chamber formed by the housing. A resilient securing device is retracted to allow the plate to swing up or down and then snaps back into place. | 3 |
TECHNICAL FIELD OF THE INVENTION
The present invention pertains to a packing pallet for telecommunications equipment and, in particular, to a packing pallet for a telecommunications switch along with its accessories, line cords, publications, and spare parts.
BACKGROUND OF THE INVENTION
Packing pallets are used to ship equipment such as, for example, a telecommunications switch with its casters. Experience has taught that prior art packing pallets, such as that shown in FIG. 1, are unacceptable because they allow shock and vibration to be passed directly to the telecommunications equipment cabinet without proper protection. As a result, the use of such prior art packing pallets has caused a large incidence of damage to the equipment. This damage has, in turn, resulted in large extra expense due to the extra expense involved in: (a) repairing damaged equipment; (b) warehousing extra equipment for replacement purposes; and (c) additional shipping costs.
In addition, the use of prior art pallets like that shown in FIG. 1 led to the fact that accessory equipment, line cords, publications, spare parts and so forth were shipped in separate boxes. As a result, these materials often arrived at a customer's site at a different than the switch. As one can readily appreciate, this caused problems in that equipment assembly was often delayed.
In light of the above, there is a need in the art for a packing pallet that can handle a telecommunications switch along with its accessories, line cords, publications, and spare parts. Further, there is a need in the art for such a packing pallet which: (a) protects the equipment from shipment damage; (b) ensures that all of the equipment will arrive with the switch; (c) eliminates tip hazards during shipment; (c) increases the total weight of a unit load, which increase will reduce potential drop height during shipment; and (d) permits easy removal of the equipment from the pallet.
SUMMARY OF THE INVENTION
Embodiments of the present invention advantageously satisfy the above-identified need in the art and provide a packing pallet that can handle a telecommunications switch along with its accessories, line cords, publications, and spare parts. Further, an embodiment of the present invention is a packing pallet which: (a) protects the equipment from shipment damage; (b) ensures that all of the equipment will arrive with the switch; (c) eliminates tip hazards during shipment; (c) increases the total weight of a unit load, which increase reduces potential drop height during shipment; and (d) permits easy removal of the equipment from the pallet.
A ROLM Systems 9751 CBX (computerized business exchange) Model 10 is a mid-range Private Business Exchange telephone switch that is modular in design. The modular design allows the customer to order 1, 2, or 3 shelves of equipment, depending on the capacity that the customer requires. The assembled configurations represent the following weights: (a) one shelf - 152 lbs; (b) two shelves - 224 lbs; and (c) three shelves - 296 lbs. Advantageously, one embodiment of the present invention is a packing pallet for the 9751 CBX Model 10 which accommodates all three configuration of the CBX from the rigors of the distribution system. As one can readily appreciate, this is advantageous because the use of a single packing pallet to accommodate all three configurations eliminates two further pallets and their associated inventory, tracking, and purchasing administration overhead. Further, this embodiment of the inventive packing pallet protects the CPU assembly of the switching system, which assembly is disposed on the first shelf of the switching equipment, from feeling shocks larger than 15 g's. As those of ordinary skill in the art appreciate, this requirement enables one to protect equipment which is more fragile than an egg, an egg being able to withstand shocks as large as 25 g's.
Advantageously, an embodiment of the inventive packing pallet can support a unit of the above-described equipment on only 160 square inches of foam cushion, or less, without having the cushion buckle. This is important because, as those of ordinary skill in the art appreciate, buckling would cause the equipment to topple over.
In accordance with the inventive pallet, a stringer is used as a bottom support for cushions and a top deck board is bolted, through the cushions, to the stringer. As we have discovered, this arrangement, advantageously permits one to use 160 square inches of foam cushions to support one, two, or three shelves of the above-described equipment, thereby reducing the number of pallets required for shipment of the various configuration from three to one.
The above-described packing pallet has the following additional advantages: (a) accessories are loaded into a box that is placed on top of the cabinet and the box is then affixed to pallet by, for example, stretch wrapping the box to the cabinet--in this manner, the entire arrangement is shipped as a unit load and this ensures that the entire shipment will arrive at the customer's site at the same time; (b) embodiments having a built-in ramp provide for easy removal of equipment from the pallet; (c) corner posts and stretch wrap film may be used to hold equipment covers securely in place during shipment; and (d) the pallet may be fabricated so that its footprint is 24"×40", which footprint conforms to industry standard and, thereby, optimizes warehouse and trucking cube utilization.
BRIEF DESCRIPTION OF THE DRAWING
A complete understanding of the present invention may be gained by considering the following detailed description in conjunction with the accompanying drawing, in which:
FIG. 1 shows, in pictorial form, an exploded isometric view of a prior art pallet;
FIG. 2 shows, in pictorial form, an exploded isometric view of an embodiment of the present invention;
FIG. 3 shows, in pictorial form, an isometric view of the embodiment of the present invention shown in FIG. 2;
FIG. 4 shows, in pictorial form, a cross section of the embodiment of the present invention shown in FIG. 2;
FIG. 5 shows, in pictorial form, an isometric view of a second embodiment of the present invention;
FIG. 6 shows, in pictorial form, the use of the embodiment of FIG. 2 to transport various configurations of a telecommunications switch and attendant materials; and
FIG. 7 shows, in pictorial form, the use of the embodiment of FIG. 5 to transport another type of telecommunications switch and attendant materials.
DETAILED DESCRIPTION
FIG. 1 shows an exploded isometric view of prior art pallet 95. As shown in FIG. 1, bottom deck boards 100, 101, and 102 are nailed, using nails like nail 105, to stringers 110 and 111. Further, polyethylene cushions 125, 126, and 127 are sandwiched between top deck plywood slabs 115 and 116, respectively. Lastly, top deck slabs 115 and 116 are bolted to stringers 110 and 111 by pallet bolts 131, 132, 133, and 134 and their attendant lockwashers, washers, and T-Nuts. The pallet bolts are held in place by T-Nuts 141, 142, 143, and 144. As shown in FIG. 1, bolts 131-134 do not traverse cushions 125-127. The pallet shown in FIG. 1 has proven to be unsatisfactory in use. This is because prior art pallet 95 cannot support a sufficient weight without buckling to enable it to be used for more than one configuration of a ROLM Systems 9751 CBX (computerized business exchange) Model 10. A 9751 CBX Model 10 is a mid-range Private Business Exchange telephone switch that is modular in design. The modular design allows the customer to order 1, 2, or 3 shelves of equipment, depending on the capacity that the customer requires. The assembled configurations represent the following weights: (a) one shelf - 152 lbs; (b) two shelves - 224 lbs; and (c) three shelves - 296 lbs. As a result, more than one type of prior art pallet 95 is required to ship various models of the hardware.
FIG. 2 shows an exploded isometric view of an embodiment of the present invention, i.e., inventive pallet 190 which accommodates all three configuration of 9751 CBX Model 10from the rigors of the distribution system. As shown in FIG. 2, bottom deck boards 200, 201, and 202 are nailed, using nails like nail 205, to stringers 210 and 211. Cushions 225 and 226 are disposed to cover the top of stringers 210 and 211, respectively. Cushions 225 and 226 are covered by top deck 215. Lastly, top deck 215 is bolted to stringers 210 and 211, through cushions 225 and 226, by pallet bolts 231, 232, 233, and 234 and their attendant lockwashers, washers, and T-Nuts. The pallet bolts are held in place by T-Nuts 241, 242, 243, and 244. We have found that above-described inventive packing pallet 190 is superior to prior art pallet 95 shown in FIG. 1 because pallet 190 provides superior resistance to buckling. As one can readily appreciate, this is advantageous because the use of the single packing pallet to accommodate all three configurations of 9751 CBX Model 10 eliminates two further pallets and their associated inventory, tracking, and purchasing administration overhead.
Further, as shown in FIG. 2, one end of cushions 225 and 226 are inclined and have holes 251 and 252, respectively, disposed therein. The holes are disposed to receive dowels 261 and 262 which are disposed in removable ramp 270. As will be readily appreciated by those of ordinary skill in the art, removable ramp 270 may be used to provide easy removal of equipment from the pallet. In a preferred embodiment of the present invention, removable ramp 270 is fabricated from, for example, 3/4 inch plywood and dowels 261 and 262, for example, 3/8 inch wooden dowels having rounded ends, are sunk into ramp 270 and glued in place.
In a preferred embodiment of the present invention, cushions 225 and 226 are polyethylene foam. For assembly, it is preferred that polyethylene cushions 225 and 226 be glued to the top of stringers 210 and 211, respectively, and be glued to the bottom of top deck 215. Moreover, in a preferred embodiment, top deck 215 is formed from 3/4 inch plywood; stringers 210 and 211 are formed from 2×4 inch board nominally; bottom deck boards 200, 201, and 202 are formed from 1×6 inch board nominally; and cushions 225 and 226 are formed from 4 lb. density polyethylene foam which is itself formed from environmentally acceptable blowing agents such as, for example, HCFC 142B or better.
FIG. 3 shows an isometric view of inventive pallet 190 and FIG. 4 shows a cross section of inventive pallet 190.
FIG. 5 shows an isometric view of a second embodiment of the present invention for use in transporting a different configuration of equipment, which pallet 300 is comprised of a first section having tapered ends for forming a ramp to deload equipment and a second section without a ramp.
FIG. 6 shows how pallet 190 of FIG. 2 is used to transport various configurations of a telecommunications switch and attendant materials. As shown in FIG. 6, inventive pallet 190 may be used to transport: (a) configuration 410 comprised of one shelf of equipment and accessory kit 450; (b) configuration 420 comprised of two shelves of equipment and accessory kit 450; and (c) configuration 430 comprised of three shelves of equipment and accessory kit 450. This result is obtained because bolts 231-234 which pass through cushions 225 and 226 provide adequate support against buckling and, as a result, permit the same amount of cushion material to be used to transport these three configurations. Further, as shown in FIG. 6, ramp 270 is stored under the equipment by inserting it thereunder along the direction shown by arrow 460. Lastly, the equipment is supported on pallet 190 by use of fluted corrugated fiber board corner posts 400 built, for example, to a thickness of one inch and by securing the corner posts by wire strips like strip 470.
FIG. 7 shows how pallet 300 of FIG. 5 is used to transport another type of telecommunications switch and attendant materials. As shown in FIG. 7, the taller parts of the equipment are covered by cardboard cap 500 and the taller parts are surrounded by stretch wrap material 520. In addition, the shorter parts of the equipment are secured by wire strips 510.
Those skilled in the art recognize that further embodiments of the present invention may be made without departing from its teachings. | A packing pallet which provides increased buckle resistance for a given amount of cushioning material. In particular, an inventive packing pallet utilizes a stringer as a bottom support for cushions and a top deck board which is bolted, through the cushions, to the stringer. | 1 |
This application is a continuation of application Ser. No. 524,615 filed May 17, 1990 now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a semiconductor resistance element and a process for fabricating same, and more particularly, to a semiconductor resistance element comprising impurities of one electrical conductive type and the opposite electrical conduction type in a semiconductor, and a process for the fabricating same.
2. Description of the Related Art
Among the processes for fabricating a resistance element of a semiconductor integrated circuit, one such process, as shown in FIG. 1, comprises an impurity of the opposite electrical conduction type diffused into a substrate 1 of a single crystal semiconductor of one electrical conduction type to form a diffused region 20 as a resistance element, and a process in which, as shown in FIG. 2, a polycrystalline or amorphous semiconductor film 22 on an insulating film 21 and impurities are diffused into the amorphous semiconductor film 22.
The former resistance element in FIG. 1 formed in the semiconductor substrate 1 is disadvantageous in that a PN junction is formed in the interface between the substrate 1 and the diffused region 20. The resistance element then has a parasitic capacitance, and this parasitic capacitance inhibits a high-speed operation of a transistor.
In contrast, the latter resistance element in FIG. 2 formed on the insulating film 21 is advantageous in that, since a PN junction is not formed and the resistance element is formed on the insulating film 21, the formation position is not restricted and the integration degree can be increased by reducing the occupied area on the integrated circuit.
According to the latter process, in which a resistance element is formed on the insulating film 21 after the formation of a semiconductor film 22 on the insulating film 21, an impurity of a single electrical conduction type, for example, boron (B), is diffused. According to this conventional process, however, even if an impurity is diffused under the same conditions, the resistance value is deviated due to the influence of hydrogen (H 2 ) generated by the heat treatment or plasma treatment at the subsequent step, or the influence of hydrogen generated from a material constituting a surrounding insulating film or metal wire by the subsequent step. In addition, the resistance value is varied widely by local changes.
When a second metal wire layer 25 is present on the resistance element 23 as shown in FIG. 3 as compared to when such a metal wire is not present, the resistance value after the formation of an interlayer film and the subsequent heat treatment (400° to 500° C.) is smaller where the second metal wire layer g is present, as shown in FIG. 4.
The reason for the change of the resistance value is considered to be as follows. As a result of the heat treatment after the formation of the second metal wire layer 25, a large quantity of H 2 is generated from the patterned second metal wire layer 25. This H 2 can easily intrude into the surrounding polysilicon through an insulating film 26.
On the other hand, a polycrystalline or amorphous semiconductor, for example, polycrystalline silicon or amorphous silicon, is different from a single crystal silicon, and since many dangling bonds of Si atoms are present, many localized levels are formed in the handicap, and electrons or positive holes are trapped in these localized levels.
If H 2 generated from the metal wire in the manner described above is caught in the polysilicon, dangling bonds are bonded with hydrogen more readily than with electrons or positive holes, with the result that the dangling bonds are inactivated.
Accordingly, the electrons or positive holes which have not been caught by the dangling bonds become free carriers, and thus the number of carriers in the silicon film is increased and the resistance value is reduced. H 2 is also generated from the first metal wire layer 24, but since the presence of the first metal layer 24 is common to all resistances, this H 2 does not provide a reason for the difference in the resistance value.
It can be considered that, when forming a resistance element, an impurity concentration is first adjusted to cope with an estimated reduction of the resistance value by a metal wire arranged in the vicinity of the resistance element or by the heat treatment temperature. However, this method is not practical for a device in which the wire layout is determined according to the requirement of a user, such as a gate array.
SUMMARY OF THE INVENTION
Accordingly, an object of the present invention is to provide a semiconductor resistance element wherein the resistance value thereof can be maintained at a constant level regardless of environmental changes such as a change of the temperature and the presence of hydrogen.
A further object of the present invention is to provide a process for fabricating the semiconductor resistance element.
According to the present invention there is provided semiconductor resistance element of one electrical conduction type comprising:
a semiconductor region including a first impurity of opposite electrical conduction type and second impurity of one electrical conduction type, wherein said second impurity is more heavily introduced so that a predetermined resistance is obtained; and
electrode regions provided on both ends of said semiconductor region.
According to the present invention, there is further provided a process for the fabrication of a semiconductor resistance element, comprising the steps of:
preparing a semiconductor substrate, introducing impurities of one electrical conduction type and impurities of the opposite electrical conduction type into a region of said semiconductor substrate,
heat-treating said impurity-introduced region of said semiconductor substrate, and
forming electrode regions at both ends of said region of the semiconductor substrate.
According to the present invention, a resistance element is formed by introducing an impurity of one electrical conduction type and an impurity of the opposite electrical conduction type formed in a semiconductor film on an insulating substrate. For example, a film of a monocrystalline (e.g., monocrystalline silicon), polycrystalline or amorphous semiconductor is formed on an insulating film, and both N-type and P-type impurities are introduced into the semiconductor film at a concentration of about 3×10 18 cm 3 .
If a resistance element is thus formed by injecting both N-type and P-type impurities, not only one carrier of an electron or a positive hole is caught by dangling bonds of atoms in the semiconductor film, but sometimes electrons are caught or positive holes are caught, and it is considered that the numbers thereof are almost equal.
Accordingly, it is considered that the carriers set free by an inactivation of dangling bonds by H 2 are an almost equal number of electrons and positive holes, and they negate each other and make no contribution to the conduction of electricity, and therefore, it is considered that the resistance value is little changed by H 2 .
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a resistance element fabricated by a first conventional process;
FIG. 2 is a perspective view of a resistance element fabricated by a second conventional process;
FIGS. 3 and 4 are a sectional view of a resistance element fabricated by the second conventional process and a view showing the characteristics of this resistance element;
FIGS. 5A through 5K are step diagrams showing an example of the present invention, in section;
FIG. 6 is a plane view showing an example of the resistance element formed according to the present invention;
FIG. 7 is a diagram illustrating the characteristics of the resistance element according to one example of the present invention;
FIG. 8 is a sectional view of a TFT (Thin Film Transistor) according to the present invention; and
FIG. 9 is a diagram illustrating the characteristics of a resistance element.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
An example of the present invention will now be described with reference to the accompanying drawings.
FIG. 5 is a step diagram showing one example of the present invention in section, wherein reference numeral 1 in the drawings represents a substrate composed of a semiconductor such as silicon, and a silicon dioxide (SiO 2 ) film 2 is formed on this substrate 1 by the CVD (Chemical Vapor Deposition) method and a semiconductor resistance element is formed on the silicon dioxide film [see FIG. 5A].
For the formation of the resistance element, a polycrystalline silicon film 3 having a thickness of, for example, about 3000 Å is laminated on the SiO 2 film 2 [see FIG. 5B], and a phosphorus (P) ion is implanted or injected into the polycrystalline silicon film 3 at an energy of 70 keV and a dosage of 1×10 15 per cm 2 by the ion implantation (injection) method. Then a boron (B) ion is injected at an energy of 35 keV and a dosage of 1×10 15 per cm 2 [see FIG. 5C]. The injection quantities can be appropriately changed according to the number of dangling bonds in the polycrystalline film 3 or the resistance value.
Then the second injection of an ion of B is carried out, to select the resistance value. In this case, the dosage is changed according to the resistance value [see FIG. 5D].
After this ion injection step, as shown in FIG. 5E, a resistance element-forming region of the polycrystalline silicon film 3 is covered with a resist mask 4, and reactive ion etching is carried out by using a gas formed by adding O 2 to CF 4 , to effect a patterning of the polycrystalline film 3 to a size of 4 μm×14 μm.
The resist mask 4 is removed and an SiO 2 film having a thickness of 3000 Å is formed on the patterned polycrystalline silicon film 3, and a resist 6 is coated on the SiO 2 film 5 [see FIG. 5F].
Then, as shown in FIG. 5G, two windows 7 are formed on the resist 6 at a distance of 5 μm from both side ends of the polycrystalline silicon film 3. The portions of the SiO 2 film exposed by the windows of the resist 6 are etched by reactive ion etching to form contact holes 8 in the SiO 2 film 5 [see FIG. 5H]. In this case, C 2 F 6 is used as the etching gas.
The resist 6 is removed, and an ion of B for forming a contact region is injected in the polycrystalline silicon film 3 through the contact holes 8 [see FIG. 5I]. The injection is carried out under the conditions of an energy of 35 keV and a dosage of 1×10 15 per cm 2 .
The substrate is then placed in a nitrogen atmosphere and annealed at 900° C. for 30 minutes, whereby the impurities in the polycrystalline silicon film 3 are activated and a contact region layer 9 is formed below the contact holes [see FIG. 5J].
Thereafter, a film of, for example, AlCu, having a thickness of about 1 μm is formed on the SiO 2 film 5 and within the contact hole 8, by the CVD method or the sputtering method, and this film is patterned by the reactive ion etching method to leave the AlCu film only on the region of the contact hole 8. This remaining AlCu film is used as an electrode 11. In this case, CCl 4 is used as the etching gas. Furthermore, an SiO 2 layer 13 is grown, for example, to a thickness of 5000 Å, by the CVD method, and then a contact hole (not shown) is formed according to need, and a film of, for example, AlCu, having a thickness of about 1 μm is formed by the gas phase growth method or sputtering method. This AlCu film is patterned by the reactive ion etching method to form a second metal wire layer (AlCu) 12.
FIG. 6 is a plane view showing the state of the resistance element before the formation of the metal wire layer 12. When the resistance value of the resistance element is measured before and after the formation of the metal wire layer 12, the characteristics as shown in FIG. 7 are obtained.
FIG. 7 shows the resistance characteristics, in which the dosage of boron at the second injection is plotted on the abscissa and the resistance value is plotted on the ordinate. The characteristics shown by the solid line are the resistance values measured just before the formation of the AlCu film 12 as shown in FIG. 5J. The characteristics indicated by the broken line are the resistance values measured after the formation of the AlCu film 12 and the heat treatment (about 450° C.) for forming an interlayer film, as shown in FIG. 5K.
The characteristics indicated by the one-dot chain line and two-dot chain line show the relationship between the injection quantity of the B ion and the resistance value, observed when only B ions are injected into the polycrystalline silicon film to form a resistance element according to the conventional process. The one-dot chain line shows the state just before the formation of the electrode and the two-dot chain line shows the state after the formation of the electrode and the heat treatment (about 450° C.) for forming an interlayer film.
From these measurement results, the resistance value is reduced after the electrode-forming step in both the process of the present invention and the conventional process, but the quantity of the change of the resistance value is smaller in the process of the present invention than in the conventional process.
For example, where it is desired to adjust the final resistance value after the formation of the AlCu film 12 and the interlayer insulating film to about 5 kΩ, by adjusting the injection quantity of impurities, according to the process of the present invention where both an acceptor and a donor are injected, the resistance value is not substantially different from the resistance value after the formation of the AlCu film 11. In contrast, in the conventional process in which only an acceptor is injected, the resistance value should be about 75 kΩ, and the resistance value is reduced to 1/7, to obtain a final resistance value of 5 kΩ. This reduction quantity becomes larger as the resistance value increases.
The reason for this is considered to be as follows.
Due to the low-temperature heat treatment for the formation of the insulating film after the formation of the AlCu film 12, hydrogen is generated from the AlCu film 12, and this hydrogen is readily intruded into the polycrystalline silicon film 3 through the SiO 2 film and the AlCu film 12. The hydrogen caught in the polycrystalline silicon inactivates the dangling bonds of the Si atom, and the carrier which has been trapped by such dangling bonds is set free. In the process of the present invention using a donor and an acceptor, the carrier thus set free includes both electrons and positive holes, and it is considered that the number of electrons and positive holes is almost equal. Accordingly, the freed electrons and positive holes negate each other and make no contribution to the conduction of electricity. Accordingly, it is construed that a resistance element that is little influenced by the presence of hydrogen can be formed.
Even in the case where only an impurity of one electrical conduction type is injected into a polycrystalline silicon film, as in the conventional process, if the impurity concentration is increased, since the ratio of the number of the carriers caught by the dangling bonds to the entire carrier number is relatively reduced, the shift quantity of the resistance value can be reduced, but since the number of carriers increases with an elevation of the impurity concentration, a high resistance value of about 10 kΩ cannot be obtained.
In contrast, in the present invention, although the impurity concentration is high, the acceptor and donor are injected substantially in the same quantities at the first injection step, and thus the number of electrons and positive holes formed in the polycrystalline film 3 is substantially equal negating each other, with the result that they apparently make no contribution to the conduction of electricity.
Accordingly, since only a small quantity of electrons or positive holes formed by the donor or acceptor introduced at the second injection step makes a practical contribution to the conduction of electricity, it is possible to increase the impurity concentration and realize a high resistance value.
In the above-explained example wherein the first and the second injection steps, i.e., two injection steps, are effected, a desired conduction type impurity having a dosage a little larger than that of the opposite conduction type impurity can be more precisely injected by injecting the dosage of the difference in the second step, than in a case where the two conduction type impurities, which have different dosages, are injected in only one step.
FIG. 9 shows a diagram illustrating the characteristics of a resistance element, more particularly shows a relationship between each dosage quantity and concentration of one conductive type impurity (in this case; boron) and the opposite conductive type impurity (in this case; phosphorus), and the difference of sheet resistivity of a resistance element (type A) providing a metal film (Al) through an insulating film and a resistance element (type B) not providing a metal film through an insulating film.
After the above-mentioned boron and phosphorus impurities are introduced at the quantity shown in FIG. 9, a further, one conduction type impurity is introduced so that 5 kΩ/□ of sheet resistivity can be obtained.
When the quantity of the impurities which are simultaneously implanted it can be found from FIG. 9 that the difference of sheet resistivity of Types A and B becomes small.
In a conventional case where impurities are not simultaneously implanted the difference of sheet resistivity becomes about 20 kΩ/□.
When FIG. 9 is considered, the impurity quantity is preferably a dosage of 1×10 14 cm -2 or more at which the difference of sheet resistivity becomes 10 kΩ/□ or less, namely, 3×10 18 cm -3 or more as the concentration. Further to obtain a more precise resistance element the impurities are preferably implanted at a dosage of 1×10 15 cm -2 at which the difference of sheet resistivity becomes about 0, namely, 3×10 19 cm -3 or more.
The introduction of impurities is carried out by steps of introducing the same quantity of one conduction type and the opposite conduction type and additionally introducing a desired conduction type impurity whereby a required resistance can be obtained. Further, there may be carried out a step of simultaneously introducing one conduction type impurity and the opposite conduction type impurity, the quantity of the one conductive impurity being increased more by a required quantity than that of the opposite conduction type, whereby a required resistance can be obtained.
FIG. 8 shows a sectional view of a thin film transistor (TFT) of another example as the present invention.
In FIG. 8, reference numerals 14 is a source/drain electrode, 15 is a gate electrode, 16 is and a gate insulating film (SiO 2 ), 17 is a source region formed on semiconductor region 3 and 18 is a drain region formed on a semiconductor region 3 respectively. The other elements are the same as those shown in FIG. 2.
The two step injection of impurity ion in the polycrystalline silicon film 3 is effected in the same manner as explained above.
In the foregoing example, a resistance element is formed by polycrystalline silicon, but amorphous silicon can be used, or other semiconductors such as germanium can be used.
Aluminum (Al) or gallium (Ga) can be used as the impurity of one electrical conduction type instead of boron (B), and as the impurity of the opposite electrical conduction type, arsenic (As) and antimony (Sb) can be used instead of phosphorus (P).
The first injection of impurities is carried out before the patterning of the polycrystalline silicon film in the foregoing example, but this injection can be carried out after such patterning.
Further, a method can be adopted in which the quantity of the impurity injected at the second injection is added to the quantity of the impurity injected at the first injection, and thus the injection of N-type ions and P-type ions can be effected at one time.
As apparent from the foregoing description, if a resistance element is formed by introducing N-type and P-type impurities into a semiconductor film formed on an insulating film, the resistance value of the resistance element can be maintained substantially at a constant level, regardless of environmental changes such as a change of the temperature and the presence of hydrogen.
The effect of diminishing the shift of the resistance value is conspicuous as the resistance value is high, and a remarkable effect is exerted in a high-resistance region.
Further, the present invention is effective for controlling variations of the resistance value due to the influence of H 2 during the plasma treatment, and for controlling variations of the resistance value due to H 2 generated from not only a metal wire as described above but also an insulating film or a passivation film, during or after the growth of the film. | A semiconductor resistance element of one electrical conduction type comprises: a semiconductor region including a first impurity of opposite electrical conduction type and second impurity of one electrical conduction type, wherein said second impurity is more heavily introduced so that a predetermined resistance is obtained; and electrode regions provided on both ends of said semiconductor region. | 7 |
FIELD OF THE INVENTION
[0001] The present invention relates to disposable personal care products, such as diapers, feminine care products and adult incontinence products. More specifically, the invention relates to products having improved absorbent core integrity, and methods for producing such products through ultrasonic compressions.
BACKGROUND OF THE INVENTION
[0002] Disposable care products are typically comprised of at least three general layers. These include an absorbent core placed between a liquid permeable inner liner and a liquid impermeable outer cover. The inner liner and outer cover can comprise one or more individual layers of materials, and additional layers can also be interposed between any of the general layers. For example, in the disposable diaper, the inner liner can comprise a surge layer consisting of thermoplastic fibers positioned beneath a thermoplastic mesh. Additionally, a tissue material, or wrap sheet, is often positioned between the outer cover and absorbent core, and between the surge layer and the absorbent core. At the diaper periphery, the material layers extending to the periphery are held together by conventional means, such as adhesives, crimping, fusing, or other methods known in the art.
[0003] The absorbent core receives and retains bodily fluids. It consists of a natural fiber batt that has a strong affinity for water and other hydrophilic components of bodily secretions. A dispersion of superabsorbent particles can also be incorporated into the fibrous core.
[0004] Maintaining a continuous, intact core, especially when these articles are used, is a recurring issue in the disposable garment industry. Breaks in the continuum of the core create open spaces that prevent the transport of fluid into the core, and the wicking of the fluid in the core. This breakdown of the core structure can cause fluids to leak out of the periphery of the diaper. The core breakdown also results in its sagging, which is visually unappealing to the consumer.
[0005] In the disposable diaper, adhesives used to bond various material interfaces within the diaper have not eliminated the breakdown of the absorbent core. The adhesive is conventionally applied in a swirl, spray or bead pattern between the outer cover and the wrap sheet, and/or between the surge layer and the wrap sheet. Moreover, adhesives placed between the wrap sheet and the inner liner reduce the absorbent property of the core by blocking the transport of fluids between these layers. The addition of an adhesive also increases the raw material costs associated with assembling disposable diapers. The standard adhesive loading is 0.31 to 0.33 grams of adhesive per diaper. Core integrity is not maintained at this loading. Additionally, it has been found that increasing the adhesive weight by tenfold, i.e., 3.1 to 3.3 grams per diaper does not appreciably improve core integrity.
[0006] Ultrasonically compressing the absorbent core between the inner liner and outer cover can be used in place of an adhesive to maintain the core integrity. Ultrasonic bonding involves high frequency mechanical energy transfers in the form of a reciprocating vertical motion. When ultrasonic energy is applied to several material layers, the vibrations within each material layer generate heat. Ultrasonic vibrations within a thermoplastic material will soften or melt the thermoplastic material if the heat generated increases the temperature of the thermoplastic material above the glass transition temperature or melting temperature, respectively. Thermoplastic materials are thus considered fusible.
[0007] The high crystallinity and high melting point of natural fibers makes these fibers infusible at the temperatures needed to soften or melt conventional thermoplastics. Since natural fibers are in general infusible, few attempts have been made to ultrasonically bond or weld a natural fiber core between two fusible materials. To ultrasonically bond a natural fiber core between two fusible materials, enough energy must be applied, and maintained within the layers, to fuse the fusible materials at the surface of the core, or to each other through the interstitial void volume in the core, without sufficiently deforming the fusible layers.
[0008] European Patent Application 0 438 113 A1 to S. J. Anapol et al. discloses an absorbent batt structure that has a discrete pattern of hydrogen bonded compressed portions formed on at least one surface of the batt. The batt contains fibers that are formed from a loose assemblage of cellulose, and, if needed, thermoplastic fibers, that has a discrete pattern of bonded compressed portions formed on at least one surface of the batt. These discrete compressions result in a batt structure with discrete density gradients, uniformly placed across the surface of the batt. These density gradients, in turn, result in enhanced fluid transfer between adjacent compressed portions, while substantially maintaining the absorbency of the batt. A water spray is applied to the surface of the batt and then an embossing roll, or ultrasonic energy, is applied to the surface to define a plurality of substantially, uniformly spaced, hydrogen-bonded compressed portions. Here, the core only is compressed and assembled into the final product, and a water spray is required to form the compressions in the core. Thus, a costly intermittent compression step is needed. The water spray may be needed to provide water molecules for hydrogen bond formation.
[0009] Other work involving absorbent articles disclose an actual fusion, or mechanical bonding of the material layers, as opposed to a pure compression of the these layers. For example, U.S. Pat. Nos. 4,823,783 and 5,059,277 to W. Willhite et al. disclose a method and apparatus for ultrasonically bonding continuous moving webs to one another using a stationary vibrating horn and a slick, thermally resistant slip layer. The slip layer is placed between the webs and the horns to prevent web damage. In this method, at least one of the webs to be bonded is comprised of a polymeric material which can be locally melted or softened by the input of mechanical energy. The slip layer maximizes heat retention in the web to be bonded, and ensures that neither the relatively delicate polymeric webs or the more resilient highly compressible webs are damaged in the bonding process. Two or more webs can be bonded together, but the protective slip layer is not bonded to the resultant laminate structure. The nature of the bond formed between one or more heat softened polymeric webs and other layers in the structure will vary depending on the chemical makeup of the other layers. If one or more layers does not soften by the input of mechanical energy, but exhibits significant interstitial void volume, the bonding will likely comprise mechanical entanglements of the melted or softened polymeric webs with the infusible web or webs, and/or the fusing of the polymeric webs to one another through the interstitial void volume in the infusible web.
[0010] U.S. Pat. Nos. 5,269,860 discloses the fusion of a thermoplastic sheet onto a thermoplastic or a nonthermoplastic fibrous textile. The thermoplastic sheet can be ultrasonically fused to a textile substrate that has an equivalent or higher melting temperature than the thermoplastic sheet. Ultrasonic energy is applied to the thermoplastic sheet, and the sheet melts before the textile surface begins to soften. This results in a fusion between the melted thermoplastic and the textile fibers. The ultrasonic energy can be applied to localized sections of the thermoplastic sheet to form various patterns of the fused thermoplastic sheet and fiber substrate. U.S. Pat. No. 5,609,702 to V. E. Andersen discloses a method for mutually bonding at least two moving continuous webs to form a laminate containing at least one puckered material layer. These webs can be bonded by thermal or ultrasonic techniques. At least one of the webs comprises weldable material; however, the preferred approach is to bond webs, each containing a weldable material.
[0011] Other work in the area of articles containing an absorbent core have combined natural fibers with heat-fusible thermoplastic fibers, or other polymer additives, to improve the fusion and compression of the core. The application of thermal or ultrasonic energy to the combined core, or to substrates adjacent to the core, thermally fuses the thermoplastic material present in the core to other fibers within the core, and to other thermoplastic materials at the interface of the core, respectively. However, the inclusion of hydrophobic thermoplastic materials in the core within the voids and interstitial spaces reduces moisture intake and rate of wicking. Moreover, the addition of thermoplastic fibers to a natural fiber core adds additional expense to the fabrication of the disposable product. Examples of such systems of the prior art are disclosed in U.S. Pat. No. 4,886,697 to L. E. Perdelwitz, et al.; U.S. Pat. Nos. 4,844,965 and 4,939,017 to C. Foxman; and International Patent Application WO 98/27904 to K. S. Lynardet al.
[0012] Thus, there is a need for disposable diapers having improved absorbent core integrity upon wear, while maintaining the absorption capacity of the natural fiber core.
[0013] There is also a need to reduce costs in the manufacturing of these articles by eliminating or reducing the amount of adhesives in the final product, and by eliminating costly and intermittent bonding procedures.
[0014] Therefore, there is a need in the art to improve the continuum of the absorbent core without increasing material and manufacturing costs associated with these products.
[0015] There is also a need to eliminate additional material components, such as adhesives, and intermittent bonding procedures.
[0016] Further, there is also a need to maintain the core absorbency of the intact core in terms of the amount of fluid intake and its retention.
SUMMARY OF THE INVENTION
[0017] The present invention is directed to disposable care products that, upon use, maintain a better core integrity and absorption and methods for their production. These products eliminate the need for additional material components, such as adhesives, and intermittent bonding procedures. Further, these products maintain the core absorbency of the intact core in terms of the amount of fluid intake and its retention.
[0018] In one aspect, the present invention comprises a disposable personal care product having improved absorbent core integrity upon wear. The product comprises a liquid permeable inner liner, a liquid impermeable outer, a natural fiber core positioned between the inner liner and outer cover, and a region containing a plurality of localized compressions formed by ultrasonically compressing the natural fiber core between, although not necessarily adjacent to, at least one upper and at least one underlying fusible material.
[0019] In another aspect, the present invention comprises a method of making a disposable personal care article having improved absorbent core integrity upon wear. The method comprises positioning a natural fiber core between, but not necessarily adjacent to, a liquid permeable inner liner and a liquid impermeable outer cover. Next, a region containing a plurality of localized compressions is formed by ultrasonically compressing the natural fiber core between, although not necessarily adjacent to, at least one upper and at least one underlying fusible material. The periphery of the article is then bonded by conventional means, such as adhesives, crimping or fusing.
[0020] This process reduces costs associated with the manufacturing of such articles by eliminating or reducing the amount of adhesives in the final product, and by eliminating costly and intermittent bonding procedures. The method also improves the continuum of the absorbent core without increasing material and manufacturing costs associated with these products.
[0021] Thus, it is an object of the present invention to provide disposable personal care products having improved absorbent core integrity upon wear while maintaining the absorption capacity of the core.
[0022] It is another object of the invention to provide disposable personal care products having improved absorbent core integrity upon wear, containing a natural fibrous core that is ultrasonically compressed between at least one upper and at least one underlying fusible material.
[0023] It is yet another object of the present invention to provide disposable personal care products having improved absorbent core integrity upon wear that do not contain an adhesive at the inner planar surface, as opposed to the edges, of any material layer.
[0024] It is an object of the present invention to provide a method of making disposable personal care products having improved absorbent core integrity upon wear while maintaining the absorption capacity of the core.
[0025] It is another object of the invention to provide a method of making disposable personal care products having improved absorbent core integrity upon wear, containing a natural fibrous core that is ultrasonically compressed between at least one upper and at least one underlying fusible material.
[0026] It is yet another object of the present invention to provide a method of making disposable personal care products having improved absorbent core integrity upon wear that do not contain an adhesive at the inner planar surface, as opposed to the edges, of any material layer.
[0027] It is a further object of the present invention to provide a method of making disposable personal care products having improved absorbent core integrity upon wear by ultrasonically compressing, in one step, the natural fiber absorbent core between at least one upper and at least one underlying fusible material.
[0028] It is an object of the present invention to provide a method of making disposable personal care products having improved absorbent core integrity upon wear by ultrasonically compressing, in one step, the natural fiber absorbent core between at least one upper and at least one underlying fusible material, and applying the ultrasonic energy to only one of the fusible materials.
[0029] It is another object of the present invention to provide a method of making disposable personal care products having improved absorbent core integrity upon wear, by ultrasonically compressing, in one step, the natural fiber absorbent core between at least one upper and at least one underlying fusible material, and applying the ultrasonic energy to only one of the fusible materials after the assembly of all the product's material layers.
[0030] These and other objects of the present invention will be more readily apparent when considered in reference with the following description.
BRIEF DESCRIPTION OF THE DRAWINGS
[0031] This patent contains at least one color photograph. Copies of this patent with the color photographs will be provided by the Patent & Trademark Office upon request and payment of the necessary fee.
[0032] [0032]FIG. 1 shows an intact diaper core in form of a light box.
[0033] [0033]FIG. 2 shows the diaper core control having “no adhesive” in front of a light box after 120 minutes of the high kick test.
[0034] [0034]FIG. 3 shows the 10 mm×10 mm compression patterned inner liner test diaper in front of a light box after 120 minutes of the high kick test.
[0035] [0035]FIG. 4 shows the 10 mm×10 mm compression patterned outer cover test diaper in front of a light box after 120 minutes of the high kick test.
DETAILED DESCRIPTION OF THE INVENTION
[0036] The present invention comprises disposable, personal care products that, upon use, maintain a better core integrity and absorption than conventional products. Such products include, but are not limited to, diapers, training pants, feminine care products, and incontinence products.
[0037] Generally, personal care products of the invention comprise three or more layers of synthetic and natural materials. These layers include a liquid permeable inner liner, an absorbent core, and a liquid impermeable outer cover. The absorbent core is positioned between the inner liner and outer cover.
[0038] The inner liner can be manufactured from a wide range of materials, such as woven and nonwoven polymeric fibers or a combination of synthetic and natural fibers. Typical polymeric fibers include polyethylene, polypropylene and polyester fibers. Typical natural fibers include cellulose, wood pulp and cotton.
[0039] The outer impermeable cover in one instance comprises a multilayered polymer films, nonwovens, laminates of films and nonwovens, laminates of nets and films, laminates of nets and nonwovens of polyethylene, polypropylene, polyesters, polyvinyl alcohols, and polyvinyl acetates. In another instance, the outer cover comprises a composite material, such as a film-coated nonwoven material.
[0040] The absorbent core comprises natural fibers, such as cellulose, wood pulp, or cotton. The core has a strong affinity for water and other hydrophilic components of bodily secretions. The absorbent core can take any form suitable for use in absorbent composites. For example, the core can be in the form of a natural fiber batt or regenerated cellulose and can contain a dispersion of superabsorbent particles. Other forms of superabsorbent materials include, but are not limited to, fibers, flakes, spheres, films, foams, sprays, and printable superabsorbent materials.
[0041] The inner liner and outer cover can comprise one or more individual layers of materials. For example, the inner liner may comprise a surge layer containing, for example, thermoplastic fibers positioned beneath a thermoplastic mesh. Further, additional layers can be interposed between any of the three general layers. For example, an inner tissue material or wrap sheet is optionally positioned between the outer cover and absorbent core, and between the surge layer and the absorbent core.
[0042] The natural fiber core of the present invention can be heated and compressed between two fusible materials using ultrasonic energy without forming an ultrasonic bond or weld and without significantly deforming the fusible materials. It may also be possible to form compressions using sufficient localized pressure in the absence of ultrasonic energy.
[0043] Ultrasonic compressions are employed to provide improved contact between the layers of the article. This contact occurs without bonding the fusible materials to the natural fiber core, or to one another. The compression sites are used in place of an ultrasonic bond to keep the natural fiber core in place and serve to reduce the break-up of the absorbent core, thus maintaining the absorption capacity of the core. While the use of ultrasonic compressions are preferred, other methods of forming the compressions are contemplated by the invention. Such methods include the use of air or hydraulic pressure.
[0044] In particular, ultrasonic energy can be applied to either the inner liner or outer cover of the article or both. Ultrasonic energy involves high frequency mechanical energy in the form of a reciprocating vertical motion. Such ultrasonic energy applied to thermoplastic materials results in a softening or melting of the thermoplastic if the heat generated increases the temperature of the thermoplastic above the glass transition temperature or melting temperature. In contrast, the high crystallinity and high melting point of the natural fibers used in the absorbent core of the present invention makes the core infusible at the temperatures needed to soften or melt conventional thermoplastics.
[0045] The compressions eliminate the need for an adhesive between the material layers of the article. The compressions can be done during assembly of the article, or can be done as a one-step process after complete assembly of all the article layers, eliminating intermittent bonding procedures and saving manufacturing time and expense. The compressions can be applied to either the inner liner or outer cover of the article. The compressions can be formed at discrete locations within the surge area of the diaper and can be prepared manually using a hand-held bonder, or in a continuous fashion on a rotary bonder.
[0046] The ultrasonic compressions, extending within the unexposed fibrous layer of the absorbent core anchor the core fibers between compression sites. In addition, the compressions act as stress points, absorbing a higher shear force, as opposed to uncompressed core, before breaking apart. Thus, these ultrasonic compressions help to reduced breaks in the continuum of the absorbent core, and this, in turn, reduces the amount of void space within the core, and the amount of fluid accumulating in the void spaces and leaking out of the periphery of the article. This is especially beneficial when the article is a diaper.
[0047] Although the scope of the invention encompasses any type of disposable personal care product, the invention will be further illustrated with regard to diapers. It will be understood by one skilled in the art that the following discussion would also apply to other types of personal care products and in no way limits the scope of the invention.
[0048] The present application teaches that the ultrasonic compression of a natural fiber core between at least one upper and at least one underlying fusible material serves to maintain the core's integrity and absorption properties when the diaper is in use. The ultrasonic compressions can replace costly adhesives and other costly bonding procedures. Moreover, the ultrasonic compressions can be formed after the product is completely assembled.
[0049] Moreover, the surface area of each compression can be small enough so that total surface area of all of the compressions comprises only a small percentage of the total surface area of the absorbent core. For example in this invention, the total area of the compressions comprises about 1.5% of the total area of the absorbent core, spread out, for example, in a pattern of 10×10, 35×40, or 20×20. This small area of compression helps to maintain the absorbent properties of the core by maximizing the amount of core fibers free to absorb and wick fluids. Finally, the compressions can be used in place of an adhesive, and thus eliminate the problems associated with the adhesive blocking the passage of fluids into the core.
[0050] Although these compression sites can be formed in one step, that is by one application of ultrasonic energy to the surface of a fusible material, after the product is completely assembled, the compression sites are generally formed during intermediate steps in the diaper assembly process so that the material layers are bonded together as individual components and then introduced to the product line.
[0051] This invention is further illustrated by the following examples, which are not to be construed in any way as imposing limitations upon the scope thereof. To the contrary, it is to be clearly understood that resort may be had to various other embodiments, modifications, and equivalents thereof which, after reading the description herein, may suggest themselves to those skilled in the art without departing from the spirit of the present invention and/or the scope of the appended claims.
EXAMPLES
Example 1
[0052] Preparation of the Ultrasonic Bonds
[0053] Ultrasonic compressions were preformed on six, size 3, test diapers. Each diaper consisted of a liqiud impervious backsheet, a cellulose pulp absorbent core, and a nonwoven thermoplastic fibrous inner liner. The cellulose core contained a dispersion of superabsorbent particles. No adhesive was applied between any of the material layers in these diapers. The diapers were processed on a standard diaper machine. All material layers were assembled together and bonded only at the perimeter of each diaper using conventional means. The perimeter bonding did not come in contact with the absorbent core. Ultrasonic compressions were then applied to the surge area of the assembled diapers.
[0054] A hand-held, plunge bonder from Sonics & Materials, Inc., model HSM 3, was used to ultrasonically compress the test diapers. The bonder was powered by a 2000 Auto-Trac (20 KHz, 2000 Watt) ultrasonic generator from Dukane Corporation. The bonder also contained a rectangular slotted horn and a dot-pattern anvil design. The horn, manufactured by Branson Ultrasonics Corporation, had dimensions of 0.5″ depth×6.0″ wide×5.5″ high. The bonder was equiped with an oblong tip, 4 ½ mm in length and 1 ½ mm in width. The bonder, operating at a power setting of “five,” efficiently locally compressed the inner liner, absorbent core and outer cover together without burning any of the material layers, or poking holes through these layers. During the compression process, each diaper remained stationary by firm, hand-held pressure.
[0055] The ultrasonic compressions were placed in the surge area of each diaper, where the absorbent core breaks apart more extensively. To identify any performance differences resulting from the direction the ultrasonic energy was applied, compressions were delivered to either the inner liner or the outer cover for each test diaper. Compressions were placed at three different spacing within the surge area: 35 mm×45 mm, 20 mm×20 mm, and 10 mm×10 mm.
[0056] The integrity of the absorbent core in the test diapers was compared against two controls. In one control, an adhesive bonded the outer cover to a wrap sheet, placed between the absorbent core and the outer cover. The adhesive add-on (loading) on the coversheet or outer liner was approximately 0.3 gram adhesive per diaper spread uniformly using a swirl pattern. In the second control, no adhesive or any other bonding mechanism, was used to hold the material layers together, other than the bonding at the diaper periphery. The core integrity of each diaper was evaluated using a “high kick” test described below.
Example 2
[0057] Evaluation of Core Integrity
[0058] The core integrity of each diaper was evaluated using a “High Kicking Baby Model.” This model simulates the high kick of an active child. Each kick is approximately 60° to 90° from floor level. Each diaper, in the dry state, was tested on this high kick model for a total of 120 minutes. The dry diaper, high kick test represents the worst case scenario for absorbent core break-up. The integrity of the diaper core was analyzed at the following time points: 10, 20, 30, 60, 90 and 120 minutes. The core integrity was analyzed by stretching each diaper along its longitudinal axis in front of a light box, with the inner liner facing the light. Each diaper was stretched to its full length and place against the surface of the light box. Two clips mounted to the glass surface of the light box held the top end of the diaper, containing the side adhesive tabs, in place. Two weights were placed at the opposite end of the diaper to stretch the diaper, and hold it in place. Prior to subjecting a diaper to the high kick test, the diaper was stretched out before the light box, and the perimeter of the intack absorbent core was traced with a permanent ink marker. The enclosed area served as a reference from which future measurements were compared. The enclosed core area in an untested diaper averaged around 22,500 square millimeter, and encompassed the entire range of the absorbent core, from the front to the back of the diaper. FIG. 1 shows an intack diaper core in front of the light box. At each time interval during the “high kick” test, each diaper was examined in front of the light box, and the approximate void space, or total area separation, within the absorbent core, measured. FIGS. 2 and 3 show the “no-adhesive” control after 120 minutes, and the 10 mm×10 mm, inner liner test diaper after 120 minutes, respectively. The lighter regions, where the background light transmitted, denoted the voids or separation within the absorbent core. The darker regions, where the background light scattered, represented intack core. The end results of the kick test are shown in Table 1. Tables 2 and 3 list the total area of separation at each time point for the ultrasonic energy delivered to the inner liner and outer cover, respectively.
TABLE 1 Core Integrity After 120 Minutes on the High Kicking Baby Model Total Area Separated (sq. mm)/% Area Separated Ultrasonic Control Control Compressions (mm × mm) (Adhesive) (No Adhesive) 35 × 40 20 × 20 10 × 10 5445/24% 6060/27% 2021/9% a 2056/9% a 319/2% a 3141/14% b 2239/10% b 1117/5% b
[0059] [0059] TABLE 2 Core Integrity During the High Kicking Baby Model Ultrasonic Compressions Delivered to Inner Liner Total Area Separated (sq. mm)/% Area Separated Time CONTROLS ULTRASONIC SPACING (mm × mm) (min) Adhesive No Adhesive 35 × 40 20 × 20 10 × 10 10 1505/7% 1874/8% 216/1% 93/1% 100/1% 20 2694/12% 2784/12% 320/2% 612/2% 106/1% 30 3014/13% 3756/17% 710/3% 828/3% 160/1% 60 3487/16% 5303/24% 790/4% 1747/4% 240/1% 90 4980/22% 5520/25% 1522/7% 1959/7% 285/1% 120 5445/24% 6060/27% 2021/9% 2056/9% 319/2%
[0060] [0060] TABLE 3 Core Integrity During the High Kicking Baby Model Ultrasonic Compressions Delivered to Outer Cover Total Area Separated (sq. mm)/% Area Separated Time CONTROLS ULTRASONIC SPACING (mm × mm) (min) Adhesive No Adhesive 35 × 40 20 × 20 10 × 10 10 1505/7% 1874/8% 409/2% 0/0% 397/2% 20 2694/12% 2784/12% 753/3% 561/3% 511/2% 30 3014/13% 3756/17% 1527/7% 738/4% 638/3% 60 3487/16% 5303/24% 2184/10% 1721/8% 743/3% 90 4980/22% 5520/25% 2609/12% 2035/9% 959/4% 120 5445/24% 6060/27% 3141/14% 2239/10% 1117/5%
[0061] The data clearly shows that the break-up the core structure significantly decreased in the test diapers containing the ultrasonic compressions as opposed to the control diapers. The integrity of the core also improves when the ultrasonic compressions are spaced closer together. A slight improvement is observed when the ultrasonic energy is applied to the inner liner as opposed to the outer cover. Also, only minimal improvement in core integrity is observed when the constructive adhesive is used as opposed to no adhesive. These results verify the conclusion that the ultrasonic compressions are anchoring the core between compression sites, and also serving as stress points, absorbing a higher shear force, before breaking apart. The improved core continuum maintains the core's absorbent properties and thus reduces the amount of leakage of fluids out of the periphery of the diaper. In this invention, the area of compression comprised about 1.5% of the total area of the absorbent core. This small area of compression sites helps to maintain the absorbent properties of the core by maximizing the amount of core fibers free to absorb and wick fluids. In addition, the elimination of any adhesive reduces the risk that the adhesive blocks the passage of fluids into the absorbent core.
[0062] The above description is intended to be illustrated and not restrictive. While particular embodiments of the present invention have been illustrated and described, it would be obvious to those skilled in the art that various other changes and modifications can be made without departing from the spirit and scope of the invention. | The present invention relates to disposable personal care products, such as diapers, feminine care products and adult incontinence products. More specifically, the invention relates to such products having improved absorbent core integrity and core absorbency. These products eliminate the need for costly adhesives The present invention also comprises a method for making the products of the invention. The method includes forming a plurality of localized compressions by ultrasonically compressing the natural fiber core between, although not necessarily adjacent to, at least one upper and at least one underlying fusible material. The periphery of the article is then bonded by conventional means, such as adhesives, crimping or fusing. This process reduces costs associated with the manufacturing of such articles by eliminating or reducing the amount of adhesives in the final product, and by eliminating costly and intermittent bonding procedures. The method also improves the continuum of the absorbent core without increasing material and manufacturing costs associated with these products. | 0 |
BACKGROUND OF THE INVENTION
CROSS-REFERENCE TO RELATED PATENT
U.S. Pat. No. 4,875,644, entitled "Electro-Repulsive Separation System for De-Icing," the disclosure of which is incorporated herein by reference (hereinafter referred to as the "Electro-Repulsive Separation System for De-Icing Patent").
1. Field of the Invention
The invention relates to de-icers for aircraft and, more particularly, to de-icers that operate by deforming ice-accumulating surfaces.
2. Description of the Prior Art
The accumulation of ice on aircraft wings and other structural members in flight is a danger that is well known. As used herein, the term "structural members" is intended to refer to any aircraft surface susceptible to icing during flight, including wings, stabilizers, engine inlets, rotors, and so forth. Attempts have been made since the earliest days of flight to overcome the problem of ice accumulation. While a variety of techniques have been proposed for removing ice from aircraft during flight, these techniques have had various drawbacks that have stimulated continued research activities.
One approach that has been used extensively is so-called mechanical de-icing. In mechanical de-icing, the leading edges of structural members are distorted in some manner so as to crack ice that has accumulated thereon for dispersal into the airstream. A popular mechanical de-icing technique is the use of expandable tube-like structures that are periodically inflatable. Inflation of the structures results in their expansion or stretching by 40% or more. Such expansion typically occurs over approximately 2-6 seconds and results in a substantial change in the profile of the de-icer, thereby cracking accumulated ice. Unfortunately, expansion of the devices can negatively influence the airflow passing over the aircraft structure. Also, they are most effective when ice has accumulated to a substantial extent, approximately 0.25 inch or more, thereby limiting their effectiveness. Desirably, ice removal would be accomplished long before accumulations approximating 0.25 inch have occurred.
A more recent mechanical de-icing technique utilizes internal "hammers" to distort the leading edges of structural members. Such an-approach is disclosed in U.S. Pat. No. 3,549,964 to Levin et al., wherein electrical pulses from a pulse generator are routed to a coil of a spark-gap pressure transducer disposed adjacent the inner wall of the structural member. The primary current in the coil induces a current in the wall of the structural member and the magnetic fields produced by the currents interact so as to deform the member.
U.S. Patent Nos. 3,672,610 and 3,779,488 to Levin et al. and U.S. Pat. No. 4,399,967 to Sandorff disclose aircraft de-icers that utilize energized induction coils to vibrate or torque the surface on which ice forms. Each of these devices employs electromagnetic coils or magneto-restrictive vibrators located on the side of the surface opposite to that on which ice accumulates. In U.S. Pat. No. 3,809,341 to Levin et al., flat buses are arranged opposite one another, with one side of each bus being disposed adjacent an inner surface of an ice-collecting wall. An electric current is passed through each bus and the resulting interacting magnetic fields force the buses apart and deform the ice-collecting walls.
A more recent approach is shown by U.S. Pat. No. 4,690,353 to Haslim et al. In the '353 patent, one or more overlapped flexible ribbon conductors are imbedded in an elastomeric material that is affixed to the outer surface of a structural member. The conductors are fed large current pulses from a power storage unit. The resulting interacting magnetic fields produce an electroexpulsive force that distends the elastomeric member. The distension is almost instantaneous when a current pulse reaches the conductors, and is believed to be effective in removing thin layers of ice. Although the device disclosed in the '353 patent is believed to be an improvement over previous mechanical de-icing techniques, certain drawbacks remain. One of the drawbacks relates to the direction of current flow in adjacent electrically conductive members. It is believed that the current flow disclosed in the '352 patent produces inefficiencies that significantly restrict the effectiveness of the device.
The Electro-Repulsive Separation System for De-Icing Patent discloses a device that is an improvement over that disclosed in the '352 patent. In the Electro-Repulsive Separation System for De-Icing Patent, the electrically conductive members are arranged such that a greater electro-expulsive force can be generated than with the serpentine configuration disclosed in the '353 patent. Also, the Electro-Repulsive Separation System for De-icing Patent teaches the delivery of a current pulse of predetermined magnitude, shape and duration that provides more effective de-icing action.
Despite the advances taught by the prior art, particularly the Electro-Repulsive Separation System for De-Icing Patent, there remains a need for a de-icer that provides effective de-icing action. In particular, it is desired to have a de-icer that has the force-generating capabilities of various prior mechanical de-icers without the drawbacks associated therewith, such as large size, difficulty in retrofitting existing structural members, and other problems.
SUMMARY OF THE INVENTION
The present invention overcomes the foregoing drawbacks of the prior art and provides a new and improved de-icer especially adapted for use with structural members in which openings are formed in the leading edge thereof. In one embodiment of the present invention, a stationary inductor coil is disposed within one of the openings, and a target is disposed in proximity with the coil, either totally outside the opening or partially outside the opening and partially inside the opening. A deflectable member for supporting the target defines an ice-accumulating surface that constrains the target and permits it to move relative to the coil.
In another embodiment of the present invention, an opening is provided in the leading edge of a structural member and a coil is disposed within the structural member over the opening. The target includes a first portion that is disposed outside the opening, and/or a second portion that is disposed within the opening. That is, the target can be disposed completely within or completely outside of the opening. As with the first-described embodiment, a deflectable support member holds the target and permits it to move relative to the coil.
With each embodiment of the invention, the target and its support member are rapidly, and forcefully, displaced away from the coil upon passing a short-duration, high-current pulse through the coil. The current flow creates an electromagnetic field that induces eddy currents in the target and support member (if metal). Upon collapse of the electromagnetic field in the coil, the target and support member are pulled rapidly to their rest positions.
In contrast with prior mechanical de-icers, most of the forces that are applied to the structural member by the de-icer according to the invention are compressive forces that are more easily accommodated than the tensile forces that are produced by various other mechanical de-icers. Further, the device can be fitted to structural members without excessive difficulty, either as part of new construction or as a retrofit.
Because the device operates on an eddy current principle, it completely avoids problems arising from directional current flow, and it provides a more effective ice-shedding action than has been possible with previous devices. In part, the effectiveness of the device is enhanced because the ice-accumulating surface is displaced a relatively great distance at a high rate of acceleration. The efficiency of the device also is much greater than prior internally disposed eddy current de-icers because the coil and the target are in surface-to-surface contact with each other, or nearly so. The referenced internally disposed de-icers require a substantial gap between the coil and the structural member in order to prevent possible damage to the coil upon rebounding of the structural member. The efficiency of the present invention is high because the ice-accumulating surface that is displaced is relatively thin and is resiliently mounted to the structural member. In those de-icers that distort the structural member itself, the ice-accumulating surface is relatively thick and may be relatively difficult to distort.
These and other features, advantages and objects of the present invention will be further understood and appreciated by those skilled in the art by reference to the following written specification, claims and appended drawings.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic, cross-sectional view of a prior art mechanical de-icer;
FIG. 2 is a schematic electrical circuit showing how the de-icer of FIG. 1 is activated;
FIG. 3 is a schematic electrical circuit showing how a plurality of de-icers according to FIG. 1 can be installed in a structural member;
FIG. 4 is a cross-sectional view of a de-icer according to the invention in which an opening is formed in the leading edge of an aircraft structure and in which a flat coil as well as a target having a flat inner surface and a contoured outer surface are used;
FIG. 5 is a cross-sectional view similar to FIG. 4 wherein a contoured coil and a contoured target are used;
FIG. 6 is a cross-sectional view similar to FIG. 4 wherein a flat coil is disposed within the structural member, a flat target is disposed within the structural member, and a force transfer member projects through the opening forwardly of the structural member;
FIG. 7 is a cross-sectional view similar to FIG. 4 of a de-icer wherein a contoured coil is disposed entirely within the structural member and a contoured target is disposed entirely within the opening;
FIG. 8 is a cross-sectional view similar to FIG. 4 wherein a contoured coil is disposed within the structural member and a contoured target is disposed partially outside the opening and partially inside the opening;
FIG. 9 is a cross-sectional view similar to FIG. 4 wherein a contoured coil is disposed partially within the opening and a contoured target is disposed outside the opening;
FIG. 10 is a cross-sectional view similar to FIG. 4 of a so-called "thin construction" embodiment of the invention wherein a contoured coil is disposed within the structural member and a contoured target is disposed within the opening;
FIG. 11 is a cross-sectional view similar to FIG. 6 of a so-called "large radius" embodiment of the invention;
FIG. 12 is a cross-sectional view similar to FIG.11 of a so-called "small radius" embodiment of the invention wherein guide members are used to constrain the movement of a stem of a force transfer member;
FIG. 13 is a cross-sectional view of a de-icer in which a contoured coil is disposed partially within the opening and a contoured target in the form of a single thin surface ply is disposed outside the opening;
FIG. 14 is a cross-sectional view similar to FIG. 13 wherein a flat coil is disposed partially within the opening, a contoured target is disposed within the opening and the flat coil is spaced from the contoured target by a non-uniform gap;
FIG. 15 is a cross-sectional view similar to FIG. 14 wherein a flat target, which is formed as an integral part of a surface ply, is disposed within the opening;
FIGS. 16 is a top plan view of a planar coil usable with the present invention;
FIG. 17 is a perspective view of a spiral-wound coil usable with the present invention;
FIG. 18 is a perspective view of a helical coil usable with the present invention;
FIG. 19 is a perspective view of two helical coils, one disposed inside the other, that are usable with the present invention;
FIG. 20 is a schematic front elevational view of the leading edge of a structural member showing one arrangement of multiple de-icers according to the invention;
FIG. 21 is a view similar to FIG. 20 showing an alternative arrangement of multiple de-icers according to the invention;
FIG. 22 is a view similar to FIG. 20 showing yet an additional arrangement of multiple de-icers according to the invention;
FIG. 23 is a schematic electrical circuit diagram for a de-icer according to the invention;
FIG. 24 is a plot of current versus time showing the profile of a current pulse used with the present invention;
FIG. 25 is a plot of displacement, velocity and acceleration versus time showing the movement of a support member according to the invention;
FIG. 26 is a graph of force versus coil current showing the performance of a de-icer in accordance with the present invention compared with prior art mechanical de-icers.
DETAILED DESCRIPTION OF THE INVENTION
The present invention provides a technique especially adapted for de-icing the leading edges of structural members. De-icing is the removal of ice subsequent to its formation upon a leading edge. A leading edge is that portion of a structural member that functions to meet and break an airstream impinging upon the surface of the structural member. Examples of leading edges are the forward portions of wings, stabilizers, struts, nacelles, rotors, and other housings and protrusions first impacted by an airstream.
FIGS. 1-3 illustrate a known mechanical de-icer 10 and electrical circuitry therefor. The de-icer 10 includes first and second coils 12 that are disposed within a structural member (such as a wing) 14 near the inner surface of the leading edge of the structural member 14. The outer surface of the structural member 14 is made of metal such as aluminum which will be referred to as the "skin." The coils 12 are mounted to a spar 16 by means of a mounting bracket 18. The coils 12 are circular in plan view. A circular, unalloyed aluminum disk 20 is bonded to the inner surface of the leading edge directly opposite each of the coils 12.
Referring to FIG. 2, each coil 12 is connected in series with an energy storage capacitor 22 and a thyristor 24. A diode 26 is connected in parallel with the capacitor 22. An electrical impulse is initiated by supplying a trigger pulse to the thyristor 24, allowing the capacitor 22 to discharge through the coil 12. Because the thyristor 24 has diode properties, the current follows the first positive loop of the RLC response, after which the thyristor 24 reopens the circuit. This leaves the capacitor 22 reverse-charged. Such reverse-charging reduces capacitor life substantially. For that reason, the diode 26 is placed across the capacitor 22.
Referring to FIG. 3, a typical spanwise installation of the coils 12 within a wing is shown. Each of the coils 12 is separated laterally from other coils 12 by about 16 inches. The coils 12 are supplied a single power unit 28 that includes a transformer 30. The capacitor 22 is connected across the secondary side of the transformer 30. A switching device 32 is connected to each of the thyristors 24 in order to provide a trigger pulse to the thyristors 24.
When the capacitor 22 is discharged through each coil 12, a rapidly forming and collapsing electromagnetic field is created that induces eddy currents in the disk 20 and the metal skin of the structural member 14. The electromagnetic fields resulting from current flow in the coil 12, the disk 20, and the skin of the structural member 14 create a repulsive force of several hundred pounds magnitude, but with a duration of only a fraction of a millisecond. A small amplitude, high acceleration movement of the skin of the structural member 14 acts to shatter, debond, and expel the ice. Two or three such "hits" are performed in short order, separated by the time required to recharge the capacitor 22, and then ice is permitted to accumulate again until it approaches an undesirable thickness. By appropriate control of the switching device 32, the coils 12 can be activated sequentially in order to create a "ripple" effect that is believed to be more effective in shedding ice due to the propagation of skin movement in both chordwise and spanwise directions.
As will be appreciated from the foregoing description, the referenced de-icer 10 depends upon deformation of the skin for its effectiveness. The displacement of the metal surface subject to icing is very limited. Typically, it requires three impact pulses to remove accumulated ice under all icing conditions. Further, although the skin is displaced only to a limited extent, it is necessary to produce strong forces in order to accomplish even that limited displacement. An additional problem is that the forces are "negative" forces in that they apply a tensile load to the leading edge. Aircraft structural members are designed to better withstand compressive loads, rather than tensile loads.
Referring now to FIG. 4, a de-icer according to the invention is indicated by the reference numeral 40. The de-icer 40 is similar to the de-icer 10 in that it employs a coil and a target that is movable relative to the coil. However, as will be discussed below, the de-icer 40 differs significantly from the de-icer 10. The differences will be apparent from the description that follows.
The de-icer 40 as shown in FIG. 4 is securely attached to the leading edge of a structural member. The leading edge, or skin, of the structural member is indicated by the reference numeral 42. Typically the skin 42 will be made of metal such as an aluminum alloy, or it will be made of a composite non-metal material such as graphite/epoxy.
The skin 42 includes an opening 44 at or near the center of the leading edge. A disk-like coil 46 is disposed at least partially within the opening 44. In each of the embodiments of de-icers 40 (FIGS. 4-15), the coil is insulated to avoid arcing between the skin 42 and coil 46 when current is transmitted to the coil 46. The coil 46 includes front and back surfaces 48 and 50, both of which are flat. Hereinafter, the coil 46 will be referred to as "flat coil" 46, but, as explained in further detail below, a contoured coil can be used effectively with the present invention. If the thickness of the skin 42 is greater than the thickness of the coil 46, the coil 46 may be disclosed completely within the opening 44.
A retainer 52 is attached to the skin within the opening 44 to hold the flat coil 46 securely in place. A plate-like target 54 generally coterminous with the opening 44 overlies the flat coil 46 and includes a flat back surface 56 that conforms to the front surface 48 and an opposing contoured front surface 58 that conforms approximately to that of the skin 42. In each of the embodiments of de-icer 40 (FIGS. 4-15) the target 54 is made of metal, such as copper or 1145 aluminum. When the retainer 52 is made from an insulating material, it serves to prevent any arcing that might occur between the skin 42 and the target 54.
The surfaces 48 and 56 preferably are in contact with each other or are spaced a small distance from each other by a gap 60, which gap 60 is preferably no greater than about 0.005 inch. A circumferentially extending flange 62 extends from the periphery of the target 54 for engagement with the retainer 52. A small gap 64 is maintained about the periphery of the target 54. An elastomeric layer or member 66 and a metal surface ply 68 form a deflectable support member that carries the target 54 and permits the target 54 to move relative to the coil 46. In the preferred embodiment, a portion of either the elastomeric layer 66 or the surface ply 68 is bonded to an outer surface of the skin 42.
Referring to FIG. 16, a construction used to implement the preferred embodiment of the coil 46 is illustrated. The coil 46 of FIG. 16 includes overlapped planar coils which are connected at a junction 78. Current flows in one direction from an input 72 to an output 74. A complete discussion of this construction is made available in U.S. Pat. No. 5,152,480 PLANAR COIL CONSTRUCTION, Adams et al. (hereinafter referred to as the "Planar Coil Construction Patent"), the disclosure of which is incorporated herein by reference.
Referring to FIGS. 17-19, other suitable configurations of the coil 46 are shown. In FIG. 17, the coil 46 is formed as a spiral coil 46a. A detailed discussion of the coil 46a is made available in U.S. Pat. No. 5,129,598 ATTACHABLE ELECTRO-IMPULSE DE-ICER, Adams et al. (hereinafter referred to as the "Attachable Electro-Impulse De-Icer Patent"), the disclosure of which is incorporated herein by reference. The coil 46a preferably has a width of approximately 0.19 inch and a thickness of approximately 0.025 inch.
Referring to FIG. 18, the coil is in the form of an insulated, helical flat coil 46b having an outer diameter of about 2.25 inches and an inner diameter of about 1.75 inches. Legs 84 and 86 project from the ends of the coil for connection to a source of current.
In FIG. 19, the coil 46b is employed in conjunction with a second, smaller, helical coil 46c that fits within the inner diameter defined by the larger coil 46b. The coil 46c employs legs 88 and 90 for connection to a source of electrical current.
The de-icer 40 preferably includes the planar coil 46. In contrast to coils 46a-46c, shown in FIGS. 17-19, which tend to be relatively thick and bulky, the planar coil 46 is relatively thin and easy to handle. A light, compact coil, such as planar coil 46, is desired in aircraft applications in which weight and size of the de-icer preferably is minimized.
Referring to FIG. 23, a control circuit for use with the de-icers of the present invention is indicated by the numeral 94. The charging circuit 96 charges up a bank of capacitors 98 (only one is illustrated for simplicity) which serve as high voltage energy storage devices. When de-icing action is desired, a control pulse 100 is fed to a triggering circuit 102 which enables discharge of the capacitor bank 98 through one or more silicon control rectifiers (SCRs) 104 to provide a high current pulse output 106 to one or more of the coils 46.
Referring further to the control circuit 94 depicted in FIG. 23, whenever an output current pulse 106 is desired, the dump load 110, which maintains the capacitor bank 98 in a discharged condition, is removed by opening switch 112. Charging current from charging circuit 96 charges the capacitor energy storage bank 98 to the desired voltage. When the SCR 104 is triggered on, the capacitor bank 98 is discharged into one of the coils 46 (not illustrated in FIG. 23), providing the high current pulse 106, whose current magnitude is monitored by means of current transformer 114.
Referring to FIG. 24, the current pulse 106 may be a clean, overdamped exponentially decaying sinusoidal wave form that is achieved by setting appropriate RLC values for the control circuit 94. In the event that the component values of the control circuit 94 are selected in a known manner, such that the circuit 94 may become underdamped or oscillatory in nature, the circuit 94 should be configured such that a rectifier 116 (FIG. 23) dumps the stored energy of the circuit inductance into the de-icing load, producing a single, non-oscillatory pulse having an extending, trailing edge.
In operation, the coil 46 is connected to a source of electrical energy such as that indicated in FIG. 23. The capacitor 98 should have a capacitance of about 500 microfarads. Upon discharge of the capacitor 98, a short-duration, high-current, high-voltage flow of electricity will be discharged through the coil 46. If the coil 46 is a four-layer planar coil, the current flow will be about 3,000 amps at 1,500 volts. The coil rise time will be about 100 microseconds, and the delay will be about 200-300 microseconds. A strong electromagnetic field will be generated that will induce eddy currents in the target 54. In turn, an electromagnetic field is generated by the target 54. The electromagnetic fields thus generated create a large repulsive force having a duration of only a fraction of a millisecond. The impact force is transferred by the target 54 to the surface ply 68, creating a small-amplitude, high-acceleration movement of the surface ply 68 that is sufficient to break up and shed any ice that has been formed.
Referring to FIG. 25, results relating to the displacement of surface ply 68 are shown. The significance of these results is discussed in the Attachable Electro-Impulse De-Icer Application.
In FIG. 5, an embodiment of de-icer 40, including a contoured coil 120, having front and back surfaces 121 and 122, is shown. Both surfaces 121 and 122 conform approximately to the shape of skin 42, and the contoured coil 120 is disposed at least partially within the opening 44. In one example, the contoured coil 120 is formed by molding one of the coils 46-46a into the desired contoured shape. A plate-like target 126 is provided generally coterminous with the opening 44 and having a contoured back surface 128, the surface 128 corresponding in shape to the front surface 121 of the contoured coil 120, and a contoured front surface 130, the surface 130 corresponding to the surface of the skin 42. The components used to support and/or retain both the coil 120 and the target 126 are the same as those used for the de-icer 40 of FIG. 4.
In FIG. 6, the flat coil 46 is disposed relatively far from the opening 44 within the structural member as defined by the skin 42. The flat coil 46 is held in place by an elongate retainer 132. A plate-like target 134 generally coterminous with the opening 44 and having flat surfaces 136 and 138 is provided. A force transfer member 142 is connected to the flat target 134. The force transfer member includes a stem 144 that projects forwardly of the target 134. The stem 144 is attached to the back surface of a plate-like element 146 which is disposed at the forward end of the stem 144 over the opening 44. The stem 144 protrudes through the opening 44. The element 146 includes a circumferentially extending flange 148 that projects from its periphery for engagement with the retainer 132. An elastomeric layer or member 66 and a metal surface ply 68 form a deflectable support member that carries the element 146 and permits the element 146 to move relative to the coil 46. As will be explained in further detail below, pursuant to a discussion of FIG. 11, the force transfer member 142 can be configured to permit considerable reduction of the circumference of opening 44.
Referring to FIG. 7, the contoured coil 120 is shown adjacent to the skin 42 within the structural member as defined by the skin 42. While the de-icers 40 of FIGS. 7-15 are shown without any sort of mounting mechanism for coils 46 and 120, it should be understood that coils 46 and 120 are mounted to the skin 42 by use of the retainer 52 (FIGS. 4 and 5) or other known mounting mechanisms. A target 152 generally coterminous with the opening 44, which approximates the size of the opening 44, is completely disposed within and substantially fills the opening 44. Additionally, the target 152 is mounted flush with a surface of the layer 66, and a clearance gap 154 is maintained between target 152 and skin 42. When the target 152 substantially fills the opening 44 and is mounted along layer 66, generated electromagnetic interference ("EMI") should be reduced considerably. EMI shielding should be further enhanced by positioning an EMI shielded gasket (not shown) in the clearance gap 154.
In FIG. 8, a construction similar to that of FIG. 7 is illustrated, except that the target 152 is only partially disposed within the opening 44 such that portion 156 projects forwardly of the opening 44. The portion 156 is generally coterminous with the opening 44 includes a flange 158 that extends beyond the circumference of the opening 44 around the periphery of the target 152. It should be appreciated that overlapping the opening 44 with flange 158 should further enhance EMI shielding.
In FIG. 9, a construction similar to that of FIG. 8 is illustrated, except that only portion 156 is used as the target and the coil 120 is disposed at least partially within the opening 44. The backside of portion 156 can be insulated from the skin 42 to prevent arcing due to the high eddy current in portion 156.
In FIG. 10, a so-called "thin" construction similar to that of FIG. 7 is illustrated. In this embodiment of the invention, a surface ply 160 of elastomer or thin metal foil is bonded to the leading edge of the skin 42. A plate-like target 161 is generally coterminous with the opening 44 and bonded to the inner surface of the ply 160. The coil 120 is disposed at least partially within opening 44, while the target 161 can be insulated electrically from skin 42 to prevent electrical arcing between the skin 42 and the target 161.
In FIG. 11, a configuration suitable for de-icing a large-radius structural member is illustrated. This embodiment of the invention is similar to that illustrated in FIG. 6, except that the opening 44 is relatively small, with only a small clearance gap 162 being provided between the stem 144 and the opening 44. Additionally, a plate-like element 164, having contoured surfaces 166 and 168 is provided. The surface area of the opening 44 is substantially smaller than the surface area of the plate-like element 164. Use of relatively small openings 44 is advantageous to the functioning of the de-icer 40 since it is undesirable, from a structural standpoint, to alter the skin 42 significantly by using large openings 44. Generated EMI should be reduced by positioning a shielded gasket 169 in the gap 162.
In FIG. 12, an embodiment of the invention suitable for de-icing of a structural member having a small radius is illustrated. This embodiment of the invention is similar to the embodiment illustrated in FIG. 11, except that components, such as the plate-like element 164, are adapted to accommodate the smaller curvature of radius of the skin 42. Moreover, the stem 144 is longer and is constrained from lateral movement by a guide 170.
Referring to FIG. 13, a de-icer 40, which uses a portion of a thin, metal surface ply 172 as a target, is shown. In this embodiment, the coil 120 is at least partially disposed within and substantially fills the opening 44, and the thin, metal surface ply 172 overlies the opening 44. A portion of ply 172 is bonded or otherwise securely attached to the skin 42. The coil 120 can alternatively be spaced from an inner surface of skin 42, provided that the resulting gap between the coil 120 and ply 172 allows for acceptable levels of displacement of ply 172. The ply 172, which is made of metal such as copper, functions as both a target and a surface ply upon which ice can accumulate. It should be recognized that the de-icer 40 of FIG. 13 is most effective when a substantial amount of eddy current can be generated in the ply 172. Moreover, the embodiment of FIG. 13 is exceedingly economical since weight is minimized through the elimination of certain components, such as the elastomeric layer 66.
In FIG. 14, an embodiment similar to that shown in FIG. 13 is illustrated, except that a contoured metal plate-like target 174 is mounted to the ply 172 completely within and substantially filling the opening 44. The flat coil 46 is positioned near the target 174 at least partially disposed within the opening 44. Additionally, the target 174 has a front surface 176 and a back surface 178, the front surface 176 being bonded to the ply 172. Since the back surface 178 of target 174 is contoured and the front surface 48 of flat coil 46 is flat, a non-uniform gap 177 is formed between the coil 46 and the target 174. As can be appreciated, the use of the non-uniform gap 177 allows for the contouring of force distribution across the target 174.
In FIG. 15, an embodiment similar to that of FIGS. 13 and 14 is shown. In the embodiment of FIG. 15, the back surface 178 of the target 174 is flat, and the target 174 is integrally formed with the ply 162 to define a common target/surface ply 162. The flat back surface 178 is parallel with the front surface 48 of flat coil 46, thereby providing a uniform gap 184.
Referring now to FIGS. 20-22, various spanwise arrangements of the de-icers 40 are illustrated. A detailed discussion of these arrangements is made available in the Attachable Electro-Impulse De-Icer Patent.
Referring to FIG. 26, a plot of force versus coil current is shown for a laboratory test. Four test results are shown. The lines bearing the reference numerals 188-191, are plots of force versus current for coils operating on the so-called electro-expulsive principle disclosed in the Electro-Repulsive Separation System for De-Icing Patent. The line labeled 191 is a plot of force versus current for a coil operating according to the invention in conjunction with a metal target. Further detailed discussion of lines 188-191, and their significance is made available in the Attachable Electro-Impulse De-Icer Application.
A relatively extensive discussion is provided in the Attachable Electro-Impulse De-Icer Patent regarding characteristic of targets in electro-impulse de-icers. The discussion generally is directed toward the following concepts:
1) the capability of a coil to induce eddy currents in a target and the capability of the target to sustain the eddy currents;
2) the recommended relationship between the area of the coil and the area of the target;
3) the characteristics of the forces acting on the target;
4) the effect of target design on impulse production; and
5) the effect of matching mechanical and electrical periods on target thickness.
Previous test results have utilized a uniform thickness of airfoil skin and/or doubler. It is possible that the thickness and shape of the target, and the spacing of the target from the coil, can be varied to tailor the force distribution along the target and thus maximize the efficiency of force transfer to ice-shedding surfaces.
Although the invention has been described in its preferred form with a certain degree of particularity, it will be understood that the present disclosure of the preferred embodiment has been made only by way of example, and that various changes may be resorted to without departing from the true spirit and scope of the invention as hereinafter claimed. It is intended that the patent shall cover, by suitable expression in the appended claims, whatever features of patentable novelty exist in the invention disclosed. | An electro-impulse de-icer for de-icing an aircraft structural member having an opening in the leading edge and including an inductor coil. The inductor coil is disposed either at least partially within the opening or adjacent to the opening. The de-icer further includes a movable metal target disposed in proximity with the coil. The target is supported by a flexible, ice-accumulating support member that permits the target to move relative to the coil and to the structural member. The support member is rapidly, and forcefully, displaced away from the coil and the structural member upon passing a short-duration, high-current pulse through the coil. The current flow creates an electromagnetic field that induces eddy currents in the target and the support member (if made of metal). Upon collapse of the electromagnetic field in the coil, the target and support member are pulled rapidly to their rest position. | 1 |
BACKGROUND OF THE INVENTION
Staplers with storage capabilities for extra staples are disclosed, as for example, in U.S. Pat. No. 1,663,242. Also, staplers with a storage capability and a removable cover for the storage compartment are available and disclosed, as for example, in U.S. Pat. No. 4,491,261.
SUMMARY OF THE INVENTION
The present invention is an improvement in staplers with storage capabilities for extra items. In accordance with the invention, the bottom of the base of the stapler is recessed to provide a storage chamber or compartment and this compartment is covered by a removable slipper. The slipper is constructed of flexible material so as to frictionally engage the base of the stapler. It is thus removably attachable in overlying relation to the storage compartment. The slipper also includes a portion which loops around the hinged end of the stapler and is attached to the top surface of the head of the stapler. Accordingly, when the slipper is removed from the base of the stapler to expose the storage compartment, it remains attached to the stapler, whereby loss or misplacement of the slipper is avoided.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of the stapler of the present invention;
FIG. 2 is a side view of the stapler;
FIG. 3 is a front view of the stapler;
FIG. 4 is a rear view of the stapler;
FIG. 5 is a bottom view of the stapler;
FIG. 6 is a side view of the stapler, pivoted to a open position for filling with staples;
FIG. 7 is a side view of the stapler with the slipper removed;
FIG. 8 is a bottom view of the stapler with the cover portion of the slipper removed from the storage compartment; and
FIG. 9 is a bottom view of the stapler showing a modified storage compartment configuration.
DETAILED DESCRIPTION OF THE INVENTION
The stapler 1 includes a head 2 and a base 3 pivotally connected to each other at one end 4 of the stapler. The head includes a housing or magazine 5 for holding a supply of staples. The base, in turn, has the conventional die 6 against which individual staples engage during the stapling operation. As shown in the drawings, the die 6 is located in the top 7 of the base so as to face the head and the forward end 8 of the staple magazine.
The head and base of the stapler are formed of relatively rigid non-brittle plastic, such as acrylonitrile-butadiene-styrene (A.B.S.). The head also includes the conventional plunger mechanism for pushing individual staples out the forward end 8 of the staple storage magazine 5, during a stapling operation. This plunger mechanism, which is not shown in the drawings, is attached to the under surface of the top of the head in overlying relation with the staple magazine 5.
The bottom 9 of the base 3 is provided with a storage compartment 10 (FIGS. 8 and 9). In FIG. 8, the storage compartment is divided into two sections 11 and 12. Section 11 is about half the size of section 12. The storage compartment shown in the embodiment of FIG. 9 is divided into two sections 13 of equal dimension. Each of these compartments can be used to store staples or other items, as desired. In each construction, the storage compartment is bounded by a peripheral wall 14. The height of the wall is preferably slightly greater than the height of the staples to be stored in the compartment.
In accordance with the invention, a slipper 15 is provided for purposes of closing the storage compartment, so as to retain the items placed therein. The slipper is constructed of a flexible compressible material, such as a thermoplastic elastomer, available from Kraton under #G2755. Preferably, the material has a rubber-like feel and a Shore hardness of A40-50. Also, in the preferred embodiment, the slipper is constructed of semi-translucent material and in a color compatible with the color of the stapler head and base.
As shown in the drawings, the slipper includes a cover portion 16 overlying and closing the storage compartment 10. For this purpose, the cover portion 16 includes a recessed area 17 defining an outer peripheral wall 18. The wall 18 is dimensioned to frictionally engage the peripheral wall 14 of the compartment so as to permit removable attachment of the cover portion in overlying relation to the compartment 10. As shown in FIG. 8, the recessed area 17 also includes an extended area 19 defined by the extended wall section 20. This extended area 19 provides room for the reinforcement piece 21 which is formed in the stapler base 3 as reinforcement for the overlying die 6. A recessed area 22 is located between the reinforcement piece 21 and the front end 23 of the base 3 of the stapler. This recessed area 22 receives the end section 24 of the cover portion of the slipper. The recessed area 22 and the end 24 are dimensioned so that the end 24 is frictionally engaged between the reinforcement member 21 and the front end 23 of the stapler when the cover portion overlies the storage compartment.
The front end 23 of the base of the stapler, in addition to engaging the cover portion of the slipper, has a pointed shape. It is also tapered downwardly, when viewed from the side. With this construction, the end 23 provides a stapler remover for removing staples from stapled sheets of paper.
The slipper 15 includes a loop portion 25 and a top portion 26. The loop portion extends around the end 4 of the stapler in space relationship therewith. As shown, it forms a smooth continuous curved configuration for connecting the cover and top portions of the slipper together. The loop portion is sufficiently flexible to permit pivoting of the stapler head 2 to an open position for filling the staple magazine 5, as shown in FIG. 6.
The slipper is secured to the stapler so that when the cover portion 16 is removed, to provide access to the storage compartment, the slipper is not accidentally lost or misplaced. In particular, the top portion 26 of the slipper is adhesively connected to the upper top surface 27 of the stapler head 2. As shown in the drawings, the upper top surface 27 is convexly curved and defines opposite peripheral side edges 28 and a front edge 29. The top portion 26 of the slipper extends beyond these peripheral edges. In addition, the cover portion of the slipper covers a lower section 30 of the opposite sides of the stapler base 3.
With the construction of the slipper as described, the stapler can be held in the hand with a comfortable feel. The rubber-like feel together with the compressibility of the material, provides a comfortable fit in the user's hand. The sides of the cover portion of the slipper can be easily engaged to bend the cover portion so as to remove it from overlying relation with the storage compartment. | A stapler having a storage compartment in the bottom of the stapler and a slipper removably attached over the storage compartment. The slipper further extends around the end of the stapler and has a top portion connected to the head of the stapler. | 1 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. application Ser. No. 13/992,085, filed Jul. 25, 2013, which is the U.S. national phase entry of PCT/SE2011/051490, with an international filing date of 9 Dec. 2011, which claims the benefit of Swedish patent application no. 1001175-7, with a filing date of 9 Dec. 2010 and Swedish patent application no. 1100062-7, with a filing date of 28 Jan. 2011, the entire disclosures of which are fully incorporated herein by reference.
TECHNICAL AREA
[0002] The present invention relates to technology for fixing and mounting accessories to tubes with different cross-sections and dimensions and to technology for transportation of goods, packaging, material etc. in e.g. warehouses and at assembly stations, by means of gravity.
BACKGROUND
[0003] Locking devices for tube constructions are used in many different applications, e.g. for connecting tubes in material racks, tent racks, work platforms and stands but also to connect accessories to tubes.
[0004] Today's locking devices are not flexible enough to adjust to new conditions. Adjustment means adjustment of e.g. a tube rack's height, width and depth, and it can also be connection of new accessories. Accessories also include new tubes, or relocation of existing accessories on an assembled tubular construction. Most locking devices usually have a limited functionality, which results in that several different variants of locking devices must be purchased in order to build the desired tubular construction and to attach accessories thereto. When a tubular construction shall be rebuilt in order to be adjusted to new conditions, it is not certain that all locking devices can be reused. This results in increased costs and unnecessary waste.
[0005] Examples of tube racks which must be adapted in terms of width, length, height, and accessories are material racks used in the manufacturing industry. When new products are introduced and production starts or when production volumes changes, there is a need of rebuilding the material facade at a production line and at warehouses where production items are stored. I.e., the material racks along the production line or in the warehouse must be adjusted to store new types of packaging and to handle new buffer levels (number of packages). Product changes and volume changes occur with more frequent interval, and today's solutions for how material racks are constructed are not flexible enough to quickly, easily and cost effectively adapt to the new conditions.
[0006] Roller conveyors are used in many different applications for by means of gravity move objects from one position to another. In e.g. material racks, roller conveyors are used to transport packaging from the loading station to the consumption station.
[0007] When new products are introduced and will start production or when production volumes change, there is a need to rebuild the material facade at a production line and at warehouses where production items are stored. I.e., the material racks and other material handling systems along the production line or in the warehouse must be adjusted to store new types of packaging and to handle new buffer level (number of packages).
[0008] Product changes and volume changes occur with more frequent interval, and today's roller conveyors, which e.g. is s part of a material rack, are not flexible enough to quickly, easily and cost effectively adapt to the new conditions. Adjustment means the possibility to adjust the rolling conveyor's length and the ability to easily replace the wheels that are assembled in the roller conveyor in order for the roller conveyor to handle new types of packaging.
[0009] Today's roller conveyors consist of a steel profile in which a number of wheels with axles are fixed directly to the steel profile. The roller conveyors are sold and delivered in predefined standard lengths. This means that the roller conveyors must be cut to the right length at the end user to fit the desired application. When the user wants to rebuild e.g. a material rack, for example by making it deeper, it means that the roller conveyors must be extended and then new roller conveyors with the correct length must be purchased.
[0010] If the user would like to reduce the depth, the roller conveyors must be cut to the correct length, which often results in waste of the roller conveyors that are difficult to reuse.
[0011] When the wheels of the roller conveyor need to be replaced, e.g. switching from plastic wheels to steel wheels, wheel for wheel in the steel profile must be replaced, which takes a very long time, at the same time as it interrupts the production. This results in that the wheels are never changed, and in practice the user instead purchases a completely new roller conveyor where the new type of rollers are assembled from the beginning. This also results in waste of roller conveyors which are difficult to reuse in other applications.
SUMMARY
[0012] The present invention solves the problems of the known technology, by that a locking device, with the subsequent patent claims specified characteristics, can be used for several different locking functions. The locking device consists of lock plates and lock housings.
[0013] According to one embodiment, a lock housing is shaped like a shell, intended for use in a locking device for fixing to an elongated element. The lock housing includes a first side comprising at least three holes, wherein at least one hole comprises threads. The hole is positioned on the first side such that an axial extension of the hole's periphery cuts the elongated element when the locking device is fixed to the elongated element, such that a screw placed in the hole with a thread can be applied to the elongated element, and that the lock housing further comprises at least two other sides substantially perpendicular to the first side. The other sides comprise a recess intended to receive the elongated element.
[0014] The other sides, which are opposite to each other, have the same dimension and shape of the recesses in order for the elongated element to run through the lock housing. The other sides include holes or protrusions intended to be connected with corresponding holes or protrusions in a lock plate.
[0015] Furthermore, is here shown a lock plate intended for connecting with a lock housing for fixating to an elongated element. The lock plate comprises a hole located in the middle of the plate, allowing the elongated element to run freely through the hole, and at least two holes or protrusions intended to be fastened in holes or protrusions of a first and a second lock housing for connecting the first and second locking house.
[0016] According to one embodiment, a locking device is intended for fixation to an elongated element. The locking device includes two lock housings, according to an embodiment shown herein, and two lock plates, according to an embodiment shown herein. Two lock housings can be assembled to form a geometry, where the assembled geometry has through holes formed by the recesses in the lock housings, whereby the through holes correspond to the geometry of the elongated element the locking device is intended to be fastened to. Holes or protrusions on the lock housings form an interface comprising at least two holes or two protrusions, which interface is found on all sides of the locking device. A lock plate with protrusions or holes corresponding to the interface, can be assembled to two sides of the lock housings for connecting of the lock housings, at which the locking device is intended to be locked to the elongated element by a screw being applied in one of the threaded holes, of which the axial extension of the periphery cuts the elongated element, such that the elongated element is pressed against the opposite lock housing at the same time as it creates tensile forces in the lock plate such that contact pressure and/or friction between the screw and the longitudinal element, and between protrusions or the holes on the lock plate, and holes or protrusions in the lock housings holds the locking device together.
[0017] According to one embodiment the locking plates include protrusions with through holes with internal threads in order to connect accessories to the locking device.
[0018] According to an exemplifying embodiment, the lock housings are shaped as a shell with one open side and a cover which is opposite to the open side. On the cover, holes are placed in a pattern, and in addition to the holes that form a pattern, there are also threaded holes. These holes can be used to attach accessories to the cover or to lock the locking device. On the other sides, there are half the hole pattern that is found on the cover and also a recess corresponding to half of the cross section on the tube that the locking device can be locked to. The recesses are always identical on two opposite sides of the lock housing. This allows the tube to run straight through the lock housing.
[0019] The lock plate has a hole in the middle that allows the tube, that the locking device shall be connected to, to run freely through the hole. This ensures that the tube does not lean on the lock plate when assembling instead of against the lock housing's recess. The lock plate has pins that are placed in accordance with the same pattern as the holes on the lock housing's cover.
[0020] When assembling the locking device to a tube, two lock housings are assembled with the open sides against each other around a tube with the dimensions corresponding to the recesses that are oriented in the tube's axial direction. The two lock housings then form a closed geometry around the tube and all sides of the locking device has a hole pattern corresponding to the hole pattern on the lock housing's cover. Two lock plates can be assembled by fitting in the pins in the hole pattern so that half of a lock plate's pin are in each lock housing. By applying a screw in the threaded hole in the middle of one of the lock housing's cover, the through tube will be pressed against the opposite lock housing at the same time as the lock plates hold the lock housings together. The locking device is then locked by means of contact pressure and friction. As the same hole pattern is found on all sides, the assembling of components by means of the same interface on all of the locking device's sides is allowed.
[0021] To attach accessories to a tube by means of a locking device, the accessories can either be connected to a through hole with thread on the lock plate's pin or the interface with the pin can be integrated into the accessory.
[0022] It is also possible to use the invention in a corresponding way but to have the pins on the lock housing and the holes in the lock plate or to replace the screw that locks the device with any other type of clamping element.
[0023] The present invention also concerns a roller conveyor that solves the problems of the known technology by that the roller conveyor, with the subsequent patent claims specified characteristics, can be used for several different dimensions of racks and other material handling systems. The roller conveyor includes an inner and outer profile and roller organs, such as wheels, which are assembled to a connecting organ, such as for example rubber strip.
[0024] The roller conveyor includes an inner and an outer profile of which the inner profile can run freely in the outer profile, and thus creating a telescopic function.
[0025] According to one embodiment, the inner and outer profile is in the form of a c-profile where the width of the opening is equally wide on both the inner and outer profile. The opening side also includes recesses which are designed to receive the axle that the roller organs are assembled to. The distance between the recesses on the profile determines the distance between the roller organs in the roller conveyor.
[0026] According to one embodiment, the roller organs are assembled to an axle which is intended to be placed in the recesses on the inner and outer profiles. When the axle has been placed in the recess, the axle also locks the inner and outer profile to each other in its longitudinal direction.
[0027] According to one embodiment either end of the roller organ's axle is assembled to a connecting organ. The axles are assembled to the connecting organ with a distance equal to the distance between the recesses on the profiles in order for the roller organs to be assembled and disassembled in the entire profile's length simultaneously.
[0028] Note that the invention can be combined freely within the patent claims' scope.
BRIEF DESCRIPTION OF THE FIGURES
[0029] The invention is described in detail below by means of enclosed exemplifying embodiments with reference to the enclosed drawings in which:
[0030] FIG. 1 shows a lock housing
[0031] FIG. 2 shows a lock plate
[0032] FIG. 3 shows locking device assembled on a tube
[0033] FIG. 4 shows locking device assembled on a tube including assembled accessories (tubes in telescopic connection)
[0034] FIG. 5 shows locking device assembled on a tube including mounted accessories (tubes in x-coupling)
[0035] FIG. 6 shows locking device with accessories (tubes) assembled on all sides
[0036] FIG. 7 shows example of a lock housing with cover in the shape of a hexagon
[0037] FIG. 8 shows an inner profile and an outer profile
[0038] FIG. 9 shows roller organ with axle
[0039] FIG. 10 shows roller organ with axle assembled to connecting organ
[0040] FIG. 11 shows connecting organ with roller organ assembled to the profiles
DETAILED DESCRIPTION
[0041] In the following, a description of embodiments will be made in reference to the enclosed drawings. It should be noted that the figures are only for illustrating embodiments and shall not be considered to limit the scope of protection. Directional specifications shall be viewed only as directional specifications in the drawings.
[0042] By means of the invention, different variants of lock functions can be created by combining two different types of components with each other. The modular based design makes it very simple to do re-constructions/re-assemblies of e.g. a tubular rack or relocation of accessories on this tubular rack.
[0043] The invention includes two different components:
Lock housing Lock plate
[0046] Two lock housings and two lock plates together create a locking device.
[0047] FIG. 1 shows a lock housing according to one embodiment, wherein the lock housing is a component shaped as a shell with an open side and a closed side in the form of a cover 5 . On the cover there is an interface with a hole pattern that forms the same pattern as the pins 1 form on the lock plate. In addition to this, there are holes with threads 7 .
[0048] There are recesses 8 on all sides of the lock housing which are perpendicular to the cover's surface 5 . Opposite sides of the lock housing always have the same dimensions of the recesses 8 . On these sides, there are also half as many holes 6 as there are pins 1 on the lock plate. These holes form half the interface that fit the pins 1 which are on the locking plate.
[0049] When two lock housings are assembled together with the open sides toward each other a closed geometry is formed with a pattern of holes 6 on all sides of the closed geometry. The same pattern is formed by the pins 1 which is on the lock plate.
[0050] When two lock housings are assembled, with the open sides toward each other, it forms in addition, by the recesses 8 , through holes on all sides that are perpendicular to the covers 5 on the two assembled lock housings. The dimensions of the through holes correspond to the dimension of the tubes that the locking device shall be locked to.
[0051] The number of sides that are perpendicular to the cover side of the lock housing divided by two, will determine how many different tube dimensions the locking device can handle. For example, a lock housing with a cover in the form of a square, has four sides that are perpendicular to the cover and it can handle two different tube dimensions. A lock housing with a cover in the form of a hexagon, has six sides which are perpendicular to the cover and can thus handle three different tube dimensions.
[0052] FIG. 2 shows a lock plate according to an embodiment in which the plate has an interface with a number of pins 1 with internal thread 3 and a number of holes 2 . Two lock plates are used to hold together two lock housings when locking. The lock plate has a hole 4 in the centre with a dimension larger than the dimension of the through half-holes in the lock housing. Accessories such as hooks, tubes, roller conveyors etc. can be connected to the lock plate, with screws through the internal threads in the pins 3 .
[0053] A lock plate does not need to be flat. The important thing is that its function regarding through holes and pins, exists. The lock plate can also be integrated in an accessory.
[0054] FIG. 3 shows a locking device which components can be fixed to tubes with dimensions corresponding to the dimensions of the through hole formed by the recesses 8 on the lock housing.
[0055] Assembling of a locking device on a tube is made by assembling two lock housings around a tube with the open sides toward each other. The recesses 8 on the lock housings with dimension corresponding to the tube dimension shall be oriented in the tube's axial direction. Lock plates are connected to two sides of the closed geometry that is formed when two lock housings are assembled. The lock plates are connected by fitting the pins 1 on the lock plate in the holes 6 that are on the sides of the closed geometry, which are perpendicular to the two lock housing's covers 5 . Locking is done by tightening a screw 9 in the thread 7 in the middle of the cover. When tightening the screw it will press the tube against the surface of the recess 8 on the opposite lock housing, simultaneously as the lock plates hold the lock housings together. The lock plates are held in place by means of contact pressure and friction between pins 1 on the lock plate and holes 6 in the lock housing. The tube is fixed to the locking device by means of contact pressure and friction in three points, screw 9 against the tube and the two surfaces in the recesses 8 of lock housing against the tube.
[0056] When a locking device consists of two lock housings and two lock plates that are fixed to a tube, the locking device is in its basic design. In its basic design, accessories can be connected to the two sides that the lock plates are assembled to.
[0057] FIG. 4 shows lock plates assembled on the sides of the closed geometry, formed by two lock housings, which are perpendicular to the tube's axial direction and perpendicular to the covers 5 on the closed geometry, and this may for example be used to lock two tubes of different dimensions to each other in the axial direction when using telescopic function. The inner tube 15 runs through the closed geometry and the outer tube 16 runs on the inner tube and is attached to one of the lock plates.
[0058] FIG. 5 shows that when lock plates are connected on the two sides that are parallel to the tube and perpendicular to the cover 5 in the closed geometry, a coupling in the form of a T or an X can be created, if a tube is attached to the lock plate.
[0059] FIG. 6 shows one embodiment where more accessories are connected through lock plates assembled to the other sides of the locking device. They could also be assembled through the thread 7 in the cover.
[0060] FIG. 7 shows an alternative geometry in which the locking device is intended to handle many different tube dimensions depending on geometry. For example, a locking device consisting of lock housings with hexagonal covers can handle three different tube dimensions.
[0061] By means of a telescopic roller conveyor different lengths of roller conveyors can be created by that the profile to which the roller organs are assembled, includes a telescopic function. The modular based design allows rebuilding of e.g. a rack very easily and enables the roller conveyor to be reused even if the dimensions of the rack are changed.
[0062] According to one embodiment, the telescopic roller conveyor includes three different modules: Inner profile, Outer profile and Connection organ with roller organs.
[0063] An inner profile and an outer profile combined with connection organ with roller organs, creates a telescopic roller conveyor.
[0064] FIG. 8 shows the inner profile 101 and the outer profile 102 according to one embodiment, in which the profiles are in the form of a C-profile. The inner profile 101 can run inside the outer profile 102 , and thereby creates a telescopic function.
[0065] In alternative embodiments, the profiles 101 , 102 can be in any other geometry as long as the inner profile 101 can run freely in the outer profile 102 and as long as there are recesses for axles and roller organs.
[0066] The profiles 101 , 102 has a first side 103 comprising at least one first recess 108 where the width of the recess is equally wide on the inner profile 101 as on the outer profile 102 . The width of the recess determines the maximum width of the rolling organs that can be assembled to the profiles.
[0067] In alternative embodiments the roller organs may comprise e.g. wheels, rollers or balls.
[0068] The first side 103 of the profiles 101 , 102 comprises at least a second recess 104 intended to receive the axle 105 to which the roller organs 106 are assembled. The other recesses 104 are separated by the same distance as the distance between the roller organs' 106 center in the roller conveyor. The distance between the other recesses 104 also determines the maximum diameter of the roller organs 106 that can be assembled to the profiles.
[0069] When roller organ 106 with its axle 105 is placed in the profiles' the other recesses 104 , the profiles are locked to each other in the longitudinal direction.
[0070] FIG. 10 shows roller organs 106 in the form of a wheel with axle 105 assembled to a connecting organ 107 . Roller organ 106 with axle 105 is assembled to the connecting organs 107 with the same distance as between the other recesses 104 on the profiles. By having roller organs 106 with axle 105 assembled to a connecting organ 107 , all roller organs 106 with axle 105 can be assembled or disassembled to the profiles simultaneously. Although the connecting organs have been cut in order to be adjusted for the length of the roller conveyor, it is always possible to reuse the connecting organs by placing several connecting organs 107 containing roller organs 106 and axle 105 , along the length of the profiles.
[0071] The roller organs being assembled to a connecting organ 107 may e.g. refer to that they are connected with string, tape, elastic band or anything else that intends to link the wheels together with a predetermined distance from each other.
[0072] A telescoping roller conveyor is shown, characterized by that the telescopic roller conveyor includes an inner profile 101 , and an outer profile 102 , wherein the inner profile 101 is designed to run inside the outer profile 102 so that the telescopic function is obtained, and wherein the inner profile 101 and the outer profile 102 at a first side 103 comprises: at least a first recess 108 designed to partially contain a roller organ 106 , and a second recesses 104 designed to receive an axle 105 connected to the roller organ 106 , and wherein the axle 105 is designed to lock the inner profile 101 and the outer profile 102 to each other in the profiles' 101 ; 102 longitudinal direction.
[0073] According to one embodiment, the telescopic roller conveyor can as described above have other recesses 104 designed to partially contain a wheel assembled on the axle 105 .
[0074] According to one embodiment, the telescopic roller conveyor can as described above have a first side 103 comprising a longitudinal slit 108 with a width intended to partially contain the roller organ 106 .
[0075] According to one embodiment, the telescopic roller conveyor can include at least two axles 105 , each one connected to roller organs 106 as described above, wherein the axles 105 include a first and second end, and wherein at least one of the first or the second ends are assembled to a connecting organ 107 at the same distance as the recesses 104 in the inner profile 101 and the outer profile 102 , so that at least two axles 105 and roller organs 106 on the roller conveyor's length can be assembled and disassembled to the profiles 101 ; 102 simultaneously.
[0076] Further, the invention includes a material rack comprising telescopic roller conveyor as described above.
[0077] The abovementioned description of embodiments shall not be understood as limiting, but can be freely combined within the scope of the claims. | The invention relates to a locking device designed to lock objects to tubes or other elongated elements. The locking device generally comprises one or more lock plates and lock housings. In one exemplary embodiment, when assembling the locking device to a tube, two lock housings are put together with open sides against each other around a tube with a dimension corresponding to approximately half of a recess which is found on the lock housing's sides and are oriented in the tube's axial direction. The two lock housings form a closed geometry around the tube. Lock plates are used to connect the two lock housings together. By applying a screw in a threaded hole in one of the lock housings' cover, the through tube is pressed against an opposite lock housing at substantially the same time as the lock plates hold the lock housings together. | 5 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation of application Ser. No. 09/133,338, filed Aug. 13, 1998, now U.S. Pat. No. 6,100,486, issued Aug. 8, 2000, which is a divisional of application Ser. No. 08/785,353, filed Jan. 17, 1997, now U.S. Pat. No. 5,927,512, issued Jul. 27, 1999, which is related to: a co-pending application having Ser. No. 08/591,238, entitled “METHOD AND APPARATUS [sic] FOR STORAGE OF TEST RESULTS WITHIN AN INTEGRATED CIRCUIT,” and filed Jan. 17, 1996; a co-pending application having Ser. No. 08/664,109, entitled “A STRUCTURE AND A METHOD FOR STORING INFORMATION IN A SEMICONDUCTOR DEVICE,” and filed Jun. 13, 1996; a divisional application having Ser. No. 09/133,336, entitled “METHOD FOR SORTING INTEGRATED CIRCUIT DEVICES” and filed Aug. 13, 1998; a co-pending application having Ser. No. 08/822,731, entitled “METHOD FOR CONTINUOUS, NON LOT-BASED INTEGRATED CIRCUIT MANUFACTURING,” and filed Mar. 24, 1997, now U.S. Pat. No. 5,856,923, issued Jan. 5, 1999; a co-pending application having Ser. No. 08/806,442, entitled “METHOD IN AN INTEGRATED CIRCUIT (IC) MANUFACTURING PROCESS FOR IDENTIFYING AND RE-DIRECTING IC'S MIS-PROCESSED DURING THEIR MANUFACTURE,” and filed Feb. 26, 1997; a co-pending application having Ser. No. 08/871,015, entitled “METHOD FOR USING DATA REGARDING MANUFACTURING PROCEDURES INTEGRATED CIRCUITS (IC'S) HAVE UNDERGONE, SUCH AS REPAIRS, TO SELECT PROCEDURES THE IC'S WILL UNDERGO, SUCH AS ADDITIONAL REPAIRS,” and filed Jun. 6, 1997; and a co-pending application having Ser. No. 08/801,565 entitled “METHOD OF SORTING A GROUP OF INTEGRATED CIRCUIT DEVICES FOR THOSE DEVICES REQUIING SPECIAL TESTING,” and filed Feb. 17, 1997, now U.S. Pat. No. 5,844,803, issued Dec. 1, 1998.
BACKGROUND
1. Field of the Invention
The present invention relates in general to integrated circuit (IC) manufacturing and, more specifically, to methods in IC manufacturing processes for sorting IC devices using identification (ID) codes, such as fuse ID's, in the devices.
2. State of the Art
Integrated circuits (IC's) are small electronic circuits formed on the surface of a wafer of semiconductor material, such as silicon, in an IC manufacturing process referred to as “fabrication.” Once fabricated, IC's are electronically probed to evaluate a variety of their electronic characteristics, cut from the wafer on which they were formed into discrete IC dice or “chips,” and then assembled for customer use using various well-known IC packaging techniques, including lead frame packaging, Chip-On-Board (COB) packaging, and flip-chip packaging.
Before being shipped to customers, packaged IC's are generally tested to ensure they will function properly once shipped. Testing typically involves a variety of known test steps, such as pre-grade, burn-in, and final, which test IC's for defects and functionality and grade IC's for speed. As shown in FIG. 1, IC's that pass the described testing are generally shipped to customers, while IC's that fail the testing are typically rejected.
The testing standards for a particular IC product are sometimes relaxed as the product “matures” such that IC's previously rejected under strict testing standards may pass the relaxed testing standards. Consequently, reject bins containing previously rejected IC's are sometimes “culled” for IC's that are shippable under relaxed testing standards by testing the rejected IC's again using the relaxed testing standards. Unfortunately, while this “culling” process does retrieve shippable IC's from reject bins, it makes inefficient use of expensive and often limited testing resources by diverting those resources away from testing untested IC's in order to retest previously rejected IC's. Therefore, there is a need in the art for an improved method of “culling” or sorting such reject bins for shippable IC's.
Similarly, as shown in FIG. 2, all the IC's from the wafers in a wafer lot typically undergo enhanced reliability testing that is more extensive and strict than normal testing when any of the wafers in the lot are deemed to be unreliable because of fabrication or other process errors. Since a wafer lot typically consists of fifty or more wafers, many of the IC's that undergo the enhanced reliability testing do not require it because they come from wafers that are not deemed unreliable. Performing enhanced reliability testing on IC's that do not need it is inefficient because such testing is typically more time-consuming and uses more resources than normal testing. Therefore, there is a need in the art for a method of sorting IC's from a wafer lot into those IC's that require enhanced reliability testing and those that do not.
Likewise, as shown in FIG. 3, a new or special “recipe” for fabricating IC's on wafers is sometimes tested by fabricating some wafers from a wafer lot using the special recipe and other wafers from the wafer lot using a control recipe. IC's from the wafers then typically undergo separate assembly and test procedures so that the test results of IC's fabricated using the special recipe are not mixed with the test results of IC's fabricated using the control recipe, and vice versa. Test reports from the separate test procedures are then used to evaluate the special recipe and to determine whether the IC's are to be shipped to customers, reworked, repaired, retested, or rejected. Unfortunately, because the IC's undergo separate test and assembly procedures, undesirable variables, such as differences in assembly and test equipment, are introduced into the testing of the special recipe. It would be desirable, instead, to be able to assemble and test the IC's using the same assembly and test procedures, and to then sort the IC's and their test results into those IC's fabricated using the special recipe and those IC's fabricated using the control recipe. Therefore, there is a need in the art for a method of identifying individual IC's fabricated using a special or control recipe and sorting the IC's based on their fabrication recipe.
As described above, IC's are typically tested for various characteristics before being shipped to customers. For example, as shown in FIG. 4, IC's may be graded in test for speed and placed in various bins (e.g., 5 nanoseconds (ns), 6 ns, and 7 ns bins) according to their grading. If a customer subsequently requests a more stringent speed grade (e.g., 4 ns), IC's in one of the bins (e.g., a 5 ns bin) are re-tested and thereby sorted into IC's that meet the more stringent speed grade (e.g., 4 ns bin) and those that do not (e.g., 5 ns bin). While this conventional process sorts the IC's into separate speed grades, it makes inefficient use of expensive and often limited testing resources by diverting those resources away from testing untested IC's in order to retest previously tested IC's. Therefore, there is a need in the art for an improved method of “culling” or sorting bins for IC's that meet more stringent standards, such as a higher speed grading.
As described in U.S. Pat. Nos. 5,301,143, 5,294,812, and 5,103,166, some methods have been devised to electronically identify individual IC's. Such methods take place “off” the manufacturing line, and involve the use of electrically retrievable ID codes, such as so-called “fuse ID's,” programmed into individual IC's to identify the IC's. The programming of a fuse ID typically involves selectively blowing an arrangement of fuses and anti-fuses in an IC so that when the fuses or anti-fuses are accessed, they output a selected ID code. Unfortunately, none of these methods addresses the problem of identifying and sorting IC's “on” a manufacturing line.
SUMMARY OF THE INVENTION
An inventive method for sorting integrated circuit (IC) devices of the type to have a substantially unique identification (ID) code, such as a fuse ID, includes automatically reading the ID code of each of the IC devices and sorting the IC devices according to their automatically read ID codes. The inventive method can be used in conjunction with an IC manufacturing process that includes providing semiconductor wafers, fabricating the IC's on each of the wafers, causing each of the IC's to store its ID code, separating each of the IC's from its wafer to form an IC die, assembling the IC dice into IC devices, and testing the IC devices. The method can also be used in conjunction with Single In-line Memory Module (SIMM), Dual In-line Memory Module (DIMM), and other multi-chip module (MCM) manufacturing processes.
In another embodiment, an inventive method for recovering IC devices from a group of IC devices that have previously been rejected in accordance with a test standard that has since been relaxed includes: storing test results that caused each of the IC devices in the group to be rejected in connection with an ID code, such as a fuse ID, associated with each device; automatically reading the ID code from each of the IC devices; accessing the test results stored in connection with each of the automatically read ID codes; comparing the accessed test results for each of the IC devices with the relaxed test standard; and sorting the IC devices according to whether their accessed test results pass the relaxed test standard in order to recover any of the IC devices having test results that pass the relaxed test standard.
By sorting the IC devices in accordance with their previously stored test results and their ID codes, the above-described inventive method eliminates the need to retest the IC devices after the test standard is relaxed in order to cull shippable IC devices from the rejected devices.
In still another embodiment, a method for sorting a group of IC devices in accordance with a first IC standard, such as a speed standard, that have previously been sorted in accordance with a second IC standard, such as a speed standard that is less stringent than the first, includes storing test results that caused each of the IC devices in the group to be sorted into the group in connection with ID codes, such as fuse ID's, of the devices, automatically reading the ID code from each of the IC devices, accessing the test results stored in connection with each of the automatically read ID codes, comparing the accessed test results for each of the IC devices with the first IC standard, and sorting the IC devices according to whether their test results pass the first IC standard.
In a further embodiment, an inventive back-end test method for separating IC devices in need of enhanced reliability testing from a group of IC devices undergoing back-end test procedures includes: storing a flag in connection with an ID code, such as a fuse ID, associated with each of the IC devices in the group indicating whether each IC device is in need of enhanced reliability testing; automatically reading the ID code of each of the IC devices in the group; accessing the enhanced reliability testing flag stored in connection with each of the automatically read ID codes; and sorting the IC devices in accordance with whether their enhanced reliability testing flag indicates they are in need of enhanced reliability testing.
Thus, the inventive method described above provides an advantageous method for sorting IC's from the same wafer lot into those IC's that require enhanced reliability testing and those that do not.
In a still further embodiment, an inventive method in an IC manufacturing process for testing different fabrication process recipes includes the following: providing first and second pluralities of semiconductor wafers; fabricating a first plurality of IC's on each of the first plurality of wafers in accordance with a control recipe; fabricating a second plurality of IC's on each of the second plurality of wafers in accordance with a test recipe; causing each of the IC's on each of the wafers to permanently store a substantially unique ID code, such as a fuse ID; separating each of the IC's on each of the wafers from its wafer to form one of a plurality of IC dice; assembling each of the IC dice into an IC device; automatically reading the ID code from the IC in each of the IC devices; testing each of the IC devices; and sorting each of the IC devices in accordance with the automatically read ID code from the IC in each of the IC devices indicating the IC is from one of the first and second pluralities of IC's.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
FIG. 1 is a flow diagram illustrating a conventional procedure in an integrated circuit (IC) manufacturing process for culling shippable IC's from a reject bin;
FIG. 2 is a flow diagram illustrating a conventional procedure in an IC manufacturing process for directing IC's to enhanced reliability testing;
FIG. 3 is a flow diagram illustrating a conventional procedure in an IC manufacturing process for testing a new or special fabrication process recipe;
FIG. 4 is a flow diagram illustrating a conventional procedure in an IC manufacturing process for speed-sorting IC's;
FIG. 5 is a flow diagram illustrating a procedure in an integrated circuit (IC) manufacturing process for culling shippable IC's from a reject bin in accordance with the present invention;
FIG. 6 is a flow diagram illustrating a procedure in an IC manufacturing process for directing IC's to enhanced reliability testing in accordance with another embodiment of the present invention;
FIG. 7 is a flow diagram illustrating a procedure in an IC manufacturing process for testing a new or special fabrication process recipe in accordance with still another embodiment of the present invention; and
FIG. 8 is a flow diagram illustrating a procedure in an IC manufacturing process for speed-sorting IC's in accordance with a further embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
As shown in FIG. 5, an inventive method for sorting integrated circuit (IC) devices is embodied in a method 10 in an IC manufacturing process for culling shippable IC's from a reject bin 12 . It will be understood by those having skill in the field of this invention that the present invention is applicable to sorting any IC devices, including Dynamic Random Access Memory (DRAM) IC's, Static Random Access Memory (SRAM) IC's, Synchronous DRAM (SDRAM) IC's, processor IC's, Single In-line Memory Modules (SIMM's), Dual In-line Memory Modules (DIMM's), and other Multi-Chip Modules (MCM's).
The method 10 includes the step 14 of fabricating IC's on wafers from a wafer lot 16 . IC's fabricated on the wafers are then programmed in a program step 18 in the manner described above with a fuse identification (ID) unique to each IC. The fuse ID may identify a wafer lot ID, the week the IC's were fabricated, a wafer ID, a die location on the wafer, and a fabrication facility ID. It will be understood, of course, that the present invention includes within its scope IC's having any ID code, including those having fuse ID's. It will also be understood that the ID code for each IC need not be unique, but instead may only specify the wafer the IC comes from, for example.
Once programmed, the IC's proceed through an assembly step 20 to a test step 22 where the fuse ID's are automatically read and stored in association with test data 24 generated in the test step 22 . Although the fuse ID's are typically read electronically, it will be understood that they may also be read optically if the fuse ID consists of “blown” laser fuses that are optically accessible. It will also be understood that the test data 24 may include data such as the following: data identifying the testing equipment that tested the IC's, operating personnel who operated the testing equipment, and the set-up of the equipment when the IC's were tested; and data indicating the time and date the IC's were tested, the yield of shippable IC's through the test step 22 , and test results for the IC's from the various stages of the test step 22 .
IC's that pass the test step 22 are typically shipped to customers, while those that fail the test step 22 are directed to the reject bin 12 . At a point in time when test standards of the test step 22 have been relaxed as described above, the IC's in the reject bin 12 are sorted in a sort step 26 by reading the fuse ID of each IC, accessing the test data 24 associated with the fuse ID, and comparing the accessed test data 24 with the relaxed test standards. Those IC's that fail even the relaxed test standards are directed back to the reject bin 12 , while those IC's that pass the relaxed test standards are typically shipped to customers. The method 10 thus successfully culls shippable IC's from the reject bin 12 without retesting the IC's.
As shown in FIG. 6, the inventive sorting method is also embodied in a back-end (i.e., after fabrication) test method 30 for separating IC's in need of enhanced reliability testing from a group of IC's undergoing back-end test procedures. IC's typically require enhanced reliability testing because the wafer they come from is unreliable as a result of fabrication errors and other unintended manufacturing process deviations.
The method 30 includes the step 32 of fabricating IC's on wafers from a wafer lot 34 . IC's fabricated on the wafers are then programmed in a program step 36 in the manner described above with a fuse identification (ID) unique to each IC. The fuse ID may identify a wafer lot ID, the week the IC's were fabricated, a wafer ID, a die location on the wafer, and a fabrication facility ID. It will be understood, of course, that the present invention includes within its scope IC's having any ID code, including those having fuse ID's. It will also be understood that the ID code for each IC need not be unique, but instead may only specify the wafer the IC comes from, for example.
Once programmed, the IC's proceed through an assembly step 38 . At this point in the IC manufacturing process, it is not uncommon for a number of wafers to have been identified as being unreliable for the reasons stated above. The fuse ID's of the IC's that come from these unreliable wafers may then be associated with a stored flag indicating the IC's come from unreliable wafers. If any wafers in the wafer lot 34 have been identified as being unreliable, the IC's proceed to a sort step 40 , where their fuse ID's are automatically read so the IC's can be sorted into those flagged as coming from the unreliable wafers that require processing through an enhanced reliability testing step 42 and those not flagged as coming from the unreliable wafers that may proceed through a standard test step 44 . Of course, those IC's that pass either the standard test step 44 or the enhanced reliability testing step 42 are typically shipped to customers, while those that fail these steps are directed to a reject bin (not shown).
Thus, the present invention provides a method 30 that directs those IC's needing enhanced reliability testing to the enhanced reliability testing step 42 while allowing those that do not require enhanced reliability testing to proceed through the standard testing step 44 .
As shown in FIG. 7, the inventive sorting method is further embodied in a method 50 for testing different fabrication process recipes. Such testing is typically done in accordance with a Special Work Request (SWR) from an engineer or technician.
The method 50 includes fabricating some of the wafers from a wafer lot 52 in a fabrication step 54 in accordance with a control process recipe that is typically the normal process recipe in use in the IC manufacturing process at the time. The remainder of the wafers from the wafer lot 52 are fabricated in another fabrication step 56 in accordance with a special or test process recipe. The special or test process recipe may change a variety of variables in the fabrication process, including doping, the thickness of IC layers, etc.
Once the IC's are fabricated in the fabrication steps 54 and 56 , the IC's are then programmed in a program step 58 in the manner described above with a fuse identification (ID) unique to each IC. The fuse ID may identify a wafer lot ID, the week the IC's were fabricated, a wafer ID, a die location on the wafer, and a fabrication facility ID. It will be understood, of course, that the present invention includes within its scope IC's having any ID code, including those having fuse ID's. It will also be understood that the ID code for each IC need not be unique, but instead may only specify the wafer the IC comes from, for example.
Once programmed, the IC's proceed through an assembly step 60 to a test step 62 where the fuse ID's are automatically read and stored in association with test data 64 generated for both the control recipe IC's and the special or test recipe IC's in the test step 62 . Although the fuse ID's are typically read electronically, it will be understood that they may also be read optically if the fuse ID consists of “blown” laser fuses that are optically accessible. It will also be understood that the test data 64 may include data such as the following: data identifying the testing equipment that tested the IC's, operating personnel who operated the testing equipment, and the set-up of the equipment when the IC's were tested; and data indicating the time and date the IC's were tested, the yield of shippable IC's through the test step 62 , and test results for the IC's from the various stages of the test step 62 .
Once the test data 64 is generated, the data 64 may be analyzed 67 to determine those IC's that are shippable and those that are not, and to determine any differences in test results between the control recipe IC's and the special or test recipe IC's. The IC's are sorted in a sort step 66 so they may be shipped, reworked, repaired, retested, or rejected in accordance with the analysis of the test results.
By sorting the control recipe 68 and special or test recipe 69 IC's at the end of the IC manufacturing process, the method 50 is able to assemble and test the IC's together and thus eliminate unintended variables introduced into the process of testing the special or test recipe by the conventional method of assembling and testing the IC's separately. The inventive method 50 thus provides more reliable test results.
As shown in FIG. 8, the inventive method for sorting IC devices is also embodied in a method 70 in an IC manufacturing process for sorting IC devices in accordance with an IC standard, such as speed, that is more stringent than an IC standard that the devices were previously sorted in accordance with. It will be understood that although the method of FIG. 8 will be described with respect to speed-sorting, the method is applicable to all situations in which IC's previously sorted in accordance with an IC standard, such as speed, need to be sorted in accordance with another, more stringent IC standard. Such IC standards may include, for example, access time, data setup time, data hold time, standby current, refresh current, and operating current.
The method 70 includes the step 72 of fabricating IC's on wafers from a wafer lot 74 . IC's fabricated on the wafers are then programmed in a program step 76 in the manner described above with a fuse identification (ID) unique to each IC. The fuse ID may identify a wafer lot ID, the week the IC's were fabricated, a wafer ID, a die location on the wafer, and a fabrication facility ID. It will be understood, of course, that the present invention includes within its scope IC's having any ID code, including those having fuse ID's.
Once programmed, the IC's proceed through an assembly step 78 to a test step 80 where the fuse ID's are automatically read and stored in association with test data 82 generated in the test step 80 . Although the fuse ID's are typically read electronically, it will be understood that they may also be read optically if the fuse ID consists of “blown” laser fuses that are optically accessible. It will also be understood that the test data 82 includes speed grading data for each IC, as described above, and may include data such as the following: data identifying the testing equipment that tested the IC's, operating personnel who operated the testing equipment, and the set-up of the equipment when the IC's were tested; and data indicating the time and date the IC's were tested, the yield of shippable IC's through the test step 80 , and test results for the IC's from the various stages of the test step 80 .
IC's that pass the test step 80 are typically directed to speed graded bins 84 , 86 , and 88 , while those that fail the test step 80 are directed to a reject bin 90 . The speed graded bins 84 , 86 , and 88 typically each contain IC's of varying speeds. For example, the bin 88 may contain a variety of 5.0 ns, 4.5 ns, 4.0 ns, 3.5 ns, etc. parts, the bin 86 may contain a variety of 6.0 ns, 5.5 ns, 5.1 ns, etc. parts, and the bin 84 may contain a variety of 7.0 ns, 6.5 ns, 6.1, etc. parts.
On occasion, customers request IC's that meet a more stringent speed standard (e.g., 4 nanoseconds (ns)) than any of the IC's in the various bins 84 , 86 , and 88 have been graded for. While bin 88 , for example, may contain IC's that will meet the more stringent speed standard, the bin 88 cannot be used to supply the customer's request because the IC's in the bin 88 have only been graded (i.e., are guaranteed to meet or exceed) a lower speed standard (e.g., 5 ns). Therefore, the present inventive method 70 sorts the IC's in a sort step 92 by reading the fuse ID of each IC, accessing the test data 82 , including the speed-grading data, associated with the fuse ID, and comparing the accessed speed-grading data with the more stringent speed standard (e.g., 4 ns). Those IC's that fail the more stringent speed standard are directed to a speed graded bin 94 , while those IC's that pass the more stringent speed standard are directed to another speed graded bin 96 where they can be used to fill the customer's request. The inventive method 70 thus sorts the IC's in accordance with a more stringent IC standard, such as speed, than they were previously sorted in accordance with without having to retest the IC's, and thus without reusing valuable testing resources to retest IC's.
Although the present invention has been described with reference to particular embodiments, the invention is not limited to these described embodiments. For example, while the various steps of the embodiments of the inventive sorting method have been described as occurring in a particular order, it will be understood that these steps need not necessarily occur in the described order to fall within the scope of the present invention. Thus, the invention is limited only by the appended claims, which include within their scope all equivalent methods that operate according to the principles of the invention as described. | An inventive method for sorting integrated circuit (IC) devices of the type having a substantially unique identification (ID) code, such as a fuse ID, includes automatically reading the ID code of each of the IC devices, and sorting the IC devices in accordance with their automatically read ID codes. The inventive method can be used in conjunction with an IC manufacturing process that includes providing semiconductor wafers, fabricating the IC's on each of the wafers, causing each of the IC's to store its ID code, separating each of the IC's from its wafer to form IC dice, assembling the IC dice into IC devices, and testing the IC devices. The inventive method is useful for, among other things, culling IC reject bins for shippable IC's, sorting IC's from a wafer lot into those that require enhanced reliability testing and those that do not, and allowing IC's fabricated using both a control fabrication process recipe and a new fabrication process recipe under test to be assembled and tested using the same equipment to reduce unintended test variables introduced when the IC's are assembled and tested separately. | 7 |
BACKGROUND OF THE INVENTION
Field of the Invention
The present invention relates generally to fluid reaction surfaces, and more specifically to a turbine airfoil with film cooling holes.
Description of the Related Art including information disclosed under 37 CFR 1.97 and 1.98
A gas turbine engine includes a turbine section that has a plurality of stages of stator vanes and rotor blades reacting to a high temperature gas flow passing through the turbine to convert the chemical energy from combustion into mechanical energy by rotating the turbine shaft. The efficiency of the turbine, and therefore of the engine, can be increased by increasing the hot gas flow that enters the turbine.
To allow for higher turbine entrance temperatures, the upper stage vanes and blades are made from exotic nickel alloys that can withstand very high temperatures and have complex internal cooling air passages to provide cooling to these airfoils. A thermal barrier coating (TBC) is also applied to the airfoil surfaces exposed to the hot gas flow in order to provide further protection from the heat. A TBC is typically made from a ceramic material. Also, the TBC is typically applied after the film cooling holes have been drilled into the airfoil surface to provide for the film cooling. These film cooling holes are limited to the diameter because of the drilling process. Thicker TBC layers have been proposed to provide more protection to the airfoil substrate from the high temperature gas flow. As the TBC gets thicker, the thermal stresses developed in the TBC will tend to cause spalling.
In some prior art applications, a thin refractory coating is used in the turbine airfoil cooling design to provide a protective coating for the turbine airfoil and thus reduce the cooling flow consumption and improve turbine efficiency. The refractory coating is made of a material that is very expensive. The refractory coating is made so thin that cooling holes are not used in the coating because the hole length to diameter ratio cannot be larger than 2, which is required for cooling holes. Because the thin refractory coating is so thin—in the order of 2 to 4 mils (one mil is 0.001 inch)—the cooling hole would have to be at least 4 to 8 mils in diameter to maintain the hole ratio of 2 to 1.
As the turbine inlet temperature increases, the cooling flow demand for cooling the airfoil increases as well, and as a result the turbine efficiency is reduced. One alternative way for reducing the cooling air consumption while increasing the turbine inlet temperature for higher turbine efficiency is to use transpiration film cooling on the cooled thicker layer of the protective coating in order to reduce the heat load on the airfoil.
It is therefore an object of the present invention to provide for an improved high temperature resistant coating applied to a turbine airfoil.
It is another object of the present invention to provide for a high temperature resistant coating with smaller diameter film cooling holes.
It is another object of the present invention to provide for a refractory material coating on a turbine airfoil with smaller diameter cooling holes.
It is another object of the present invention to provide for a process of forming small diameter cooling holes in a refractory material using modules that form the holes.
BRIEF SUMMARY OF THE INVENTION
The present invention is a turbine airfoil with a refractory coating applied to the surface in which the coating includes small diameter cooling holes formed therein. The cooling holes are formed by placing a module of a leachable ceramic material into trenches already formed within the surface of the airfoil substrate. The module includes an array of trusses extending chordwise and spanwise, each truss having a plurality of hole forming extensions to form the cooling holes. The module is placed within the trenches formed on the blade substrate, a refractory coating is applied over the module, and the module is leached away leaving the cooling holes and the diffusion openings formed within the refractory coating.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
FIG. 1 shows a top view of a cross section of a turbine blade with the cooling holes of the present invention.
FIG. 2 shows a close-up view of the cooling holes of FIG. 1 .
FIG. 3 shows a side view of one of the modules used to form the cooling holes of the present invention.
FIG. 4 shows a top view of the module of FIG. 3 .
DETAILED DESCRIPTION OF THE INVENTION
The present invention is a turbine airfoil, such as a rotor blade or a stator vane, used in a gas turbine engine, in which the turbine airfoil includes a thick refractory coating to provide protection form a higher external gas flow temperature than would a typical ceramic TBC used on the airfoil. The airfoil 10 in the present invention is shown in FIG. 1 and has a leading edge and a trailing edge, and a pressure side and a suction side. Internal cooling air supply channels 11 are formed within the airfoil walls and are separated by ribs 12 that also reinforce the airfoil walls. Exit cooling holes 16 are located in the trailing edge of the blade 10 and discharge cooling air from the downstream channel of the blade. Cooling holes 13 are formed in the main wall or substrate 14 of the blade and connect the internal cooling air supply channels to the cooling holes of the present invention best described in FIG. 2 .
FIG. 2 shows the details of the small cooling holes formed in the coating applied to the outer surface of the airfoil on the substrate 14 . Cooling supply holes 13 are formed in the substrate by any of the well known processes such as drilling. The cooling holes 13 function as metering holes for the individual cooling holes 22 that are formed within the coating 21 . Each cooling supply hole 13 ends into a diffusion chamber 13 that is also formed within the substrate 14 . The cooling holes 22 connect the diffusion chamber 23 to the exterior surface of the coating 21 .
The cooling holes 22 are formed into the coating 21 by a process that uses a plurality of modules or mini cores 31 shown in FIGS. 3 and 4 that form a number of the cooling holes 22 in the coating 21 . The module or mini core 31 is rectangular in shape and includes core trusses that extend in the vertical and horizontal directions as seen in FIG. 4 . Two horizontal trusses 33 and three vertical trusses 32 form a rectangular shaped module with two openings 34 inside. Cooling hole shaped pins 22 extend from the flat surface of the trusses the length equal to about that of the thickness of the coating to be applied. One metering hole 13 would supply cooling air to the diffusion chamber formed by one of the vertical trusses 32 of the module 31 shown in FIG. 4 . Thus, the module 31 shown in FIG. 4 would be associated with three metering holes 13 with one metering hole for each of the three vertical trusses 32 . The substrate 14 has an arrangement of trenches machined or cast into the blade wall and having a spherical cross sectional shape as seen in FIG. 2 . The size and shape of the trenches formed in the substrate 14 will be the same as the module or min core 31 , since the module will be placed into the trenches before the coating is applied. The module or mini core 31 is made of a leachable ceramic material of the kind used to form hollow turbine airfoils with internal cooling passages using the lost wax process.
To produce the turbine blade (or stator vane), the blade is cast and the trenches that will form the diffusion chamber 23 will be machined into the blade substrate or cast with the blade. The blade substrate thus has an array of trenches formed in the shape of the module 31 shown in FIG. 4 in which three vertical or primary trenches extend between two horizontal or secondary trenches with three metering holes 13 drilled in the substrate at about the midpoint of each of the three vertical or primary trenches. The primary trenches include a metering hole connected to the trench. The secondary trenches connect two adjacent primary trenches. The metering holes 13 for each of the trenches that form the diffusion chamber 23 are drilled into the blade to connect the trench to the cooling supply channel 11 . Primary diffusion chambers are formed from the vertical or primary trenches, and secondary diffusion chambers are formed from the horizontal or secondary trenches. The modules 31 are placed within the trenches such that the outer substrate surface and the top surface of the modules are flush. The cooling hole forming pins 35 extend outward in the size and length of the cooling holes that will be formed later. The coating 21 is applied to the substrate with all of the modules 31 in place. When the coating is dried, the ceramic material that forms the modules is leached out. With the ceramic material leached out, the diffusion chamber 23 and the cooling hole 22 remains and forms the cooling air passage from the metering hole 13 to the opening on the surface of the coating 21 . In the present embodiment, the coating is a refractory material such as Iridium or Rhodium that can withstand higher gas flow temperatures than the typical ceramic thermal barrier coatings. Thus, a turbine airfoil with the refractory coating and the small diameter cooling holes can produce transpiration cooling of the airfoil that will allow for exposure to the higher gas flow temperatures. This will allow for a gas turbine engine with a higher turbine inlet temperature, which will provide for higher engine efficiency. Also, because of the small cooling holes that will allow transpiration cooling for the refractory coating, the refractory coating can be thicker than a non-cooled refractory coating. The thicker refractory coating will also provide for additional protection to the blade substrate from the extreme gas flow temperature. In the present invention, the refractory coating has a thickness of about 0.005 inches to 0.008 inches. With a thickness in the smaller range of 0.005 inches, to keep a cooling hole length to diameter ratio of 2, the diameter of the cooling hole would have to be 0.0025 inches. The process of forming cooling holes of the present invention is capable of forming cooling holes of this small diameter.
FIG. 4 shows the grid of trench forming trusses extending in a vertical and horizontal direction with openings 34 formed between the trusses that are in the shame shape and size as the trenches on the blade substrate. The present invention shows three vertical trenches and two horizontal trenches. However, this could be rotated 90 degrees without departing from the spirit and scope of the present invention. Also, instead of the trusses forming a rectangular array or grid, a triangular array or grid can be used. Three trenches in which the two side trenches could extend at about 30 degrees from the normal while the base trench would connect the two. The metering holes would be associated with the longer side trenches, with the base trench acting as the secondary diffuser connecting the two primary diffusers together.
FIG. 1 shows a portion of the airfoil wall to include the cooling holes with diffusion chambers as described in the present invention above for the purpose of clarity. However, the entire airfoil wall from the leading edge to the trailing edge along the pressure side and the suction side includes the cooling holes. | A turbine airfoil or a substrate exposed to a high temperature environment having a plurality of modular formed cooling circuits with diffusion chambers and cooling holes for each module. Each module includes diffusion chambers and transpiration cooling holes and is placed on the airfoil substrate and a refractory material is formed over the modules. The modules are then leached away leaving the diffusion chambers and cooling holes formed between the substrate and the refractory coating. | 5 |
BACKGROUND OF THE INVENTION
Peristaltic pump systems are commonly utilized in medical applications. For instance, such pumps are often employed during cardiovascular surgery to facilitate circulation of blood between a patient and a heart-lung machine. Other common medical uses are the transfer of blood between a patient and a kidney dialyzer, and intravenous feeding of IV solutions.
Peristaltic pump systems are relatively simple in construction typically consisting of a housing having rollers which progressively compress a flexible tube at spaced intervals against an arcuate surface or raceway so as to flatten or locally reduce the cross-sectional area of the tube. As the rollers continue to roll over the tube, the successive flattened portions expand or return to the original cross-sectional area due to the resilience of the tube which generates a subatmospheric pressure in the tube to draw the fluid therein.
The efficiency of the pump depends on the flexing characteristics of the tube. A tube which completely seals at the flattened cross-sectional area prevents reverse flow of fluid and reflux of air to establish a volumetric pump whereby the rate of flow of fluid ca be accurately calculated by the rotational speed of the rollers. Commercially available peristaltic pump tubes are uniformly cylindrical with a uniform wall thickness and provide a fast recovery rate of the flattened portion to the normal cross-sectional area, however, the shape of the tube produces voids or cavities during expansion and the resiliency of the tube may cause excessive subatmospheric pressures to be created which may draw air into the pump system, or cause damage to the blood and other tissues, which is objectionable.
A variety of tubes incorporating various geometric configurations have been provided in an attempt to provide a more efficient pumping system with relatively little success. For instance, in U.S. Pat. No. 4,131,399 longitudinally extending internal notches or external ridges are provided to prevent the tube from completely occluding which renders the tube useless for many applications and will produce variable vacuum conditions.
U.S Pat. Nos. 2,406,485 and 3,192,863 incorporate tubes having configurations which reinforce the tube and permit the tube to completely occlude as the rollers pass thereover. However, in U.S. Pat. No. 2,406,485 the tube is provided with an internal notch and a reinforcing external ridge which produces an increased wall thickness and the hose requires special adapters for connecting the tube to standard extracorporeal devices since the tube is not of a circular cross-sectional shape. Also, stretching of the tube, requiring special tools, is necessary during installation which is an inconvenience and is time consuming for the operator. Similarly, the tube in U.S. Pat. No. 3,192,863 incorporates a special configuration including a longitudinally extending fin projecting therefrom which requires additional material to form the tube and a complicated raceway construction for receiving and supporting the same.
It is an object of the invention to provide a tube for peristaltic pumps wherein the tube incorporates a simple construction for optimizing and controlling the flexing characteristics of the tube.
Another object of the invention is to provide a tube for peristaltic pumps wherein the tube is provided with a pair of longitudinally extending notches or grooves defined in the exterior surface thereof for improved control and flexing characteristics and permitting the tube to completely seal with a minimum of strain imparted to the tube.
A further object of the invention is to provide a tube of a generally circular cross-section for peristaltic pump systems wherein the tube incorporates longitudinally extending notches or grooves defined in the exterior surface thereof whereby the depth of the notches and the durometer of the tube may be selected to control the flexing characteristics of the tube and generate the desired negative pressures for a particular application.
A further object of the invention is to provide a tube which is safe for medical applications as excessive negative pressure at the cannulation site is prevented.
Still a further object of the invention is to provide a tube incorporating a pair of external notches or grooves formed by removing material at the areas which would otherwise undergo the greatest strain during compression to prevent the tube from cracking and bursting over extended periods of usage.
Another object of the invention is to provide a tube for peristaltic pump systems wherein the tube incorporates a simple low cost construction which is easily and quickly installed in conventional peristaltic pumps without requiring stretching or special tools.
The tube of the invention is adapted for use in peristaltic pump systems wherein fluid is transferred through the tube by the action of rollers progressively compressing the tube at spaced intervals against an arcuate raceway having an axis common to that about which the rollers rotate. The tube includes an inlet end, an outlet end, and an internal passage extending therebetween. Exteriorly, the tube is provided with a pair of longitudinally extending oppositely disposed notches or grooves defined in the exterior surface thereof.
The notches or grooves are located at the areas of the tube which would otherwise undergo the greatest strain when the tube is compressed, to provide improved flexing characteristics and permit the tube to completely occlude at the locally flattened cross-sectional areas. The geometric configuration and depth of the notches and the durometer of the tube may be selected to optimize the flexing characteristics of the tube during return of the tube to its normal shape to generate the desired negative pressures for a particular application. Because the tube completely occludes, a volumetric pump is established, and no leak passages are created for return or reverse flow of fluid or reflux of air.
The tube is less susceptible to cracking and bursting over extended periods of usage as the material which normally would have undergone the greatest strain has been removed to form the notches. Because the notches are formed exteriorly, the interior of the tube maintains a substantially circular cross-section for easily and conveniently connecting the inlet and outlet ends to standard extracorporeal devices. The simple construction of the tube provides improved efficiency in peristaltic pumps while a low cost construction is maintained.
BRIEF DESCRIPTION OF THE DRAWINGS
The aforementioned objects and advantages of the invention will be appreciated from the following description and accompanying drawings wherein:
FIG. 1 is an elevational, sectional view of a peristaltic pump system embodying the inventive concepts of the invention,
FIG. 2 is an elevational, cross-sectional, enlarged view of a conventional prior art tubing commonly utilized in peristaltic pump systems in a non-compressed condition,
FIG. 3 is an elevational, cross-sectional view of a portion of the conventional tubing of FIG. 2 in a partially compressed condition illustrating the non-occluded passage immediately after compression by the roller,
FIG. 4 is an elevational, cross-sectional, enlarged view of a tube embodying the inventive concepts of the invention in a non-compressed condition,
FIG. 5 is an elevational, sectional view as taken along Section 5--5 of FIG. 1 illustrating the completely occluded condition of the tube of the invention when compressed,
FIG. 6 is an elevational, cross-sectional view of another version of a tube in accord with the invention,
FIG. 7 is an elevational, cross-sectional view of one preferred commercial version of a tube in accord with the invention,
FIG. 8 is an enlarged, detail, cross-sectional view of a notch shown in the embodiment of FIG. 7, and
FIG. 9 is a cross-sectional view of a tube in accord with the invention having co-extruded layers of different materials.
DESCRIPTION OF THE PREFERRED EMBODIMENT
With reference to FIG. 1, a typical peristaltic pump system utilizing the inventive concepts in accord with the invention is generally indicated at 10. The pump 10 is useful in many industrial and medical applications. For instance, in medical applications the pump 10 may be utilized to circulate blood between a patient and a heart-lung or kidney machine.
The system 10 includes a housing 12 having a front wall 14, a rear wall 16, and opposite side walls 18 and 20. The housing 12 defines an interior chamber 22 having an arcuate surface which forms a raceway 24 tangential to a pair of passages 26 and 28 which intersect the front wall 14. A drive shaft 30 vertically projects into the chamber 22 and drives a rotor 32 having oppositely extending arms 34 which are provided with rollers 36 at the outer ends thereof. Preferably, the drive shaft 30 is driven by a motor, not shown, in the conventional manner.
The pumping system 10 also employs a tube 38 through which the fluid, such as blood, being circulated in the pump 10 is conveyed by action of the rollers 36 progressively compressing the tube 38 against the raceway 24. The geometric construction of the tube 38 incorporates notches or grooves formed in the exterior surface thereof in accord with the inventive concepts to optimize the flexing characteristic of the tube to control pressures therein, as later described, and overcome the deficiencies of prior art tubes commonly utilized in similar pumping systems.
For purpose of illustration, a typical prior art tube commonly utilized in such pump systems is shown in FIGS. 2 and 3 generally indicated at 40 having at inner diameter 41. The normal cross-sectional shape of the tube 40 in a non-compressed, or at rest, condition is of a circular configuration, FIG. 2. When the tube 40 is compressed by a roller passing thereover the inner bore may be completely closed, but as the roller passes the tube begins to expand and each transverse portion thereof just engaged by the roller and raceway tends to assume the shape of a flattened figure eight, FIG. 3 as the tube starts to resume its shape. The opposite sides of the tube 40 are flattened against each other, but the folds 42 cause the portions of the tube adjacent the folds 42 to rapidly open creating voids 44 which are disadvantageous during pump operation as explained below.
When the supply of fluid to be pumped is less than the capacity of the pump the voids 44 constitute and create a pumping chamber and subatmospheric pressure is generated in the tube which may cause a sufficient vacuum or subatmospheric pressure to be produced which causes air to be drawn into the system at the cannulation site, cavitation of gasses in solutions, and trauma of the tissue in contact with the cannula.
Referring to FIGS. 1, 4 and 5, the tube 38 of the invention includes an inlet end 46, an outlet end 48, and a passageway 50 of a generally circular cross-section extending therebetween. Preferably the tube 38 is formed of a resilient plastic or elastomeric material. The inlet end 46 is adapted to be connected to a supply line, not shown, such as a blood supply line in communication with a patient's heart while the outlet end is provided for discharging or returning blood to the patient or to a subsequent component.
Exteriorly, the tube 38 includes a surface 51 and is provided with a pair of oppositely disposed notches or grooves 52 which extend longitudinally along the length thereof. The tube 38 is located within the housing 12 such that the inlet and outlet ends protrude past the front wall through the passage 26 and 28, respectively, and the notches 52 are oriented so that as the tube is compressed the notches define the top and bottom apexes thereof with respect to FIG. 5.
During operation, as the rollers 36 roll over and progressively compress the tube 38 against the raceway 24, the adjacent sides of the tube tend to flatten against one another. The presence of the notches 52 promotes ease of collapse of the tube as the material which would otherwise have undergone the greatest strain has been removed. This permits the passageway 50 to completely occlude with a minimum of force exerted by the rollers a illustrated in FIG. 5. As the roller 36 passes over the tube 38 the locally flattened portions tend to expand and assume the original cross-sectional area of FIG. 4, due to the resilience of the tube. However, the reduced wall thickness resulting from notches 52 "weakens" the tube recovery to its normal shape.
By varying the geometric configuration and depth of the external notches 52 and controlling the durometer of the tube material, the compression and rate of speed at which the tube returns to the original cross-sectional area may be controlled to generate the desired subatmospheric pressures for a particular application. For example, in FIG. 6 a tube 38, is illustrated having a pair of V-shaped notches 54 in accord with the invention, and FIG. 7 illustrates a tube 38" having a pair of notches 56 constructed in accord with the preferred notch form in the practice of the invention.
With reference to FIGS. 7 and 8, where the preferred commercial form of the notches is disclosed, the notches 56 each include converging substantially linear sidewalls 58 which each engage a base 60. This preferred form of the invention functions well, and as an example of a commercial form of the inventive concepts the following dimensional relationships exist with respect to the embodiment of FIGS. 7 and 8.
The tube 38" has an internal diameter of 0.375 inches, and a radial wall thickness of 0.100 inches. The circumferential opening of the notches 58 as represented at A is 0.095 inches, while the circumferential dimension of the base 60 is represented at dimension B and is 0.045 inches. The radial depth of the notches 58 is substantially two-thirds of the radial thickness of the tube 38" wherein the radial dimension C separating the base 60 from the tube inner bore is 0.035 inches. These dimensions used with a silicone material tube having a 50 durometer works well. Radiuses of 0.015 inches are formed at the intersection of the notch sidewalls 58 with the base 60 and the exterior surface of the tube.
FIG. 9 discloses a variation of the invention wherein an inner co-extruded layer 62 is located within the outer layer 38"', which is identical to tube 38". Notches 56' are formed in the tube 38'" identical to those previously described. In the embodiment of FIG. 9 the inner layer 62 may be formed of a special material as to be particularly inert or non-contaminating with respect to the medium being pumped or to impart greater strength for higher pressure applications, and the presence of the notches 56' permits a two layer hose of the type described to have the physical characteristics desired in accord with the inventive concepts wherein the resultant vacuum pressures can be controlled.
In the practice of the invention the use of the notches 52, 54, and 56 closely controls the subatmospheric pressures created as the hose returns to its normal shape after compression by the rollers. By regulating the radial depth and configuration of the notches relatively low subatmospheric pressure can be produced which reduces trauma to the blood cells, reduces trauma to the tissue at the cannulation site and minimizes the potential to aspirate air at the cannulation site. Specific negative pressures can be produced which reduce the likelihood of injuring the patient.
Because the notches permit the tube to fully occlude a volumetric pump is established whereby the flow rate of the fluid can be accurately calculated by the rotational speed of the rollers. The notches 52, 54 and 56 also provide an advantage in that the portion of material which would normally be subjected to the greatest strain is removed which reduces the likelihood of the tube from cracking or bursting over prolonged periods of usage.
The low cost, simple construction of tubes incorporating the inventive concepts provide improved efficiency in peristaltic pumps without adding to the overall cost. As the tubes maintain a circular cross-sectional shape such tubes are conveniently connected to standard extracorporeal components without requiring special tools or stretching which permits the tubes to be easily replaced, when necessary, or spliced into existing pump systems.
It is appreciated that various modifications to the inventive concepts may be apparent to those skilled in the art without departing from the spirit and scope of the invention. | The invention relates to a tube for peristaltic pumps wherein rotating members progressively compress the tube to force fluid therethrough for discharging at an outlet end. The tube includes a pair of oppositely disposed longitudinally extending notches or grooves defined in the exterior surface thereof which enhance the flexing characteristics of the tube, permit the flattened cross-sectional area to completely seal with minimal force applied by the rotating members and controls the vacuum pressures generated. The depth and geometric configuration of the notches and the durometer of the tube may be selected to control the compression and expansion characteristics of the tube section to generate and control the desired vacuum or subatmospheric pressure levels for a particular application. | 5 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a process for preparing peroxidic perfluoropolyethers obtained by photooxidation of tetrafluoroethylene in the presence of solvents.
More particularly it refers to a process which does not utilize chlorofluorocarbon solvents which, as well known, have a dangerous impact on the ozone (ODP) and cause greenhouse effect (GWP).
2. Description of the Related Art
It is well known that TFE photooxidation processes at low temperature to produce peroxidic perfluoropolyethers are industrially carried out in CFC solvents, for instance R12. According to international agreements relating to the reduction and to the elimination of CFC from the market, the need to find substitutive solvents was felt.
Said substitutive solvents must allow the carrying out of the synthesis without causing drawbacks compared with the present solvents, in particular with R12 (CF 2 Cl 2 dichloro-difluoromethane) which is the most utilized solvent due to its optimal performances. The solvent must not produce chain transfer, since, if desidered, one must be able to obtain also a control on the molecular weight. Moreover a substitutive solvent of R12 must allow the obtainment of a polymer having a low content of peroxidic units (PO) with a good productivity. An ideal solvent is the one which allows to obtain performances similar to those obtainable with R12 by operating in the same conditions of reactor volume, gas flow-rate, power of the radiant lamp and reaction temperature.
It is known indeed that in the photooxidation process of tetrafluoroethylene (TFE), in the presence of CFC solvents, polymers with a lower PO can be obtained if the radiant power of the UV lamp is increased or if one works at higher temperatures, the TFE flow-rate and the reactor volume being equal. However the increase of radiant lamp involves higher process costs and the temperature increase implies lower yields.
Therefore the substitutive solvents are to be considered with the same radiant power, reactor configuration, temperature and reactants flow rate. An optimal solvent will be the one which gives the highest productivity with the lowest PO, with the same reaction.
In the patents of the art, as solvents used in the tetrafluoroethylene photooxidation, are mentioned prevailingly specific chlorofluorocarbon or perfluorinated solvents, optionally containing oxygen atoms, and CFC are especilally used in the synthesis as preferred solvents. See for instance patents U.S. Pat. No. 4,451,646, U.S. Pat. No. 5,354,922, U.S. Pat. No. 3,847,978 and U.S. Pat. No. 3,715,378.
SUMMARY OF THE INVENTION
The Applicant has unexpectedly and surprisingly found a specific solvent not containing chlorine which is capable of giving a polymer with low content of peroxidic units (PO) and with good productivity, quite comparable to those obtained with R12.
Object of the present invention is an oxidation process of tetrafluoroethylene at temperatures comprised between -80° C. and -50° C., preferably between -70° C. and -50° C., in the presence of UV radiations and pentafluoroethane (125) as solvent.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The radiation utilized, the oxygen and TFE flow-rate are those well known in the art of CFC solvents and are described for instance in U.S. Pat. No. 3,715,378, incorporated herein by reference. The polymers obtained have the following general formula:
A--O--(CF.sub.2 --CF.sub.2 --O).sub.p --(CF.sub.2 --O--).sub.q --(O).sub.r --B
wherein the terminals A and B can be equal to or different from each other and comprise --CF 3 , --COF, --CF 2 COF, --CF 2 X wherein X indicates a radicalic group deriving from the type of the transfer agent utilized, for istance it can be F, Cl, etc.; the indexes p, q and r equal to or different from each other are integers, the sum p+q is a number comprised between 2 and 1000, preferably 10 and 400, the q/p ratio is comprised between 0.1 and 10, preferably between 0.2 and 5, the r/(p+q) ratio is such as to lead to a peroxidic perfluoropolyether having a PO generally lower than 4.5-5, preferably lower than 4, generally comprised between 1 and 3.5. The PO value is expressed as grams of active oxygen (16 amu) (atomic mass unit) per 100 grams of polymer.
The TFE concentration generally ranges between 0.005 and 1 mole per liter of solution, preferably 0.01-0.5 mole/1; therefore the TFE flow-rate is such as to give these concentrations.
The amount of oxygen utilized is sufficient to saturate the solution, generally one operates with an excess of oxygen with respect to TFE and the partial pressures of oxygen are generally comprised between 0.1 and 2 atm, preferably 0.2 and 1.
The process of the invention, if desired, can be carried out in the presence of a chain transfer agent if a control of the molecular weight is desired. As transfer agents, well known in the art, one can mention for instance: fluorine, chlorine, chlorotrifluoroethylene (CTFE), etc.
The peroxidic perfluoropolyethers can be then transformed into products without peroxidic oxygen by means of a thermal treatment at temperatures generally comprised between 100°-250° C. or by UV radiations, in the presence or not of solvents. The so obtained product can be submitted to fluorination treatment to obtain perfluoropolyether with perfluoroalkylic terminals.
Alternatively the peroxidic crude product can be submitted to chemical reduction and to successive transformation reactions to obtain functional products. See for instance U.S. Pat. No. 3,715,378. The chemical reduction is for instance carried out according to methods described in U.S. Pat. No. 4,451,646, 3,847,978. The derivative thus obtained in the form of salt of the carboxylic acid can be submitted to decarboxylation processes in the presence of hydrogen donors substances, among which glycols, water, etc., to obtain perfluoropolyethers having both terminals --OCF 2 H. See for instance European patent application EP 95111906.4 in the name of the Applicant.
A further object of the present invention is a solvent containing as essential component pentafluoroethane in admixture with linear or branched perfluoroalkanes, for instance from 3 to 7 carbon atoms among which perfluoropropane and/or perfluoroheptane can be mentioned. The volume ratios between 125 and the other indicated perfluorinated solvent generally range from 9:1 to 1:7, preferably from 1:1 to 4:1. The mixtures of solvents show PO and productivity values similar to those of 125. This is quite unexpected if it is considered that perfluoroheptane alone for instance leads to very high PO values and therefore to very low productivity if comparisons are made with the same PO.
In the case of the synthesis of peroxidic polymers having a high molecular weight, it is preferable, according to a preferred embodiment of the invention, to utilize the mixtures of solvents indicated above. According to the present invention, when it is mentioned the molecular weight, it is meant a number average molecular weight.
The following examples are given for illustrative purposes and are not limitative of the present invention.
EXAMPLE 1
In a cylindric reactor for photosynthesis, equipped inside with coaxial sheaths, containing a 150 W high pressure mercury lamp, cooled by recirculation of fluid transparent to UV radiations, equipped moreover with refrigerant maintained at the temperature of -75° C. and of feeding pipes for feeding the reacting gas, is cooled at -50° C. and charged with 415 cc of hydropentafluoroethane (R125).
12.0Nl/h of oxygen have started to be fed and after few minutes the mercury lamp is turned on.
6.0Nl/h of tetrafluoroethylene and 0.040Nl/h of chlorine diluted with 2.4Nl/h of nitrogen are then fed.
These input are kept constant for the whole test, equal to 300 minutes, as well as the temperature (-50° C.).
At the end of the reaction the lamp is turned off, the reactants flows are closed and the solvent and the gaseous by-products are let evaporate until reaching room temperature. The oil remained in the reactor is discharged and degassed under vacuum to eliminate the residual traces of solvent and by-products; weighed, it results equal to 67.8 g, which corresponds to a specific productivity of 33 g/h/l. The iodometric analysis of the peroxidic content indicates a PO equal to 1.84 (expressed as grams of active oxygen/100 g of product). The kinematic viscosity at 20° C. of the product results equal to 600 cSt. The 19 F--NMR analysis confirms the following structure:
T--(CF.sub.2 CF.sub.2 O).sub.n (CF.sub.2 O).sub.m (CF.sub.2 CF.sub.2 OO).sub.p (CF.sub.2 OO).sub.q --T
wherein T=OCF 2 Cl, OCF 2 CF 2 Cl, OCF 3 , OCF 2 COF, OCOF.
The (p+n)/(q+m) ratio is equal to 0.94 and the n/m ratio is equal to 0.74.
The number average molecular weight calculated by the 19 F--NMR spectrum is equal to 12800.
EXAMPLE 1A
(Comparative)
In the same reactor of Example 1 cooled at -50° C., 440 cc of dichlorodifluoromethane are introduced. 12.0 Nl/h of oxygen are fed and after few minutes the mercury lamp is turned on. 6.0 Nl/h of tetrafluoroethylene are then fed for the whole test (300 minutes) by maintaining the temperature at -50° C. When the reaction is over the lamp is turned off, the reactants flows are closed and the solvent and the reaction by-products are let evaporate. The oil remained in the reactor, after degassing, results equal to 70.8 g which corresponds to a specific productivity of 32 g/h/l. The PO results equal to 1.66 and the viscosity at 20° C. equal to 350 cSt. The 19 F--NMR indicates a structure similar to the one reported in Example 1, with the same type of terminals. The (p+n)/(q+m) ratio results equal to 0.81 and the n/m one equal to 0.67. The average molecular weight calculated by NMR is equal to 10300.
EXAMPLE 2
420 cc of hydropenta-fluoroethane (R125) are introduced in the reactor of Example 1 at the temperature of -50° C.
One operates with the same procedure as in Example 1, by feeding 18.8 Nl/h of oxygen, 9.0 Nl/h of tetrafluoroethylene and 0.040 Nl/h of chlorine diluted in a stream of 2.4 Nl/h of nitrogen.
After 300 minutes of reaction 99.5 g of product (corresponding to a specific productivity of 47 g/h/l), having PO=1.88 and viscosity equal to 4700 cSt, are obtained. The NMR analysis indicates a structure similar to that of Example 1, with (p+n)/(q+m) ratio=1.27 e n/m=1.04 and molecular weight equal to 26700.
EXAMPLE 2A
(Comparative)
440 cc of dichlorodifluoromethane are introduced in the reactor of Example 1 at the temperature of -50° C. One operates with the same procedure as in Example 1, by feeding 18.0 Nl/h of oxygen and 9.0 Nl/h of tetrafluoroethylene for 300 minutes. 103.5 g of oil (corresponding to a specific productivity of 47 g/h/l), having PO=2.02 and viscosity equal to 1380 cSt are obtained. The NMR analysis indicates a structure similar to that of Example 1, with (p+n)/(q+m) ratio=1.07 e n/m=0.84 and molecular weight equal to 17300.
EXAMPLE 3
400 cc of hydropentafluoroethane are introduced in the reactor of Example 1 at the temperature of -50° C. One operates with the same procedure as in Example 1, by feeding 24.0 Nl/h of oxygen, 12.0 Nl/h of tetrafluoroethylene and 0.060 Nl/h of chlorine diluted in a stream of 2.4 Nl/h of nitrogen. After 300 minutes of reaction 144.4 g of product (corresponding to a specific productivity of 73 g/h/l), having PO=2.45 and viscosity equal to 2300 cSt, are obtained. The NMR analysis indicates a structure similar to that of Example 1, with (p+n)/(q+m) ratio=1.55 e n/m=1.21 and average molecular weight equal to 20700.
EXAMPLE 3A
(Comparative)
440 cc of dichlorodifluoromethane are introduced in the reactor of Example 1 at the temperature of -50° C. One operates with the same procedure as in Example 1, by feeding 24.0 Nl/h of oxygen and 12.0 Nl/h of tetrafluoroethylene for 300 minutes. 166 g of product (corresponding to a specific productivity of 76 g/h/l), having PO=2.65 and viscosity equal to 7160 cSt, are obtained. The NMR analysis indicates a structure similar to that of Example 1, with (p+n)/(q+m) ratio=1.44 e n/m=1.04 and average molecular weight equal to 31000.
EXAMPLE 4
430 cc of a 1:1 mixture by volume of perfluoropropane and R125 are introduced in the reactor of Example 1 at the temperature of -50° C., wherein 5.3 g of product obtained in Example 1, used as activator, were previously dissolved. One operates as in Example 1, by feeding 12.0 Nl/h of oxygen, 6.0 Nl/h of TFE and 0.021 Nl/h of chlorotrifluoroethylene diluted in a stream of 0.7 Nl/h of nitrogen. After 240 minutes of reaction 77.9 g of polymer (corresponding to a specific productivity of 45 g/h/l), having PO=2.57 and viscosity equal to 2500 cSt, are obtained. The NMR analysis indicates a structure similar to that of Example 1, with (p+n)/(q+m) ratio=1.69 e n/m=1.18 and average molecular weight equal to 21400.
EXAMPLE 4
(Comparative)
420 cc of R12 are introduced in the reactor of Example 1 at the temperature of -60° C., wherein 5.3 g of product obtained in example 1, used as activator, were previously dissolved. One operates as in Example 1, by feeding 12.0 Nl/h of oxygen and 6.0 Nl/h of TFE. After 240 minutes of reaction 76.9 g of polymer (corresponding to a specific productivity of 46 g/h/l), having PO=2.53 and viscosity equal to 2100 cSt, are obtained. The NMR analysis indicates a structure similar to that of example 1, with (p+n)/(q+m) ratio=1.65 e n/m=1.17 and average molecular weight equal to 20000.
EXAMPLE 5
430 cc of a 1:1 mixture by volume of perfluoropropane and R125 are introduced in the reactor of Example 1 at the temperature of -60° C., wherein 6.6 g of product obtained in Example 1, used as activator, were previously dissolved. One operates as in Example 1, by feeding 18.0 Nl/h of oxygen, 9.0 Nl/h of TFE and 0.021 Nl/h of chlorotrifluoroethylene diluted in a stream of 0.7 Nl/h of nitrogen. After 240 minutes of reaction 123.8 g of polymer (corresponding to a specific productivity of 72 g/h/l), having PO=3.48 and viscosity equal to 100000 cSt, are obtained. The NMR analysis indicates a structure similar to that of example 1, with (p+n)/(q+m) ratio=2.87 and n/m=1.73.
EXAMPLE 6
410 cc of a 20:80 mixture by volume respectively of perfluoropropane and R125 are introduced in the reactor of Example 1 at the temperature of -600° C., wherein 4.5 g of product obtained in Example 1, used as activator, were previously dissolved. One operates as in Example 1 by feeding 18.0 Nl/h of oxygen, 9.0 Nl/h of TFE and 0.030 Nl/h of chlorotrifluoroethylene diluted in a stream of 1.0 Nl/h of nitrogen. After 240 minutes of reaction 116.9 g of polymer (corresponding to a specific productivity of 71 g/h/l), having PO=3.21 and viscosity equal to 25000 cSt, are obtained. The NMR analysis indicates a structure similar to that of Example 1, with (p+n)/(q+m) ratio=2.49 and molecolar weight equal to 48000.
EXAMPLE 7
430 cc of a 20:80 mixture by volume respectively of perfluoropropane and R125 are introduced in the reactor of Example 1 at the temperature of -600° C., wherein 5.6 g of product obtained in Example 1, used as activator, were previously dissolved. One operates as in Example 1, by feeding 18.0 Nl/h of oxygen, 9.0 Nl/h of TFE and 0.030 Nl/h of chlorotrifluoroethylene diluted in a stream of 1.0 Nl/h of nitrogen. After 240 minutes of reaction 125.8 g of polymer (corresponding to a specific productivity of 73 g/h/l), having PO=3.75 and viscosity equal to 24000 cSt, are obtained. The NMR analysis indicates a structure similar to that of Example 1, with (p+n)/(q+m) ratio=3.50 and n/m=1.95 and molecolar weight equal to 47000.
EXAMPLE 7A
(Comparative)
430 cc of R12 are introduced in the reactor of Example 1 at the temperature of -60° C., wherein 6.0 g of product obtained in Example 1, used as activator, were previously dissolved. One operates as in Example 1, by feeding 18.0 Nl/h of oxygen, 9.0 Nl/h of TFE and 0.021 Nl/h of chlorotrifluoroethylene diluted in a stream of 0.7 Nl/h of nitrogen. After 240 minutes of reaction 125.5 g of polymer (corresponding to a specific productivity of 75 g/h/l), having PO=3.44 and viscosity equal to 5500 cSt, are obtained.
The NMR analysis shows a structure similar to that of Example 1, with (p+n)/(q+m) ratio=2.48 and n/m=1.65 and molecolar weight equal to 28000. | Tetrafluoroethylene oxidation process comprising the step of oxidizing tetrafluoroethylene in solution at temperatures between -80° C. and -50° C. in the presence of ultraviolet radiation, oxygen and perfluoroethane (125) as solvent to obtain peroxidic perfluoropolyethers. | 2 |
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