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RELATED APPLICATIONS
[0001] This application is a continuation application of copending U.S. patent application Ser. No. 15/004,783 filed on Jan. 22, 2016, which is a continuation application of U.S. patent application Ser. No. 14/821,599 filed on Aug. 7, 2015 and issued as U.S. Pat. No. 9,244,189 on Jan. 26, 2016, which is a continuation application of U.S. patent application Ser. No. 14/163,374 filed on Jan. 24, 2014 and issued as U.S. Pat. No. 9,133,703 on Sep. 15, 2015, which is a divisional application of U.S. patent application Ser. No. 12/816,250 filed on Jun. 15, 2010 and issued as U.S. Pat. No. 8,659,298 on Feb. 25, 2014, which is a continuation application of U.S. patent application Ser. No. 11/835,154 filed on Aug. 7, 2007 and issued as U.S. Pat. No. 7,775,301 on Aug. 17, 2010, the disclosures of which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] The present application is generally related to steering tools for horizontal directional drilling and, more particularly, to a system and method using supplemental magnetic information in a steering tool type arrangement.
[0003] A boring tool is well-known as a steerable drill head that can carry sensors, transmitters and associated electronics. The boring tool is usually controlled through a drill string that is extendable from a drill rig. The drill string is most often formed of drill pipe sections, which may be referred to hereinafter as drill rods, that are selectively attachable with one another for purposes of advancing and retracting the drill string. Steering is often accomplished using a beveled face on the drill head. Advancing the drill string while rotating should result in the drill head traveling straight forward, whereas advancing the drill string with the bevel oriented at some fixed angle will result in deflecting the drill head in some direction.
[0004] One approach that has been taken by the prior art for purposes of monitoring the progress of a boring tool in the field of horizontal directional drilling, resides in what is commonly referred to as a “steering tool”. This term has come to describe an overall system which essentially predicts the position of the boring tool, as it is advanced through the ground using a drill string, such that the boring tool can be steered toward a desired target or along a planned drill path within the ground. Steering tool systems are considered as being distinct from other types of locating systems used in horizontal directional drilling at least for the reason that the position of the boring tool is monitored in a step-wise fashion as it progresses through the ground. For this reason, positional error can accumulate with increasing progress through the ground up to unacceptable levels.
[0005] Generally, in a steering tool system, pitch and yaw angles of the drill-head are measured in coordination with extension of the drill string. From this, the drill-head position coordinates are obtained by numerical integration. Nominal or measured drill rod lengths can serve as a step size during integration. While this method appears to be sound and might enable an experienced driller to use the steering tool successfully, there are a number of concerns with respect to its operation, as will be discussed immediately hereinafter.
[0006] With respect to the aforementioned positional error, it is noted that this error can be attributed, at least in part, to pitch and yaw measurement errors that accumulate during integration. This can often result in large position errors after only a few hundred feet of drilling.
[0007] Another concern arises with respect to underground disturbances of the earth's magnetic field, which can cause significant yaw measurement bias errors, potentially leading to very inaccurate position estimates.
[0008] Still another concern arises to the extent that steering effectiveness of a typical HDD drill bit depends on many factors including drill bit design, mud flow rate and soil conditions. For example, attempting to steer in wet and sandy soil with the tool in the 12 o'clock roll position might become so ineffective that measured pitch does not provide correct vertical position changes. That is, the orientation of drill head, under such drilling conditions, does not necessarily reflect the direction of its travel.
[0009] One approach in dealing with the potential inaccuracy of the steering tool system is to confirm the position of the drill head independently. For example, the drill head can be fitted with a dipole transmitter. A walk over locator can then be used to receive the dipole field and independently locate the drill head. This approach is not always practical, for example, when drilling under a river, lake or freeway. In these situations, the operator might notice position errors too late during drilling and consequently might not have an opportunity to implement a drill-path correction.
[0010] The foregoing examples of the related art and limitations related therewith are intended to be illustrative and not exclusive. Other limitations of the related art will become apparent to those of skill in the art upon a reading of the specification and a study of the drawings.
SUMMARY
[0011] The following embodiments and aspects thereof are described and illustrated in conjunction with systems, tools and methods which are meant to be exemplary and illustrative, not limiting in scope. In various embodiments, one or more of the above-described problems have been reduced or eliminated, while other embodiments are directed to other improvements.
[0012] In general, a system and associated method are described in which a steering tool is movable by a drill string and steerable in a way that is intended to form an underground bore along an intended path, beginning from a starting position.
[0013] In one aspect, a sensing arrangement, forming one part of the steering tool, detects a pitch orientation and a yaw orientation of the steering tool at a series of spaced apart positions of the steering tool along the underground bore, each of which spaced apart positions is characterized by a measured extension of the drill string. At least one marker is positioned proximate to the intended path, for transmitting a rotating dipole field such that at least a portion of the intended path is exposed to the rotating dipole field. A receiver, forming another part of the steering tool, receives the rotating dipole field with the steering tool at a current one of the spaced apart positions to produce magnetic information. A processor is configured for using the detected pitch orientation, the detected yaw orientation and the measured extension of the drill string in conjunction with the magnetic information, corresponding to the current one of the positions of the steering tool, to determine a current location of the steering tool, relative to the starting position, with a given accuracy such that using only the detected pitch orientation, the detected yaw orientation and the measured extension of the drill string to determine the current position, without the magnetic information, would result in a reduced accuracy in the determination of the current location, as compared to the given accuracy.
[0014] In another aspect, a sensing arrangement is provided, forming one part of the steering tool, for detecting a pitch orientation and a yaw orientation of the steering tool. The steering tool is moved sequentially through a series of spaced apart positions along the underground bore. Each of the spaced apart positions is characterized by a measured extension of the drill string. At least one marker is arranged, proximate to the intended path, for transmitting a rotating dipole field such that at least a portion of the intended path is exposed to the rotating magnetic dipole. The dipole field is received using a receiver that forms another part of the steering tool, with the steering tool at a current one of the spaced apart positions on the portion of the intended path, to produce magnetic information. A processor is configured for using the detected pitch orientation, the detected yaw orientation and the measured extension of the drill string in conjunction with the magnetic information, corresponding to the current one of the positions of the steering tool, to determine a current location of the steering tool relative to the starting position with a given accuracy such that using only the detected pitch orientation, the detected yaw orientation and the measured extension of the drill string to determine the current location, without the magnetic information, results in a reduced accuracy in the determination of the current location, as compared to the given accuracy.
[0015] In still another aspect, a sensing arrangement is provided, forming one part of the steering tool, for detecting a pitch orientation and a yaw orientation of the steering tool. The steering tool is moved sequentially through a series of spaced apart positions to form the underground bore. Each of the spaced apart positions is characterized by a measured extension of the drill string, a detected pitch orientation and a detected yaw orientation. At least one portion of the intended path is identified along which an enhanced accuracy of a determination of the current location of the steering tool is desired. One or more markers is arranged proximate to the portion of the intended path, each of which transmits a rotating dipole field such that at least the portion of the intended path is exposed to one or more rotating dipole fields. A receiver is provided, as part of the steering tool, for generating magnetic information responsive to the rotating dipole fields. A processor is configured for operating in a first mode using the detected pitch orientation, the detected yaw orientation and the measured extension of the drill string to determine a current location of the steering tool corresponding to any given one of the spaced apart positions with at least a given accuracy and for defaulting to a second mode using the detected pitch orientation, the detected yaw orientation, the measured extension of the drill string and the magnetic information, when the magnetic information is received, to determine the current location of the steering tool with an enhanced accuracy that is greater than the given accuracy.
[0016] In yet another aspect, a method for establishing a customized accuracy in determination of a position of the steering tool with respect to the intended path is described. A sensing arrangement, forming one part of the steering tool, detects a pitch orientation and a yaw orientation of the steering tool. The steering tool is moved sequentially through a series of spaced apart positions to form the underground bore. Each of the spaced apart positions is characterized by a measured extension of the drill string, a detected pitch orientation and a detected yaw orientation. One or more portions of the intended path are identified along which an enhanced accuracy of the determination of the current location of the steering tool is desired. One or more markers are arranged proximate to each one of the portions of the intended path where each of the markers transmits a rotating dipole field such that each one of the identified portions of the intended path is exposed to one or more rotating dipole fields. As a result of the transmission range of the rotating dipole field, more than just those portions of the intended path may be exposed to the rotating dipole field(s). A receiver is provided, as part of the steering tool, for generating magnetic information responsive to the rotating dipole fields. A processor is configured for operating in a first mode using the detected pitch orientation, the detected yaw orientation and the measured extension of the drill string to determine a current location of the steering tool corresponding to any given one of the spaced apart positions with at least a given accuracy and for operating in a second mode using the detected pitch orientation, the detected yaw orientation, the measured extension of the drill string and the magnetic information to determine the current location of the steering tool with an enhanced accuracy that is greater than the given accuracy, at least for the one or more portions of the intended path, to customize an overall position determination accuracy along the intended path.
[0017] In addition to the exemplary aspects and embodiments described above, further aspects and embodiments will become apparent by reference to the drawings and by study of the following descriptions.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] Exemplary embodiments are illustrated in referenced figures of the drawings. It is intended that the embodiments and figures disclosed herein are to be illustrative rather than limiting.
[0019] FIG. 1 is a diagrammatic view, in elevation, of a system according to the present disclosure operating in a region.
[0020] FIG. 2 is a diagrammatic plan view of the system of FIG. 1 in the region.
[0021] FIG. 3 a is a block diagram which illustrates one embodiment of a steering tool that is useful in the system of FIGS. 1 and 2 .
[0022] FIG. 3 b is a diagrammatic view, in perspective, of a marker that is useful in the system of FIGS. 1 and 2 .
[0023] FIG. 3 c shows a coordinate system in which pitch and yaw are illustrated.
[0024] FIGS. 4 and 5 illustrate one embodiment of a setup technique that can be used in conjunction with the system of FIGS. 1 and 2 .
[0025] FIG. 6 is a diagrammatic view, in elevation, of a drill path along which the steering tool is disposed, shown here to illustrate one embodiment of a technique for providing an initial solution estimate for the position of the steering tool.
[0026] FIG. 7 a is a diagrammatic, further enlarged view, of a portion of FIG. 6 , shown here to illustrate further details of the initial solution estimate technique.
[0027] FIG. 7 b is a flow diagram which illustrates one possible embodiment of a technique for determining the position of the steering tool using a Kalman filter.
[0028] FIG. 8 is a plot of random distance error versus distance.
[0029] FIGS. 9 a and 9 b are plots of pitch angle and yaw angle, respectively, versus drill string length for use in a detailed simulation.
[0030] FIG. 10 a is a plot in a simulation of estimated Y (lateral) steering tool position with respect to X position, employing a basic steering tool without the use of markers.
[0031] FIG. 10 b is a plot in the simulation of estimated Z (elevational) steering tool position with respect to X position, employing a basic steering tool without the use of markers.
[0032] FIG. 10 c is a plot, for the simulation of FIGS. 10 a and 10 b, of steering tool coordinate position error versus X position, which illustrates positional errors for the X, Y and Z axes without the use of markers.
[0033] FIG. 11 a is a plot in a simulation of estimated Y (lateral) steering tool position with respect to X position, employing a steering tool in conjunction with one marker.
[0034] FIG. 11 b is a plot in the simulation of estimated Z (elevational) steering tool position with respect to X position, employing the steering tool in conjunction with one marker.
[0035] FIG. 11 c is a plot, for the simulation of FIGS. 11 a and 11 b, of steering tool coordinate position error versus X position, which illustrates positional errors for the X, Y and Z axes with the use of one marker.
[0036] FIG. 12 a is a plot in a simulation of estimated Y (lateral) steering tool position with respect to X position, employing a steering tool in conjunction with two markers.
[0037] FIG. 12 b is a plot in the simulation of estimated Z (elevational) steering tool position with respect to X position, employing the steering tool in conjunction with two markers.
[0038] FIG. 12 c is a plot, for the simulation of FIGS. 12 a and 12 b , of steering tool coordinate position error versus X position, which illustrates positional errors for the X, Y and Z axes with the use of two markers.
[0039] FIG. 13 a is a plot in a simulation of estimated Y (lateral) steering tool position with respect to X position, employing a steering tool in conjunction with three markers.
[0040] FIG. 13 b is a plot in the simulation of estimated Z (elevational) steering tool position with respect to X position, employing the steering tool in conjunction with three markers.
[0041] FIG. 13 c is a plot, for the simulation of FIGS. 13 a and 13 b , of steering tool coordinate position error versus X position, which illustrates positional errors for the X, Y and Z axes with the use of three markers.
[0042] FIGS. 14 a - c are plots of position error estimates, available through the Kalman filter analysis, versus the X axis and directly compared with position error plots show in FIG. 13 c for the drill path of FIGS. 13 a and 13 b
[0043] FIG. 15 is a diagrammatic plan view of a drilling region for a concluding portion of an intended drill path, shown here to illustrate various aspects of arranging and moving markers along the drill path.
[0044] FIG. 16 is a diagrammatic plan view of the drilling region and drill path of FIG. 16 , shown her to illustrate further aspects with respect to arranging and moving markers along the drill path.
DETAILED DESCRIPTION
[0045] The following description is presented to enable one of ordinary skill in the art to make and use the invention and is provided in the context of a patent application and its requirements. Various modifications to the described embodiments will be readily apparent to those skilled in the art and the generic principles taught herein may be applied to other embodiments. Thus, the present invention is not intended to be limited to the embodiment shown, but is to be accorded the widest scope consistent with the principles and features described herein, including modifications and equivalents, as defined within the scope of the appended claims. It is noted that the drawings are not to scale and are diagrammatic in nature in a way that is thought to best illustrate features of interest. Descriptive terminology such as, for example, upper/lower, right/left, front/rear top/bottom, underside and the like has been adopted for purposes of enhancing the reader's understanding, with respect to the various views provided in the figures, and is in no way intended as being limiting.
[0046] Turning now to the figures, wherein like components are designated by like reference numbers whenever practical, attention is immediately directed to FIGS. 1 and 2 , which illustrate an advanced steering tool system that is generally indicated by the reference number 10 and produced according to the present disclosure. FIG. 1 is a diagrammatic elevation view of the system, whereas FIG. 2 is a diagrammatic plan view of the system. System 10 includes a drill rig 18 having a carriage 20 received for movement along the length of an opposing pair of rails 22 which are, in turn, mounted on a frame 24 . A conventional arrangement (not shown) is provided for moving carriage 20 along rails 22 . A steering tool 26 includes an asymmetric face 28 and is attached to a drill string 30 which is composed of a plurality of drill pipe sections 32 . An intended path 40 of the steering tool includes positions that are designated as k and k+1. The steering tool is advanced from position k to k+1 by either a full or a fraction rod length. If very short drill pipe sections are used, the distance between positions k and k+1 could be greater than a rod length. By way of example, drill pipe sections have a rod length of two feet would be considered as very short. The steering tool is shown as having already passed through points 1 and 2 , where point 1 is the location at which the steering tool enters the ground at 42 , serving as the origin of the master coordinate system. While a Cartesian coordinate system is used as the basis for the master coordinate systems employed by the various embodiments disclosed herein, it is to be understood that this terminology is used in the specification and claims for descriptive purposes and that any suitable coordinate system may be used.
[0047] An x axis 44 extends from entry point 42 to a target location T that is on the intended path of the steering tool, as seen in FIG. 1 and illustrated as a rectangle, while a y axis 46 extends to the left when facing in the forward direction along the x axis, as seen in FIG. 2 . A z axis 48 extends upward, as seen in FIG. 1 . Further descriptions will be provided at an appropriate point below with respect to establishing this coordinate system.
[0048] As the drilling operation proceeds, respective drill pipe sections, which may be referred to interchangeably as drill rods, are added to the drill string at the drill rig. For example, a most recently added drill rod 32 a is shown on the drill rig in FIG. 2 . An upper end 50 of drill rod 32 a is held by a locking arrangement (not shown) which forms part of carriage 20 such that movement of the carriage in the direction indicated by an arrow 52 causes section 32 a to move therewith, which pushes the drill string into the ground thereby advancing the boring operation. A clamping arrangement 54 is used to facilitate the addition of drill pipe sections to the drill string. The drilling operation is controlled by an operator (not shown) at a control console 60 which itself can include a telemetry section 62 connected with a telemetry antenna 64 , a display screen 66 , an input device such as a keyboard 68 , a processor 70 , and a plurality of control levers 72 which, for example, control movement of carriage 20 .
[0049] Turning now to FIG. 3 a, an electromechanical block diagram is shown, illustrating one embodiment of steering tool 26 that is configured in accordance with the present disclosure. Steering tool 26 includes a slotted non-magnetic drill tool housing 100 . A triaxial magnetic field sensing arrangement 102 is positioned in housing 100 . For this purpose, a triaxial magnetometer or coil arrangement may be used depending on considerations such as, for example, space and accuracy. A triaxial accelerometer 104 is also located in the housing. Outputs from magnetic field sensing arrangement 102 and accelerometer 104 are provided to a processing section 106 having a microprocessor at least for use in determining a pitch orientation and a yaw heading of the steering tool. A dipole antenna and associated transmitter 108 are optionally located in the steering tool which can be used, responsive to the processing section, for telemetry purposes, for transferring encoded data such as roll, pitch, magnetometer readings and accelerometer readings to above ground locations such as, for example, telemetry receiver 62 ( FIG. 1 ) of console 60 via a dipole electromagnetic field 110 and for locating determinations such as, for example, determining a distance to the steering tool. For such locating determinations, dipole electromagnetic field 110 can be used in conjunction with a walkover locator, although this is not a requirement and is not practical in some cases, as discussed above. Generally, the dipole axis of the dipole antenna is oriented coaxially with an elongation axis of the steering tool in a manner which is well-known in the art. Of course, all of these functions are readily supported by processing section 106 , which reads appropriate inputs from the magnetometer and accelerometer, performs any necessary processing and then performs the actual encoding of information that is to be transmitted.
[0050] In another embodiment, processing section 106 is configured for communication with processor 70 ( FIG. 1 ) of console 60 using a wire-in-pipe approach wherein a conductor is provided in drill string 30 for transferring information above ground as described, for example, in commonly owned U.S. Pat. No. 6,223,826 entitled AUTO-EXTENDING/RETRACTING ELECTRICALLY ISOLATED CONDUCTORS IN A SEGMENTED DRILL STRING, which is incorporated by reference in its entirety. The conductor in the drill string is in electrical communication with a line 112 that is in electrical communication with processing section 106 . It is noted that this approach may also be used to provide power to a power supply 114 from above ground, as an alternative or supplemental to the use of batteries.
[0051] Still referring to FIG. 3 a , regulated power supply 114 , which may be powered using batteries or through the aforedescribed wire-in-pipe arrangement, provides appropriate power to all of the components in the steering tool, as shown. It is noted that magnetic field sensor 102 can be used to measure the field generated by a rotating magnet as well as measuring the Earth's magnetic field. The later may be thought of as a constant, much like a DC component of an electrical signal. In this instance, the Earth's magnetic field may be used advantageously to determine a yaw heading.
[0052] Referring again to FIGS. 1 and 2 , system 10 is illustrated having three markers 140 a - c, each of which includes a rotating magnet for generating a rotating dipole field. Markers 140 a and 140 b are arranged along a line that is generally orthogonal to the X axis, while marker 140 c is offset toward drill rig 18 . A rotating dipole field can be generated either by a rotating magnet or by electromagnetic coils. Throughout this disclosure, the discussion may be framed in terms of a rotating magnet, but the described applications of magnets carry over to coils and wire loops with only minor modifications. As will be described in further detail, markers can be placed along the drill-path so that they are at least generally close to the target or other points of interest where high positioning accuracy is required, although one or two markers may provide sufficient accuracy for many drilling applications. That is, the marker signal should be receivable by the steering tool along a portion of the intended path including the target or other point(s) of interest. Aside from this consideration, the position of each marker can be arbitrary. Markers can be placed on the ground, on an elevated structure or even lowered within the ground. In each case, the marker can be at an arbitrary angular orientation. The rotation frequency (revolutions per second) of each magnet can be on the order of 1 Hz, but dipole field frequencies should be distinguishable if more than one marker/magnet is in use. A frequency difference of at least 0.5 Hz is considered to be acceptable for this purpose. Each magnet emits a rotating magnetic dipole field whose total flux is recorded by the steering tool magnetometer and subsequently converted to distance between magnet and tool. During rotation, the magnet of each marker emits a time dependent magnetic dipole field that is measured by the tri-axial magnetometer of the steering tool. As will be seen, a minimum value of the recorded total flux provides a distance between each marker and the steering tool.
[0053] Turning now to FIG. 3 b, one embodiment of marker 140 is diagrammatically illustrated. It is noted that aforedescribed markers 140 a - c may be of this design as well as any additional markers used hereinafter. In this embodiment, each marker 140 can include a drive motor 142 having an output shaft 144 which directly spins a magnet 146 having a north pole, which is visible. Motor 142 is electrically driven by a motor controller 148 to provide stable rotation of the magnet. The motor can rotate the magnet slowly, for example, at about 1 revolution per second (1 Hz), as indicated by arrow 150 , thereby emitting a rotating magnetic dipole field 152 (only partially shown). It should be appreciated that a relatively wide range of rotational speeds may be employed, for example, from approximately 0.5 Hz to 600 Hz. In one embodiment, a proportional-integral-derivative (PID) controller can be used to drive motor 142 with user selectable rotational velocity. It is noted that such PIDs are commercially available. A benefit associated with using lower rotational velocity resides in a decreased influence by local magnetic objects such as, for example, rebar. If a higher rotational velocity is desired loop antennas can be used to create the rotational field. Further, the rotational velocity can be varied so that the fields from various markers are distinguishable when simultaneously rotating. A suitable power supply can be used, as will be recognized by one having ordinary skill in the art, such as for example a battery and voltage regulator, which have not been shown. It should be appreciated that there is no need for an encoder, since the specific angle of the magnet, corresponding to a particular measurement position, is not involved in making the determinations that are described below. Further, orientation sensors and a telemetry section in marker 140 are not needed. As will be seen, variation in rotation rate of magnet 146 will introduce associated positional error. Hence, a desire to increase measurement accuracy is associated with increasing the rotational stability of magnet 146 .
[0054] Still referring to FIG. 3 b, while the axis of rotation of magnet 146 is illustrated as being vertical, this is not a requirement. The axis of rotation can be horizontal or at some arbitrary tilted orientation. Moreover, positioning of the marker for field use does not require orienting the marker in any particular way. This remarkable degree of flexibility and ease of positioning these markers is one of the benefits of the system and method taught herein.
[0055] Most conventional applications of the steering tool function rely on a nominal value for drill rod length when integrating pitch and yaw to determine position. In accordance with the present disclosure, however, pitch and yaw can be measured more than once along each drill rod such that the distance between successive steering tool measurement positions can be less than the nominal length of one drill rod. This is particularly the case when the length of the drill rod is exceptionally long such as, for example, thirty feet. For this purpose, a laser distance meter, a potentiometer, an ultrasonic arrangement or some other standard distance measurement device can be mounted on the drill rig. An ultrasonic arrangement will be described immediately hereinafter.
[0056] Referring again to FIGS. 1 and 2 , a drill string measuring arrangement includes a stationary ultrasonic transmitter 202 positioned on drill frame 18 and an ultrasonic receiver 204 with an air temperature sensor 206 ( FIG. 2 ) positioned on carriage 20 . It should be noted that the positions of the ultrasonic transmitter and receiver may be interchanged with no effect on measurement capabilities. Transmitter 202 and receiver 204 are each coupled to processor 70 or a separate dedicated processor (not shown). In a manner well known in the art, transmitter 202 emits an ultrasonic wave 208 that is picked up at receiver 204 such that the distance between the receiver and the transmitter may be determined to within a fraction of an inch by processor 70 using time delay and temperature measurements. By monitoring movements of carriage 20 , in which drill string 30 is either pushed into or pulled out of the ground, and clamping arrangement 54 , processor 70 can accurately track the length of drill string 30 throughout a drilling operation. While it is convenient to perform measurements in the context of the length of the drill rods, with measurement positions corresponding to the ends of the drill rods, it should be appreciated that this is not a requirement and the ultrasonic arrangement can provide the total length of the drill string at any given moment in time. Further, the length according to the number of drill rods multiplied by nominal rod length can be correlated to the length that is determined by ultrasonic measurement.
[0057] Referring to FIG. 1 , control console 60 , in this embodiment, serves as a base station to communicate with steering tool 26 , to monitor its power supply, to receive and process steering tool data and to send commands to the steering tool, if so desired. Determined drill-path positions and estimated position errors can be displayed on display screen 66 for monitoring by the system operator. This functionality may also be extended to a remote base station configuration, for example, by using telemetry section 64 to transmit information 210 to a remote base station 212 for display on a screen 214 .
Measured Quantities
[0058] The steering method requires measurement of the following variables:
[0059] Tool pitch and yaw angles φ,β
[0060] Distances D i between N M magnets and the steering tool (i=1, . . . N M )
[0061] Magnet positions (X M i ,Y M i ,Z M i ), (i=1, . . . N M )
[0062] Initial tool position (X 1 ,Y 1 ,Z 1 )
[0063] Rod length increments Δs k+1 (k=1,2,3, . . . )
[0064] Referring to FIGS. 1 and 2 , pitch and yaw are measured and magnet-to-tool distances are determined at a series of tool positions including the initial tool position. Point 1 , which is additionally denoted by the reference number 42 , designates the position of drill begin. The steering tool is currently located at a measurement position k and is intended to proceed to position k+1. These positions can correspond to the end points of a drill rod or to intermediate points along the length of each drill rod. As discussed above, intermediate points may be needed, for example, when an exceptionally long drill rod is used such as, for example, 30 feet. Higher accuracy will generally be provided through the use of relatively more measurement positions. In some cases, the drill rod length may be sufficiently short that the number of drill rods may provide a sufficiently accurate value as to the length of the drill string. The latter situation may also be characterized by drill rods having a tolerance in their average length that is reasonably close to a nominal value. In some embodiments, there may be no correspondence between the drill rod length and the measurement positions, for example, where a measurement system, such as is employed by system 10 , is capable of measuring and monitoring an overall length of the drill string. For purposes of simplicity of description, it will be assumed that the drill rod length is used in the remainder of this description to establish the measurement positions. It is noted that measurements at each measurement position may be performed on-the-fly while pushing and/or rotating the drill string; however, enhanced accuracy can be achieved by stopping movement of the steering tool at each of the measurement positions during the measurements. A rod length increment Δs k+1 is defined as the arc-length between tool measurement positions (X k ,Y k ,Z k ) and (X k+1 ,Y k+1 ,Z k+1 ). The setup of this coordinate system is described immediately hereinafter.
Set-Up of Steering System
[0065] Referring to FIG. 3 c, in conjunction with FIGS. 1 and 2 , the origin and directions of the X,Y,Z—coordinate system can be specified in relation to drill begin point 1 and target T. The location where drilling begins is a convenient choice for the origin and the direction from this position to the projection of the target onto a level plane through the origin defines the X-coordinate axis. The Z-coordinate axis is positive upward and the Y-coordinate axis completes a right-handed system. If desired, a different right-handed Cartesian coordinate system or any suitable coordinate system may be used. In the present example, the formulation constrains the X-axis to be level. As noted above, yaw orientation is designated as β measured from the X axis in a level X, Y plane, whereas pitch orientation is designated as φ measured vertically from the yawed tool position in the X, Y plane as represented by a dashed line in the X, Y plane. FIG. 3 c defines pitch and yaw as Euler angles that require a particular sequence of yaw and pitch rotations in order to rotate the steering tool from a hypothetical position along the X axis into its illustrated position.
Magnet Position Measurements
[0066] The use of an Electronic Distance Measurement device (EDM) is currently the quickest and most accurate method of defining the X-coordinate axis and measuring magnet position coordinates. However, using an EDM for this purpose requires the presence of a surveyor at the HDD job site, which may sometimes be difficult to arrange. Accordingly, any suitable method may be used.
[0067] As an alternative to an EDM, a laser distance measurement device can be used. Devices of this kind are commercially available with a maximum range of about 650 feet and a distance measurement accuracy of ⅛ of an inch; the Leica Disto™ laser distance meter is an example of such a device. The device is placed at the position of drill-begin and pointed at the target to obtain the distance between these two positions. For short range measurements, the device can be handheld, but for larger distances it should be fixedly mounted to focus reliably. When an EDM, laser distance measurement device or similar device is used to determine the magnet positions, the accuracy of the device itself can be used as the magnet position error in the context of the discussions below.
[0068] Referring to FIGS. 4 and 5 , one embodiment of a setup technique is illustrated. FIG. 4 illustrates a diagrammatic plan view of steering tool 26 positioned ahead of drill begin point 1 with target T arranged along the X axis and a marker M 1 that is offset from the X axis. The target is located at coordinates X t ,Y t ,Z t . FIG. 5 illustrates a diagrammatic elevational view of steering tool 26 positioned ahead of drill begin point 1 on a surface 230 of the ground. In one embodiment, a laser distance meter (LDM) can be used having a tilt sensor so that horizontal and vertical distances X t ,Z t to the target can either be calculated or are directly provided by the LDM. The relative position (ΔX, ΔY, ΔZ) between the target and a marker, M 1 , located near the target can also be measured using the LDM, with a measuring tape or in any other suitable manner. Marker position coordinates can be obtained by adding position increments to target coordinates, as follows:
[0000] X M1 =X t ×ΔX (1)
[0000] Y M1 =ΔY (2)
[0000] Z M1 =Z t +ΔZ (3)
[0069] The foregoing procedure can be repeated for any number of markers that are arranged proximate to the target.
[0070] In another embodiment, the position of each marker can be measured directly, for example using an EDM, with no need to measure the location of the target, so long as some other position has been provided that establishes the X axis from point 1 of drill begin. For example, a marker M 2 may be arranged along the X axis. As will be further described, location accuracy along the X axis can be customized based on the arrangement of markers therealong. The need for enhanced accuracy for some portion of the path of the steering tool can be established, for example, based on the presence of a known inground obstacle 232 .
Reference Yaw Angle
[0071] Continuing to refer to FIGS. 4 and 5 , a reference yaw angle β ref is defined as the yaw angle of the steering tool, measured by the steering tool, with its elongation axis aligned with the X-direction. In the present example, the reference yaw angle is measured as a compass orientation from magnetic north, based on the Earth's magnetic field. Since steering tool yaw has previously been defined as positive for a counterclockwise rotation the particular reference yaw angle β ref shown in FIG. 4 is negative. Accordingly, in order to measure yaw accurately without interference from the magnetic influence of the drill rig, the steering tool can be placed on a level ground a sufficient distance ahead of the drill; 30 feet is usually adequate. The elongation axis of the steering tool is at least approximately on or at least parallel to the X-axis. Yaw angle β m , measured as a compass heading during steering, is subsequently replaced by β=β m −β ref .
Steering Procedure Formulation
[0072] Nomenclature
[0073] c A =pitch and yaw error covariance matrix
[0074] C e =empirical coefficient
[0075] C M =magnet position error covariance matrix
[0076] D=distance between marker and steering tool
[0077] F=continuous state equations matrix
[0078] H=observation coefficient vector
[0079] N M =number of markers
[0080] P=error covariance matrix
[0081] Q=continuous process noise covariance parameter matrix
[0082] Q k =discrete process noise covariance matrix
[0083] R=observation covariance scalar
[0084] {right arrow over (r)}=vector of magnet position measurement error
[0085] s=arc-length along drill-rod axis
[0086] v D =distance measurement noise
[0087] v M =magnet position measurement noise
[0088] {right arrow over (x)}=state variables vector
[0089] X,Y,Z=global coordinates
[0090] X k ,Y k ,Z k =steering tool position coordinates
[0091] z=measurement scalar
[0092] β=yaw angle
[0093] δX,δY,δZ=position state variables
[0094] δX M ,δY M ,δZ M =magnet position increments δβ,δφ=yaw and pitch angle increments
[0095] Δs=rod length increment
[0096] φ=pitch angle
[0097] Φ k =discrete state equation transition matrix
[0098] σ=standard deviation
[0099] σ 2 =variance, square of standard deviation
Subscripts
[0100] bias=bias error
[0101] D=distance
[0102] ex=exact value
[0103] i=i-th magnet
[0104] k=k-th position on drill path
[0105] M=magnet
[0106] m=measured
[0107] ref=reference
[0108] 1=initial tool position (drill begin at k=1)
Superscripts
[0109]
(
)
.
=
d
d
s
[0110] ( ) − =indicates last available estimate
[0111] ( )′=transpose
[0112] ( )*=nominal drill path
[0113] {circle around ({right arrow over (x)})}=state variables vector estimate
Tracking Equations
[0114] The method is based on two types of equations, referred to as steering tool process equations and distance measurement equations. The former are a set of ordinary differential equations describing how tool position (X,Y,Z) changes along the drill-path as a function of measured pitch φ and yaw β and shown as equations 4.
[0000]
{
X
.
Y
.
Z
.
}
=
{
cos
φ
cos
β
cos
φ
sin
β
sin
φ
}
(
4
)
[0115] The over-dot indicates that derivatives of position coordinates are to be taken with respect to arc-length s along the axis of the drill rod. Pitch and yaw angles are illustrated in FIG. 3 c. Accordingly, the premise of a conventional steering tool resides in a numerical integration of equations 4 with respect to arc length s of the drill string. Unfortunately, as discussed above, this technique readily produces potentially serious positional errors in and by itself.
[0116] The aforementioned distance measurement equations are of the form:
[0000] D 2 =( X M −X ) 2 +( Y M −Y ) 2 +( Z M −Z ) 2 (5)
[0117] The distance measurement equations express distance D between the center of a rotating magnet of a marker and the center of tri-axial steering tool magnetometer 102 (see FIG. 1 ) in terms of tool position (X,Y,Z) and magnet position (X M ,Y M ,Z M ). Accordingly, N M of such equations can be written for a system, corresponding to the total number of markers.
[0118] The origin of the global X,Y,Z-coordinate system in which tool position will be tracked can be chosen to coincide with the location of drill begin (point 1 in FIGS. 1 and 2 ).
[0000] X 1 =0 Y 1 =0 Z 1 =0 (6)
[0119] Equations (4), (5) and (6) represent an initial value problem that can be solved for steering tool position coordinates.
Nonlinear Solution Procedures
[0120] The foregoing initial value problem can be solved using either a nonlinear solution procedure, such as the method of nonlinear least squares, the SIMPLEX method, or can be based on Kalman filtering. The latter will be discussed in detail beginning at an appropriate point below. Initially, however, an application of the SIMPLEX method will be described where the description is limited to the derivation of the nonlinear algebraic equations that are to be solved at each drill-path position. Details of the solver itself are well-known and considered as within the skill of one having ordinary skill in the art in view of this overall disclosure.
[0121] The present technique and other solution methods can replace the derivatives {dot over (X)},{dot over (Y)},Ż in equations (4) with finite differences that are here written as:
[0000]
X
.
=
X
k
+
1
-
X
k
Δ
s
k
+
1
(
7
)
Y
.
=
Y
k
+
1
-
Y
k
Δ
s
k
+
1
(
8
)
Z
.
=
Z
k
+
1
-
Z
k
Δ
s
k
+
1
(
9
)
[0122] Resulting algebraic equations read:
[0000] f 1 =X k+1 −X k −Δs k+1 cos φ k cos β k =0 (10)
[0000] f 2 =Y k+1 −Y k −Δs k+1 cos φ k sin β k =0 (11)
[0000] f 3 =Z k+1 −Z k −Δs k+1 sin φ k =0 (12)
[0123] The distance measurement equations (5) provide additional N M equations written as:
[0000] f 4 i =D k−1, i 2 −( X k+1 −X M i ) 2 −( Y k−1 −Y M i ) 2 −( Z k+1 −Z M i ) 2 =0 (13)
[0124] Starting with the known initial values (Equations 6) at drill begin, the coordinates of subsequent positions along the drill path can be obtained by solving the above set of nonlinear algebraic equations (10-13) for each new tool position. The coordinates of position k+1 are calculated iteratively beginning with some assumed initial solution estimate that is sufficiently close to the actual location to assure convergence to the correct position. One suitable estimate will be described immediately hereinafter.
[0125] Referring to FIGS. 6 and 7 a, the X,Z plane is illustrated with a drill path 240 formed therein and in a direction 242 using a plurality of drill rods 32 , at least some of which have been designated by reference numbers. FIG. 7 a is an enlarged view within a dashed circle 244 of FIG. 6 . An initial solution estimate is given by a point on what may be referred to as a nominal drill-path 246 that can be found by linear extrapolation of the previously predicted/last determined position to a predicted position 248 . The linear extrapolation is based on equations 4 and a given incremental movement Δs k+1 of the steering tool from a k th position where:
[0000]
{
X
k
+
1
*
Y
k
+
1
*
Z
k
+
1
*
}
=
{
X
k
Y
k
Z
k
}
+
Δ
s
k
+
1
{
cos
φ
k
cos
β
k
cos
φ
k
sin
β
k
sin
φ
k
}
(
14
)
[0126] Where predicted positions are indicated in equations 14 using an asterisk ( )*. It should be appreciated that the position of the steering tool is characterized as predicted or estimated since the location is not identified in an affirmative manner such as is the case, for example, when a walk-over locater is used. The use of a steering tool differs at least for the reason that the position of the steering tool is estimated or predicted based on its previous positions. Thus, the actual position of the steering tool, for a sufficiently long drill path, can be significantly different than the position that is determined by a steering tool technique, as a result of accumulating error, if this error is not managed appropriately.
[0127] Application of the SIMPLEX method requires definition of a function that is to be minimized during the solution procedure. An example of such a function that is suitable in the present application reads:
[0000]
F
=
∑
p
=
1
3
+
N
M
f
p
2
(
15
)
[0128] As noted above, it is considered that one having ordinary skill can conclude the solution procedure under SIMPLEX in view of the foregoing.
Kalman Filter Solution
[0129] In another embodiment, a method is described for solving the tracking equations employing Kalman filtering. The filter minimizes the position error caused by measurement uncertainties in a least square sense. The filter determines position coordinates as well as position error estimates.
[0130] The three tool position coordinates (X,Y,Z) are chosen as the main system parameters. Increments (δX,δY,δZ) of these parameters are referred to as state variables. The solution method can be characterized as a predictor-corrector technique. Assuming all drill-path variables are known at a last determined position and a drill string increment is known, the current or next-determined position on the drill path can be approximated by linear extrapolation, as described above with respect to FIGS. 6 and 7 a. This is the predictor step that gives a point on nominal drill path 246 . The Kalman filter, in turn, performs a corrector step in which state variables are calculated and added to the nominal drill path.
[0131] Initial tool position coordinates (X 1 ,Y 1 ,Z 1 ) are assumed and corresponding error variances (σ 2 X 1 ,σ 2 Y 1 ,σ 2 Z 1 ) are known. For example, at (X 1 ,Y 1 ,Z 1 ), which is the origin of the coordinate system, the error variances are zero. If (X 1 ,Y 1 ,Z 1 ) is not the origin, the error variances are based on the accuracy of measurement from the origin. The tracking procedure starts from this initial position and proceeds along the drill path, as follows:
[0132] As is illustrated in FIGS. 6 and 7 a, the last known drill path position (X k ,Y k ,Z k ) is extrapolated linearly to obtain an approximate or estimated tool position, previously introduced as nominal drill path position (X k+1 *, Y k+1 *, Z k+1 *).
[0133] The filter determines state variables (δX k+1 ,δY k+1 ,δZ k+1 ) and standard deviations of position error (σ X k+1 ,σ Y k+1 ,σ Z k+1 ).
[0134] State variables are added to the nominal drill path position to find the new tool position (X k+1 ,Y k+1 ,Z k+1 ).
[0000]
{
X
k
+
1
Y
k
+
1
Z
k
+
1
}
=
{
X
k
+
1
*
Y
k
+
1
*
Z
k
+
1
*
}
+
{
δ
X
k
+
1
δ
Y
k
+
1
δ
Z
k
+
1
}
(
16
)
Measurement Errors
[0135] The Kalman filter takes the following random measurement errors into account which must therefore be known before tracking begins.
[0136] Tool pitch and yaw angle errors σ φ , σ β
[0137] Distance error σ β
[0138] Magnet position errors (σ X M ,σ Y M ,σ Z M )
[0139] Initial tool position errors (σ X 1 ,σ Y 1 ,σ Z 1 )
[0140] Error values are empirical and depend on the type of instrumentation used. Note that the effect of drill rod length measuring error is not part of the analysis since arc-length along the axis of the drill rod is used as an independent variable.
[0141] Knowing initial tool position errors (σ X 1 ,σ Y 1 ,σ Z 1 ), the corresponding error covariance matrix P 1 is given as:
[0000]
P
1
=
[
σ
X
1
2
0
0
0
σ
Y
1
2
0
0
0
σ
Z
1
2
]
(
17
)
[0142] Adding the latter to equations (4) to (6) completes the formulation of the initial value problem to be solved by Kalman filtering.
Linearized Tracking Equations
[0143] In addition to various measured quantities that are summarized above, the Kalman filter solution uses input of the following parameters.
[0144] Φ k discrete state equation transition matrix
[0145] Q k discrete process noise covariance matrix
[0146] z measurement scalar
[0147] H observation coefficient vector
[0148] R observation error covariance scalar
[0149] The above parameters are derived by linearizing the steering tool process equations and distance measurement equations about the nominal drill path position. The resulting two sets of linear equations are the so-called state equations and the observation equations. They are summarized below.
[0150] The state variables are defined as position increments.
[0000] {right arrow over (x)} =(δ X,δY,δZ )′ (18a)
[0000] {right arrow over ({dot over (x)})} =(δ {dot over (X)},δ{dot over (Y)},δŻ )′ (18b)
[0151] The state equations governing state variables read
[0000] {right arrow over (x)} k+1 =Φ k {right arrow over (x)} k +Δs k+1 G k {right arrow over (u)} k (19)
[0152] Where Δs k+1 G k {right arrow over (u)} k represents pitch and yaw measurement noise. It is noted that, hereinafter, subscripts may be dropped for purposes of clarity. Accordingly:
[0000] Φ=I (20)
[0000] Q =cov((Δ s )( G{right arrow over (u)} ) (21)
[0000] and
[0000] {right arrow over (u)} =(δΦ,δβ)′ (22)
[0000]
G
=
[
-
sin
φ
cos
β
-
cos
φ
sin
β
-
sin
φ
sin
β
cos
φ
cos
β
cos
φ
0
]
(
23
)
[0153] The discrete noise covariance matrix Q k becomes:
[0000] c A = [ σ φ 2 0 0 σ β 2 ] ( 24 ) Q=c e (Δ s ) 2 Gc A G′ (25)
[0154] Note that the empirical coefficient c e has been added to equation (25) in order to account for pitch and yaw bias errors. It has unit value if pitch and yaw measurement errors are entirely random.
[0155] The observation equation of a rotating magnet reads:
[0000] z=H{right arrow over (x)}+v D +v M (27)
[0000] R =cov( v D +v M ) (28)
[0156] Where the term v D represents distance measurement noise and the term v M represents magnet position measurement noise. The term H will be described at an appropriate point below. The symbol z, seen in equation (27) is a difference between measured distance D and calculated distance D* from a marker to the nominal drill path position, given as:
[0000] z=D−D* (29)
[0000] D* 2 =( X*−X M ) 2 +( Y*−Y M ) 2 +( Z*−Z M ) 2 (30)
[0157] The first term H on the right hand side of equation (27) is the observation coefficient vector, written as:
[0000]
H
=
(
X
*
-
X
M
D
*
,
Y
*
-
Y
M
D
*
,
Z
*
-
Z
M
D
*
)
(
31
)
[0158] The following form of the observation covariance scalar R is used in the steering tool method:
[0000] R=σ 2 D +Hc M H′ (32)
[0000]
c
M
=
[
σ
X
M
2
0
0
0
σ
Y
M
2
0
0
0
σ
Z
M
2
]
(
33
)
Projection of State Variables and Estimation Errors
[0159] An estimate of the state vector at the next steering tool position k+1 is denoted by {circumflex over ({right arrow over (x)})} and its error covariance matrix is P − where the superscript ( ) − indicates the last available estimate. Before the filter is applied at the new tool position, set
[0000] {circumflex over ({right arrow over (x)})}={0} (34)
[0160] The error covariance matrix P k is projected to the new position using
[0000] P k+1 − =Φ k P k Φ k ′+Q k (35)
Kalman Filter Loop
[0161] The filter loop is executed once for each marker, resulting in a flexible arrangement that is able to process any number of markers in use by the steering tool system.
[0162] The classical, well documented version of the filter loop is chosen as a basis for the current steering tool embodiment. It consists of three steps:
[0163] Kalman gain:
[0000] K=P − H ′( HP − H′+R ) −1 (36)
[0164] State variables:
[0000] {circumflex over ({right arrow over (x)})}={circumflex over ({right arrow over (x)})} − +K ( z−H{circumflex over ({right arrow over (x)})} − ) (37)
[0165] Error covariance matrix:
[0000] P =( I−KH ) P − (38)
Position Coordinate Errors
[0166] Having completed the filter analysis at a new position, its coordinates are given by equation (16). Corresponding one-sigma position errors follow from:
[0000] σ X =√{square root over ( P 11 )} (39)
[0000] σ Y =√{square root over ( P 22 )} (40)
[0000] σ Z =√{square root over ( P 33 )} (41)
[0167] FIG. 7 b is a flow diagram, generally indicated by the reference number 260 , which illustrates one embodiment of a Kalman filter implementation according to the descriptions above. At 262 , the nominal position of the steering tool at k+1 is determined using equation 14. At 264 , the error covariance matrix is projected to position k+1 using equation 35. The state vector is initialized at 266 . Beginning with step 270 , a loop is entered using magnetic measurements associated with one marker. The distance D* between a point on the nominal drill path and the marker is determined per equation 30. The observation coefficient vector H in turn is calculated using equation 31. Equation 32 provides the observation covariance scalar R. At 272 , the Kalman filter is executed using equations 36-38. At 274 , a determination is made as to whether magnetic information is available that is associated with another marker. If so, execution returns to step 270 . If magnetic information from all markers has been processed, step 276 establishes the final coordinates of the current position of the steering tool based on equation 16 and can associate a position error estimate with these coordinates, based on equations 39-41.
Numerical Simulations
[0168] Several numerical simulations were performed to estimate positions of the steering tool assisted by up to three rotating magnets. In all cases the steering tool was tracked, moving along a drill-path defined by:
[0000] 0≦X ex ≦300 ft (42)
[0000] Y ex = 15 sin ( π 300 X ex ) ( 43 ) Z ex =−2 Y ex (44)
[0169] Note that drilling starts at the origin of the global coordinate system. The steering tool reaches a maximum depth of 30 feet and yaws to the side with a maximum lateral displacement of 15 feet before it reaches the target 300 feet out. The above coordinates are exactly known coordinates from which values for pitch, yaw and tool to magnet distances were derived.
[0170] Table 1 summarizes random and bias errors that were added to these exact values to generate “measured” data.
[0000]
TABLE 1
Errors for Generating “Measured” Simulation Data
Pitch Error
σ ø = 0.25 deg
φ bias = 0.25 deg
Yaw Error
σ β = 0.50 deg
β bias = 0.50 deg
Drill Rod Length Error
σ Δs = 0.01 ft
Distance Error
D bias = 0.02 ft
(See also, FIG. 8)
[0171] FIG. 8 sets forth random distance error σ D in feet, plotted against distance D in feet. It is noted that errors were chosen based on empirical measurements with specific pitch and yaw sensors as well as with rotating magnets. Table 2 summarizes the random errors used as input for the filter. Note that the rod length increment error is used only for generating measured data; it is not used by the filter.
[0000]
TABLE 2
Random Errors Used in Kalman Filter
Pitch Error
σ φ = 0.5 deg
Yaw Error
σ β = 1 deg
Distance Error
σ D (see FIG. 8)
Magnet Position Errors
σ X M = σ Y M = σ Z M = 0.02 ft
Initial Position Error
σ X 1 = σ Y 1 = σ Z 1 = 0
[0172] FIGS. 9 a and 9 b are plots against drill string length, in feet, which compare exact with “measured” pitch and yaw angles, respectively, used in all the simulations described below. Exact pitch and yaw values are shown by dotted lines, while measured pitch and yaw values are shown by solid lines. Increments between adjacent measurement positions along the drill-path were approximately three feet.
[0173] Estimated steering tool positions and position errors are illustrated by FIGS. 10 a - c, as an application of the basic steering tool function without the use of markers. It is noted that, in subsequent figures, an increasing number of magnets is added to the system to demonstrate the improvements that are provided through the use of markers. Illustrated position errors are shown as the differences between estimated and exact values. Since “measured” values for pitch and yaw contain bias as well as random components, lateral and vertical position errors are also biased. FIG. 10 a is a diagrammatic plan view of the estimated drill path, designated by the reference number 300 , whereas FIG. 10 b is an elevational view of the estimated drill path, designated by the reference number 302 . FIG. 10 c illustrates the X coordinate positional error as a solid line 310 , the Y coordinate positional error as a dashed line 312 and the Z coordinate positional error as a dotted line 314 . In the present example, without the use of magnets, it can be seen that there is a continuously accumulating Y coordinate error, which increases to about three feet upon reaching X=300 feet, the X axis coordinate of target T. The Z coordinate error is over one foot.
[0174] Referring collectively to FIGS. 11 a - c, simulations are now presented including the use of markers. One marker 320 is used at a location of X=300 ft, Y=−5 ft, and Z=5 ft. FIG. 11 a is a diagrammatic plan view of the estimated drill path, designated by the reference number 322 , whereas FIG. 11 b is an elevational view of the estimated drill path, designated by the reference number 324 . FIG. 11 c illustrates the X coordinate positional error as a solid line 326 , the Y coordinate positional error as a dashed line 328 , and the Z coordinate positional error as a dotted line 330 . In the present example, with the use of only one magnet near target T, it can be seen that the Y coordinate error is dramatically reduced to just over one foot upon reaching the target X coordinate at 300 feet.
[0175] Referring collectively to FIGS. 12 a - c , a second marker 340 is added at a location of X=305 ft, Y=0 ft and Z=5 ft. FIG. 12 a is a diagrammatic plan view of the estimated drill path, designated by the reference number 342 , whereas FIG. 12 b is an elevational view of the estimated drill path, designated by the reference number 344 . FIG. 12 c illustrates the X coordinate positional error as a solid line 346 , the Y coordinate positional error as a dashed line 348 , and the Z coordinate positional error as a dotted line 350 . In the present example, with the use of two magnets near target T, it can be seen that the Y coordinate error is still further reduced to a relatively small fraction of one foot upon reaching the target X coordinate at 300 feet. Moreover, the X and Z coordinate errors are likewise reduced to a small fraction of one foot upon reaching the target X coordinate at 300 feet.
[0176] Referring collectively to FIGS. 13 a - c , a third marker 360 is added at a location of X=300 ft, Y=5 ft and Z=5 ft. FIG. 13 a is a diagrammatic plan view of the estimated drill path, designated by the reference number 362 , whereas FIG. 13 b is an elevational view of the estimated drill path, designated by the reference number 364 . FIG. 12 c illustrates the X coordinate positional error as a solid line 366 , the Y coordinate positional error as a dashed line 368 , and the Z coordinate positional error as a dotted line 370 . In the present example, with the use of three magnets near target T, it can be seen that the X, Y and Z coordinate errors are reduced to a very small fraction of one foot upon reaching the target X coordinate at 300 feet. In view of the foregoing, the use of two or three markers proximate to a point of interest on the drill path (such as the target) enables a high precision guidance of the steering tool to a target at least 300 feet out from the point of drill begin, or enables high precision steering relative to some point of interest along the drill path at least 300 feet out.
[0177] It should be appreciated that, in the aforedescribed numerical simulations, errors defined as the difference between estimated and exact positions can be calculated, since exact drill-path coordinates are known. This type of error can not be calculated during actual drill-head tracking. Accordingly, a different type of error estimate is used for actual drilling. The Kalman filter analysis provides such an error estimate in the form of standard deviations of position coordinates. In this regard, FIGS. 14 a - c illustrate the two types of position errors for the drill-path of FIGS. 13 a - b with three markers placed near the target. The solid lines denote the +1 sigma position error provided by the Kalman filter analysis, whereas the dashed lines represent the corresponding −1 sigma errors. For comparison, the position errors of FIG. 13 c, defined as the difference between estimated and exact positions, are also shown in FIGS. 14 a - c . As seen, position errors expressed in terms of standard deviations vary smoothly along the drill-path since they are based on a statistical measure. In contrast, estimated positions and, hence, the errors shown as dotted lines in FIGS. 14 a - c are based on one set of partly random measurements resulting in an irregular distribution of position errors. Repeating the Kalman filter analysis with a different set of random measurements would produce different error distributions of this type. Numerical simulations were performed with c e =16.
[0178] Attention is now directed to FIGS. 15 and 16 for purposes of describing additional aspects of the present disclosure. FIG. 15 illustrates a plan view of a drilling region 400 having a concluding section of an intended drill path 402 defined therein. Further, a first inground obstacle 404 and a second inground obstacle 406 are shown in relation to intended path 402 . As can be seen, intended path 402 has been specifically designed to avoid inground obstacles 404 and 406 . Such path design can be based on any knowledge of inground features that should be avoided and can include a reliance on any suitable resource including but not limited to utility surveys, available design drawings and exploratory excavations. Moreover, inground obstacles 404 and 406 are intended to represent any type of feature within the ground that should be avoided.
[0179] Still referring to FIGS. 14 and 15 , an exemplary plurality of markers 140 a - e is distributed along intended path 402 such that markers 140 a and 140 b are in the vicinity of obstacle 404 , marker 104 c is in the vicinity of obstacle 406 , and markers 140 d and 140 e are in the vicinity of target T. It should be appreciated that orientation of the markers is arbitrary so long as the steering tool, on the intended path and proximate to some inground feature of interest, is capable of receiving at least the magnetic field that is emanated by the markers in its general vicinity. As seen above, with each marker that is added proximate to target T, there is a corresponding increase in steering tool accuracy. That is, the steering tool tracks the intended path with proportionally increasing accuracy. Placement of markers proximate to points of interest, as illustrated, likewise produces a corresponding increase in accuracy along any portion of the intended path that is exposed to the magnetic field that is emanated by that marker. In this way, an enhanced steering accuracy, of a selective degree, can be provided at any desired point or points along the intended path. Accordingly, a highly advantageous customized steering accuracy is provided along the intended path. In this regard, as discussed above, the described technique readily accommodates receiving signals from any number of markers at any given point along the intended path or receiving no marker signals for some portions of the path, such as might be the case at a point 410 midway between markers 140 c and 140 d of the present example.
[0180] Even though the present example illustrates the use of five markers, fewer markers may actually be necessary since the markers can be moved along the intended drill path responsive to the progression of the steering tool. For example, after the steering tool passes obstacle 404 , marker 140 a can be moved to the position of marker 140 c . At a suitable time, marker 140 b can be moved to the position of marker 140 d . Once the steering tool passes obstacle 406 , marker 140 a can then be moved to the illustrated position of marker 140 e . Accordingly, long drill runs can be made with as few as one or two markers.
[0181] Applicants consider that sweeping advantages are provided over the state-of-the-art with respect to steering tool systems and methods. While there are systems in the prior art that use rotating magnet signals, it should be apparent from the detailed descriptions above that providing the capability to use rotating magnet signals in the context of a steering tool system is neither trivial nor obvious. In this regard, Applicants are unaware of any prior art use of a rotating magnet signal in the context of a steering tool system and, particularly, with such flexibility and ease of use where the rotating magnet field markers can not only be arbitrarily placed, but arbitrarily oriented.
[0182] While a number of exemplary aspects and embodiments have been discussed above, those of skill in the art will recognize certain modifications, permutations, additions and sub-combinations thereof. It is therefore intended that the following appended claims and claims hereafter introduced are interpreted to include all such modifications, permutations, additions and sub-combinations as are within their true spirit and scope. | A steering tool is movable by a drill string to form an underground bore along an intended path. A sensing arrangement of the steering tool detects its pitch and yaw orientations at a series of spaced apart positions along the bore, each position is characterized by a measured extension of the drill string. The steering tool further includes a receiver. At least one marker is positioned proximate to the intended path, for transmitting a rotating dipole field to expose a portion of the intended path to the field for reception by the receiver. The detected pitch orientation, the detected yaw orientation and the measured extension of the drill string are used in conjunction with magnetic information from the receiver to locate the steering tool. The steering tool may automatically use the magnetic information when it is available. A customized overall position determination accuracy can be provided along the intended path. | 4 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The preferred embodiment of the present invention is related to a method for modifying a photomask layout, and more particularly, to a method for estimating the number of dissections of an edge on a photomask layout before performing OPC (optical proximity correction).
2. Description of the Prior Art
In a photolithographic stage, an optical proximity effect often occurs, which jeopardizes the performance of a semiconductor device when patterns on the mask are transferred onto the wafer surface. Optical proximity effect causes deviation of patterns transferred on the wafer. Such deviations are usually related to the characteristics of the patterns to be transferred, the topology of the wafer, the source of the light, and various process parameters.
Optical proximity correction is one of the methods to correct and compensate for the deviations caused by the optical proximity effect. The commercially available OPC software can correct the original photomask layout using a theoretical image, so as to obtain correctly exposed photomask image layouts on the wafers.
The key point of the OPC is the dissection of the edges on an original photomask layout. In the traditional process, the manufacturer chooses hot points on the original photomask layout, and empirically estimates the number of segments of an edge on the hot point. Then, operational parameters including the number of segments are sent to the OPC software to obtain a corrected photomask layout. The above-mentioned original photomask layout refers to the desired photomask layout on the wafer after the photolithographic step. The hot point refers to regions at which the optical proximity effect often occurs. The hot point may be, for example, at the pitch or the bridge.
Although selecting many hot points can generate a more precise corrected photomask layout, much time is wasted in calculating the unneeded hot points. If, however, a hot point is not selected by the manufacturer based on his experience, the corrected photomask layout generated by the OPC software may become rough.
Therefore, a rule for selecting hot points and estimating dissecting segments is needed to replace the selection procedure based on human experience.
SUMMARY OF THE INVENTION
It is one of the objectives of the present preferred embodiment to provide a method for selecting hot points and estimating dissecting segments before proceeding an OPC process.
According to a preferred embodiment of the present invention, a method for modifying a photomask layout comprises: providing a photomask layout having at least an edge with at least a first evaluation point and a second evaluation point on the edge; interpreting the photomask layout to generate an interpreted photomask layout, wherein the interpreted photomask layout comprises an interpreted edge pattern, and the interpreted edge pattern has a third evaluation point corresponding to the first evaluation point and a fourth evaluation point corresponding to the second evaluation point; measuring a distance between the first evaluation point and the third evaluation point to obtain a first shift; measuring a distance between the second evaluation point and the fourth evaluation point to obtain a second shift; calculating a shift gradient between the first shift and the second shift; and determining the number of segment(s) between the first evaluation point and the second evaluation point.
According to another preferred embodiment of the present invention, a method for modifying a photomask layout comprises: providing a photomask layout having at least an edge with a plurality of evaluation points on the edge; interpreting the photomask layout to generate an interpreted photomask layout and an interpreted edge pattern, wherein the interpreted edge pattern is the edge after interpretation; measuring a shift disposed between the edge and the interpreted edge pattern and corresponding to each evaluation point; calculating a shift gradient between two adjacent evaluation points; and estimating the number of segment(s) between two adjacent evaluation points.
These and other objectives of the present preferred embodiment will no doubt become obvious to those of ordinary skill in the art after reading the following detailed description of the preferred embodiment that is illustrated in the various figures and drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 depicts a schematic diagram illustrating an original photomask layout according to a preferred embodiment of the present invention.
FIG. 2 depicts a schematic diagram illustrating a corrected photomask layout obtained by performing OPC on the original photomask layout.
FIG. 3 depicts the normalized light intensity distribution vs. an X position of the original photomask layout and of the corrected photomask layout.
FIG. 4 a depicts an original photomask layout and the interpreted photomask layout.
FIG. 4 b depicts a magnified localized region of FIG. 4 a.
FIG. 5 is a table illustrating results of the shift gradient.
FIG. 6 shows a flow chart of a method for modifying a photomask layout according to a preferred embodiment of the present invention.
DETAILED DESCRIPTION
FIG. 1 depicts a schematic diagram illustrating an original photomask layout according to a preferred embodiment of the present invention. FIG. 2 depicts a schematic diagram illustrating a corrected photomask layout obtained by performing OPC on the original photomask layout. FIG. 3 depicts the normalized light intensity distribution vs. an X position of the original photomask layout and of the corrected photomask layout.
As shown in FIG. 1 and FIG. 2 , an original photomask layout 10 and a corrected photomask layout 20 are depicted in FIG. 1 and FIG. 2 , respectively. The corrected photomask layout 20 is generated by performing OPC on the original photomask layout 10 .
First, the original photomask layout 10 is interpreted to obtain an interpreted contour of the original photomask layout 10 by utilizing simulation software with an operational parameter as 193 nm light source. A corrected photomask layout 20 is interpreted to obtain an interpreted contour of the corrected photomask layout 20 by utilizing the simulation software with an operational parameter as 248 nm light source. The interpreted contour of the original photomask layout 10 refers to the contour actually transferred onto a wafer after a photolithographic process. The interpreted contour of the corrected photomask layout 20 refers to the contour actually transferred onto a wafer after the photolithographic process.
Then, according to the interpreted contours of the original photomask layout 10 and the corrected photomask layout 20 , the light intensity distributions of the interpreted contours of the original photomask layout 10 and the corrected photomask layout 20 are obtained, as is shown in FIG. 3 .
The light intensity distribution of the interpreted contour of the original photomask layout 10 using a 193 nm light source and the light intensity distribution of the interpreted contour of the corrected photomask layout 20 using a 248 nm light source have similar tendencies.
That is, the interpreted contour of the original photomask layout 10 generated by using a 193 nm light source is similar to the interpreted contour of the corrected photomask layout 20 generated by using a 248 nm light source. Therefore, the interpreted contour of the original photomask layout 10 illuminated by the 193 nm light source can represent the major features of the interpreted contour of the corrected photomask layout 20 illuminated by the 248 nm light source. For example, hot points on the original photomask layout 10 can represent that the corresponding region of the corrected photomask layout 20 also has hot points.
Accordingly, for a lithographic process using a 248 nm light source, an interpreted contour of a corrected photomask layout can be approximately represented by an interpreted contour of an original photomask layout generated by using a 193 nm light source.
In this way, for a lithography process using a 248 nm light source, locations of hot points can be determined according to the interpreted contour of the original photomask layout using a 193 nm light source, before running OPC.
Although only 193 nm and 248 nm wavelength are described in the above, wavelengths other than 193 nm and 248 nm can be used in the present invention. Generally, before running OPC, the wavelength (193 nm in the above example) used to interpreting the original photomask is shorter than the wavelength (248 nm in the above example) used to exposing the wafer in the later lithographic process.
A method for modifying a photomask layout is described in the following.
In the following preferred embodiment, a 193 nm light source is used. FIG. 4 a depicts an original photomask layout and the interpreted photomask layout of the original photomask layout. FIG. 4 b depicts a magnified localized region of FIG. 4 a . FIG. 5 is a table illustrating results of the shift gradient.
As shown in FIG. 4 a and FIG. 4 b , an original photomask layout 30 is provided. The original photomask layout 30 is the desired photomask layout on the wafer after a lithographic process. Please refer to FIG. 4 b . A plurality of evaluation points is disposed on the original photomask layout 30 . For example, five evaluation points such as 1 , 2 , 3 , 4 and 5 are disposed on an edge L. There are other evaluation points disposed on other regions of the original photomask layout 30 as well, which are omitted for brevity. Then, as shown in FIG. 4 a , an interpreted photomask layout 40 (shown in sloping lines) is generated by interpreting the original photomask layout 30 . The interpreted photomask layout 40 represents the layout transferred to a wafer by using the original photomask layout 30 as a mask after the photolithographic process. The interpretation of the original photomask layout 30 is performed by inputting simulation parameters such as wavelength of the light source (193 nm for this embodiment), the numerical aperture, and the shape of the light source into commercial simulation software. Then, the interpreted photomask layout 40 of the original photomask layout 30 can be generated.
As shown in FIG. 4 b , an interpreted edge pattern L′ is also generated after the edge L is interpreted with the original photomask layout 30 . A plurality of evaluation points such as evaluation points 1 ′, 2 ′, 3 ′, 4 ′, 5 ′ are disposed on the interpreted edge pattern L′ and the evaluation points 1 ′, 2 ′, 3 ′, 4 ′, 5 ′ correspond to the evaluation points 1 , 2 , 3 , 4 , 5 , respectively. The evaluation points 1 and 1 ′ are at the same Y position. The evaluation points 2 and 2 ′, 3 and 3 ′, 4 and 4 ′, 5 and 5 ′ are at the same Y position respectively. According to another preferred embodiment, the evaluation points can be at the same X position. The number of evaluation points on an edge should be greater than 2.
The shortest possible distance between evaluation points 1 and 1 ′, 2 and 2 ′, 3 and 3 ′, 4 and 4 ′, 5 and 5 ′ is measured. The shortest distance between evaluation points 1 and 1 ′, 2 and 2 ′, 3 and 3 ′, 4 and 4 ′, 5 and 5 ′ represent shifts between the edge L and the interpreted edge pattern L′ and corresponds to evaluation points 1 , 2 , 3 , 4 , 5 , respectively. Then, a first shift S 5 , a second shift S 2 , a third shift S 3 , a fourth shift S 4 , and a fifth shift S 5 can be obtained after the above mentioned measurement. A shift gradient of adjacent evaluation point is then calculated. The shift gradient is a change between the shifts of two adjacent evaluation points per unit distance. More specifically, the shift gradient is calculated by using the following equation (1).
Δ S n,n+1 =( S n −S n+1 )÷ h n,n+1 (1)
wherein n is the number of evaluation points, n=1,2,3,4. . . (number of evaluation points−1), S n,n+1 is the shift gradient between the evaluation points n and n+1, S n is the n th shift, and h is the distance between two adjacent evaluation points on the edge L (for example, h 1,2 is the distance between evaluation points 1 and 2 ; h 2,3 is the distance between the evaluation points 2 and 3 ).
Please refer to FIG. 5 . The results of the shifts and shift gradients are illustrated in FIG. 5 . The first shift S 1 corresponding to evaluation point 1 is 8.23, the second shift S 2 corresponding to evaluation point 2 is 4.1, the third shift S 3 corresponding to evaluation point 3 is 3.06, the fourth shift S 4 corresponding to evaluation point 4 is 2.1, and the fifth shift S 5 corresponding to evaluation point 5 is 3.1. The shift gradient between evaluation point 1 and 2 is 4.1, the shift gradient between evaluation point 2 and 3 is 1.07, the shift gradient between evaluation point 3 and 4 is 0.96, and the shift gradient between evaluation point 4 and 5 is −1.
In this way, the number of segment(s) between two adjacent evaluation points can be estimated according to the shift gradient between the two adjacent evaluation points. According to applicants' research, the higher the shift gradient, the greater the number of segments required. A higher shift gradient between two adjacent points means a more severe optical proximity effect occurs between the two adjacent points. Therefore, a greater number of segments is needed between the two adjacent points to correct the optical proximity effect.
In this way, the manufacturer can compare each shift gradient to estimate the number of segments between two adjacent evaluation points, and input the estimation into commercial OPC software.
Take the above embodiment as an example: the shift gradient between evaluation points 1 and 2 is 4.1 is the highest among other shift gradients. The shift gradient between evaluation points 4 and 5 is −1 which is lower than the shift gradient between evaluation points 1 and 2 . Therefore, a greater number of segments is needed between evaluation points 1 and 2 than between evaluation points 4 and 5 .
As mentioned above, there is a plurality of evaluation points disposed in every region of the original photomask layout 30 . All the evaluation points will go through the shift gradient calculation. A region with high shift gradient may be defined as a hot point, such as the edge L. In another preferred embodiment, a T-shaped region marked by a circle 50 in FIG. 4 a is identified as a hot point as well.
Then, a number of segments between adjacent evaluation points can be estimated according to the gradient shifts of the evaluation points on the hot point. Therefore, before running OPC, hot points of the original photomask layout 30 can be selected according to gradient shifts rather than according to a manufacturers' experience.
FIG. 6 shows a flow chart of the method for modifying photomask layout according to a preferred embodiment of the present invention.
First, an original photomask layout with a plurality of evaluation points is provided. Then, the original photomask layout is interpreted to generate an interpreted photomask layout. After that, a shift disposed between the original photomask layout and the interpreted photomask layout and corresponding to each evaluation point is measured. Subsequently, shift gradients between two adjacent evaluation points are calculated. Later, a number of segments between two adjacent evaluation points is estimated according to the shift gradients.
All in all, the preferred embodiment of the present invention provides a method to estimate positions of hot points and number of segments by theoretical data rather than manufacturers' experience. Therefore, hot points are selected more precisely and a number of dissections becomes more accurate.
Those skilled in the art will readily observe that numerous modifications and alterations of the device and method may be made while retaining the teachings of the invention. | A method for modifying a photomask layout includes the following steps. First, a photomask layout having at least an edge is provided. A plurality of evaluation points are positioned on the edge. Then, the photomask layout is interpreted to have an interpreted photomask layout and an interpreted edge pattern. The interpreted edge pattern is formed by interpreting the above-mentioned edge. After that, a shift between the edge and the interpreted edge and corresponding to each of the evaluation points is calculated. Afterwards, a shift gradient between two evaluation points can be derived from the shift. Finally, a number of segments between each two evaluation points can be estimated. | 6 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is the continuation application U.S. patent application Ser. No. 14/359,811 filed 21 May 2014 which is the National Stage of International Application No. PCT/GB2012/052900, filed 22 Nov. 2012, which claims priority from and the benefit of United Kingdom Patent Application No. 1120143.1 filed on 22 Nov. 2011. The entire content of this application is incorporated herein by reference.
BACKGROUND OF THE PRESENT INVENTION
[0002] It is known that gas-phase acoustic fields induce local pressure differences around the surfaces of liquid droplets (King, L. V. Proc. Roy. Soc., A147, 212-240 (1934)). The forces produced by acoustic standing waves are significantly larger than those produced by travelling waves. Acoustic standing waves can be produced either using an ultrasound transmitter (sonotrode) and a reflector or by using a pair of ultrasound transmitters.
[0003] It is known to cause droplets to be levitated in the nodes of standing-wave ultrasound fields. Similar techniques are used for lateral stabilization of droplet position in wind tunnels in which droplets are suspended vertically by balancing gravitational and aerodynamic forces (Lupi, V. D., Hansman, L. J. Journal of Atmospheric and Oceanic Technology, 8, 541-552, (1991)). Under appropriate conditions, droplet breakup can also be induced, and this effect can be used to atomize streams of liquid.
[0004] It is also known, for example, to use an ultrasonic standing wave arrangement to produce a paint spray mist for painting a workpiece.
[0005] It is desired to provide an improved ion source and method of ionising a sample.
SUMMARY OF THE PRESENT INVENTION
[0006] According to an aspect of the present invention there is provided an ion source for a mass spectrometer comprising:
[0007] an ionisation device arranged and adapted to emit a stream of droplets; and
[0008] one or more ultrasonic transmitters or sonotrodes arranged and adapted to create one or more acoustic standing waves downstream of the ionisation device.
[0009] One of the problems with certain types of conventional ion sources such as Electrospray ion sources is that they can emit droplets at least some of which have a relatively large diameter. The relatively large droplets do not then completely desolvate which results in a loss of analyte signal. The solution to this problem according to the present invention is to provide one or more ultrasonic transmitters downstream of the ionisation device (e.g. Electrospray ion source). The one or more ultrasonic transmitters create acoustic standing waves which, for example, further nebulise the stream of droplets emitted from the ionisation device. As a result, the droplets are significantly reduced in size by the acoustic standing waves resulting in significantly improved desolvation compared to conventional arrangements. Furthermore, the nodes of the acoustic standing waves can be adjusted in order to optimise the subsequent transmission of analyte sample into and through the sampling orifice of the mass spectrometer thereby improving sensitivity.
[0010] It is apparent, therefore, that the present invention is particularly advantageous.
[0011] The droplets may predominantly comprise charged droplets. Alternatively, the droplets may predominantly comprise uncharged or neutral droplets.
[0012] The ion source preferably comprises an ultrasonic transmitter or sonotrode and a reflector. Alternatively, the ion source may comprise two ultrasonic transmitters or sonotrodes.
[0013] According to the preferred embodiment the ultrasonic transducer is arranged and adapted to emit ultrasonic waves having a frequency in the range: (i) 20-30 kHz; (ii) 30-40 kHz; (iii) 40-50 kHz; (iv) 50-60 kHz; (v) 60-70 kHz; (vi) 70-80 kHz; (vii) 80-90 kHz; (viii) 90-100 kHz; and (ix) >100 kHz.
[0014] The one or more ultrasonic transmitters are preferably positioned so that the one or more acoustic standing waves interact with the stream of droplets.
[0015] The one or more acoustic standing waves are preferably arranged and adapted to induce internal mixing of the stream of droplets.
[0016] The one or more acoustic standing waves may be arranged and adapted to move or translate the stream of droplets.
[0017] The one or more acoustic standing waves are preferably arranged and adapted to focus or defocus the stream of droplets.
[0018] The one or more acoustic standing waves are preferably arranged and adapted to further nebulise the stream of droplets.
[0019] The one or more acoustic standing waves are preferably arranged so as to result in a reduction of the average size of droplets in the stream of droplets.
[0020] In a mode of operation the one or more acoustic standing waves are preferably arranged so as to trap at least some droplets for a period of time.
[0021] The ion source preferably further comprises a device arranged and adapted to introduce or mix a reagent and/or reagent ions with the droplets.
[0022] The reagent and/or reagent ions preferably react or interact with the droplets.
[0023] The reagent and/or reagent ions preferably react or interact via Electron Transfer Dissociation, Electron Capture Dissociation, ozonolysis, Hydrogen-Deuterium exchange (“HDx”), charge reduction, photo dissociation or thermal dissociation.
[0024] The ion source preferably further comprises a control system arranged and adapted to control the residence time or interaction time between droplets and a reagent and/or reagent ions.
[0025] The ion source is preferably maintained in use at Atmospheric pressure, at a pressure greater than atmospheric pressure or at sub-atmospheric pressure.
[0026] The one or more ultrasonic transmitters are preferably arranged and adapted to create one or more gas phase acoustic standing waves.
[0027] The ionisation device preferably comprises an Atmospheric Pressure Ionisation (“API”) ionisation device.
[0028] The Atmospheric Pressure Ionisation ionisation device preferably comprises an Electrospray ion source, an Atmospheric Pressure Chemical Ionisation (“APCI”) ion source, an Impactor ion source wherein a sample is ionised upon impacting a target, a Laser ion source, an ultra-violet (“UV”) photoionisation device or an infra-red (“IR”) photoionisation device
[0029] The ion source preferably further comprises either a Field Induced Droplet Ionisation (“FIDI”) ionisation device, a Glow Discharge lamp ionisation device, a laser metastable ionisation device, a Direct Analysis in Real Time (“DART”) ionisation device or a secondary ionisation Electrospray ionisation device for ionising droplets held in and/or emerging from the one or more acoustic standing waves.
[0030] The ion source preferably further comprises one or more grid electrodes for applying an electric field to droplets held in the one or more acoustic standing waves.
[0031] The one or more grid electrodes are preferably at least partially acoustically transparent at a frequency at which the one or more ultrasonic transmitters emit ultrasonic waves.
[0032] According to another aspect of the present invention there is provided a mass spectrometer comprising an ion source as described above.
[0033] The mass spectrometer preferably comprises an ion inlet. The ion inlet preferably leads from a preferably substantially atmospheric pressure region to a preferably substantially sub-atmospheric pressure region. Analyte molecules and/or ions are preferably arranged to emerge from the one or more acoustic standing waves adjacent the ion inlet so that the analyte molecules and/or ions enter the mass spectrometer via the ion inlet.
[0034] The mass spectrometer preferably further comprises a gas phase ion mobility spectrometer or separator, wherein the ion mobility spectrometer or separator is arranged and adapted to separate analyte ions temporally according to their ion mobility.
[0035] According to another aspect of the present invention there is provided a method of ionising a sample comprising:
[0036] emitting a stream of droplets; and
[0037] causing the stream of droplets to interact with one or more acoustic standing waves.
[0038] According to another aspect of the present invention there is provided a method of mass spectrometry comprising a method of ionising a sample as described above.
[0039] According to an embodiment the mass spectrometer may further comprise:
[0040] (a) an ion source selected from the group consisting of: (i) an Electrospray ionisation (“ESI”) ion source; (ii) an Atmospheric Pressure Photo Ionisation (“APPI”) ion source; (iii) an Atmospheric Pressure Chemical Ionisation (“APCI”) ion source; (iv) a Matrix Assisted Laser Desorption Ionisation (“MALDI”) ion source; (v) a Laser Desorption Ionisation (“LDI”) ion source; (vi) an Atmospheric Pressure Ionisation (“API”) ion source; (vii) a Desorption Ionisation on Silicon (“DIOS”) ion source; (viii) an Electron Impact (“EI”) ion source; (ix) a Chemical Ionisation (“CI”) ion source; (x) a Field Ionisation (“FI”) ion source; (xi) a Field Desorption (“FD”) ion source; (xii) an Inductively Coupled Plasma (“ICP”) ion source; (xiii) a Fast Atom Bombardment (“FAB”) ion source; (xiv) a Liquid Secondary Ion Mass Spectrometry (“LSIMS”) ion source; (xv) a Desorption Electrospray Ionisation (“DESI”) ion source; (xvi) a Nickel-63 radioactive ion source; (xvii) an Atmospheric Pressure Matrix Assisted Laser Desorption Ionisation ion source; (xviii) a Thermospray ion source; (xix) an Atmospheric Sampling Glow Discharge Ionisation (“ASGDI”) ion source; (xx) a Glow Discharge (“GD”) ion source; and (xxi) an Impactor ion source; and/or
[0041] (b) one or more continuous or pulsed ion sources; and/or
[0042] (c) one or more ion guides; and/or
[0043] (d) one or more ion mobility separation devices and/or one or more Field Asymmetric Ion Mobility Spectrometer devices; and/or
[0044] (e) one or more ion traps or one or more ion trapping regions; and/or
[0045] (f) one or more collision, fragmentation or reaction cells selected from the group consisting of: (i) a Collisional Induced Dissociation (“CID”) fragmentation device; (ii) a Surface Induced Dissociation (“SID”) fragmentation device; (iii) an Electron Transfer Dissociation (“ETD”) fragmentation device; (iv) an Electron Capture Dissociation (“ECD”) fragmentation device; (v) an Electron Collision or Impact Dissociation fragmentation device; (vi) a Photo Induced Dissociation (“PID”) fragmentation device; (vii) a Laser Induced Dissociation fragmentation device; (viii) an infrared radiation induced dissociation device; (ix) an ultraviolet radiation induced dissociation device; (x) a nozzle-skimmer interface fragmentation device; (xi) an in-source fragmentation device; (xii) an in-source Collision Induced Dissociation fragmentation device; (xiii) a thermal or temperature source fragmentation device; (xiv) an electric field induced fragmentation device; (xv) a magnetic field induced fragmentation device; (xvi) an enzyme digestion or enzyme degradation fragmentation device; (xvii) an ion-ion reaction fragmentation device; (xviii) an ion-molecule reaction fragmentation device; (xix) an ion-atom reaction fragmentation device; (xx) an ion-metastable ion reaction fragmentation device; (xxi) an ion-metastable molecule reaction fragmentation device; (xxii) an ion-metastable atom reaction fragmentation device; (xxiii) an ion-ion reaction device for reacting ions to form adduct or product ions; (xxiv) an ion-molecule reaction device for reacting ions to form adduct or product ions; (xxv) an ion-atom reaction device for reacting ions to form adduct or product ions; (xxvi) an ion-metastable ion reaction device for reacting ions to form adduct or product ions; (xxvii) an ion-metastable molecule reaction device for reacting ions to form adduct or product ions; (xxviii) an ion-metastable atom reaction device for reacting ions to form adduct or product ions; and (xxix) an Electron Ionisation Dissociation (“EID”) fragmentation device; and/or
[0046] (g) a mass analyser selected from the group consisting of: (i) a quadrupole mass analyser; (ii) a 2D or linear quadrupole mass analyser; (iii) a Paul or 3D quadrupole mass analyser; (iv) a Penning trap mass analyser; (v) an ion trap mass analyser; (vi) a magnetic sector mass analyser; (vii) Ion Cyclotron Resonance (“ICR”) mass analyser; (viii) a Fourier Transform Ion Cyclotron Resonance (“FTICR”) mass analyser; (ix) an electrostatic or orbitrap mass analyser; (x) a Fourier Transform electrostatic or orbitrap mass analyser; (xi) a Fourier Transform mass analyser; (xii) a Time of Flight mass analyser; (xiii) an orthogonal acceleration Time of Flight mass analyser; and (xiv) a linear acceleration Time of Flight mass analyser; and/or
[0047] (h) one or more energy analysers or electrostatic energy analysers; and/or
[0048] (i) one or more ion detectors; and/or
[0049] (j) one or more mass filters selected from the group consisting of: (i) a quadrupole mass filter; (ii) a 2D or linear quadrupole ion trap; (iii) a Paul or 3D quadrupole ion trap; (iv) a Penning ion trap; (v) an ion trap; (vi) a magnetic sector mass filter; (vii) a Time of Flight mass filter; and (viii) a Wein filter; and/or
[0050] (k) a device or ion gate for pulsing ions; and/or
[0051] (l) a device for converting a substantially continuous ion beam into a pulsed ion beam.
[0052] The mass spectrometer may further comprise either:
[0053] (i) a C-trap and an orbitrap (RTM) mass analyser comprising an outer barrel-like electrode and a coaxial inner spindle-like electrode, wherein in a first mode of operation ions are transmitted to the C-trap and are then injected into the orbitrap (RTM) mass analyser and wherein in a second mode of operation ions are transmitted to the C-trap and then to a collision cell or Electron Transfer Dissociation device wherein at least some ions are fragmented into fragment ions, and wherein the fragment ions are then transmitted to the C-trap before being injected into the orbitrap (RTM) mass analyser; and/or
[0054] (ii) a stacked ring ion guide comprising a plurality of electrodes each having an aperture through which ions are transmitted in use and wherein the spacing of the electrodes increases along the length of the ion path, and wherein the apertures in the electrodes in an upstream section of the ion guide have a first diameter and wherein the apertures in the electrodes in a downstream section of the ion guide have a second diameter which is smaller than the first diameter, and wherein opposite phases of an AC or RF voltage are applied, in use, to successive electrodes.
[0055] According to an embodiment the mass spectrometer further comprises a device arranged and adapted to supply an AC or RF voltage to the electrodes. The AC or RF voltage preferably has an amplitude selected from the group consisting of: (i) <50 V peak to peak; (ii) 50-100 V peak to peak; (iii) 100-150 V peak to peak; (iv) 150-200 V peak to peak; (v) 200-250 V peak to peak; (vi) 250-300 V peak to peak; (vii) 300-350 V peak to peak; (viii) 350-400 V peak to peak; (ix) 400-450 V peak to peak; (x) 450-500 V peak to peak; and (xi) >500 V peak to peak.
[0056] The AC or RF voltage preferably has a frequency selected from the group consisting of: (i) <100 kHz; (ii) 100-200 kHz; (iii) 200-300 kHz; (iv) 300-400 kHz; (v) 400-500 kHz; (vi) 0.5-1.0 MHz; (vii) 1.0-1.5 MHz; (viii) 1.5-2.0 MHz; (ix) 2.0-2.5 MHz; (x) 2.5-3.0 MHz; (xi) 3.0-3.5 MHz; (xii) 3.5-4.0 MHz; (xiii) 4.0-4.5 MHz; (xiv) 4.5-5.0 MHz; (xv) 5.0-5.5 MHz; (xvi) 5.5-6.0 MHz; (xvii) 6.0-6.5 MHz; (xviii) 6.5-7.0 MHz; (xix) 7.0-7.5 MHz; (xx) 7.5-8.0 MHz; (xxi) 8.0-8.5 MHz; (xxii) 8.5-9.0 MHz; (xxiii) 9.0-9.5 MHz; (xxiv) 9.5-10.0 MHz; and (xxv) >10.0 MHz.
BRIEF DESCRIPTION OF THE DRAWINGS
[0057] Various embodiments of the present invention will now be described, by way of example only, and with reference to the accompanying drawings in which:
[0058] FIG. 1 shows a preferred embodiment of the present invention wherein a stream of droplets is emitted from a liquid source such as an Electrospray ion source and interacts with an acoustic standing wave generated by two sonotrodes or one sonotrode and a reflector.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0059] A preferred embodiment of the present invention will now be described.
[0060] FIG. 1 shows a preferred embodiment of the present invention wherein a stream of droplets is emitted from a liquid source such as an Electrospray ion source and interacts with an acoustic standing wave generated by two sonotrodes or one sonotrode and a reflector.
[0061] According to an embodiment one or more standing-wave acoustic fields are introduced into a mass spectrometer (MS) source which has several benefits when an analyte is introduced in a stream of liquid or liquid droplets by e.g. Electrospray.
[0062] One of the limitations of known liquid interface MS sources is a loss of analyte due to incomplete desolvation of large droplets. Advantageously, according to the preferred embodiment large droplets can be broken up by acoustic fields. The resulting droplets can be sampled more efficiently into a first vacuum stage of a mass spectrometer and they will also evaporate faster thereby improving the sensitivity of the device.
[0063] According to an embodiment of the present invention some additional control of the position of droplets is possible via acoustic lensing within the source region. For example, optimisation of the position of acoustic nodes relative to the sampling orifice enables the transmission into the first vacuum stage to be improved. This improves the sensitivity of the mass spectrometer.
[0064] It is known that competition among analytes for the surface layer of droplets can have a significant effect on observed Electrospray MS response (Enke, C., Anal. Chem., 69 (23), 4885-4893, (1997)). Internal mixing induced in the droplets by the acoustic field will advantageously reduce suppression of the signal for species with relatively low surface affinity.
[0065] Further enhancement of the atomisation process may be achieved by operating the device above or below atmospheric pressure. According to an embodiment characteristics of the standing acoustic waves such as intensity, node position and frequency of the ultrasound field can also be adjusted. This may be performed either manually or automatically in response to changes in temperature, pressure, flow conditions etc. Feedback from the observed MS signal may be used to control this adjustment.
[0066] One or more partially acoustically transparent grids may be positioned close to the region where the acoustic standing waves are generated. The grids may be utilised in order that an electric field for ionisation of the droplets can be applied and sustained without electrical breakdown occurring. The technique can be used to manipulate fields of electrically neutral droplets or charged droplets. Ionisation may occur prior to, inside or following the acoustically active regions.
[0067] An additional force may be applied to the droplets to increase the residence time of the droplets in the acoustic field even to the extent of trapping the droplets. Additionally, an electric field may be used to generate ion plumes from the droplets.
[0068] Increasing the residence time of droplets has additional benefits when reactions are performed in the MS source region. For example, chemical and physical reactions such as ozonolysis, hydrogen-deuterium exchange, atmospheric pressure ETD/ECD, charge reduction, photo-dissociation and thermal dissociation can be performed.
[0069] Reagents which are incompatible with a conventional analyte delivery system (e.g. Electrospray) may advantageously be introduced into the source region of the preferred embodiment. The reaction time with the analyte may be controlled and mixing improved through interaction with the acoustic field.
[0070] A yet further advantage of the present invention is that preferential sampling of small droplets or ions by positional manipulation of larger droplets reduces contamination of ion-optical surfaces and sampling orifices, thereby increasing time between cleaning and/or reducing background signals/noise.
[0071] Although the present invention has been described with reference to preferred embodiments, it will be understood by those skilled in the art that various changes in form and detail may be made without departing from the scope of the invention as set forth in the accompanying claims. | An ion source for a mass spectrometer is disclosed comprising an ionisation device which emits a stream of droplets and one or more ultrasonic transmitters which create one or more acoustic standing waves. The acoustic standing waves may be used to further nebulise the stream of droplets and induce internal mixing of the droplets. | 8 |
CROSS REFERENCE TO RELATED APPLICATIONS
This application is a continuation of U.S. patent application Ser. No. 11/406,172, filed Apr. 18, 2006, which issued as U.S. Pat. No. 7,199,565 on Apr. 3, 2007 and is incorporated by reference as if fully set forth.
FIELD OF INVENTION
The present invention is related to voltage regulation circuits. More particularly, the present invention is related to a voltage regulator that uses semiconductor devices to provide generally fixed output voltages over varying loads with minimal voltage dropout on the output.
BACKGROUND
Low-dropout (LDO) voltage regulators have gained popularity with the growth of battery-powered equipment. Portable electronic equipment including cellular telephones, pagers, laptop computers and a variety of handheld electronic devices has increased the need for efficient voltage regulation to prolong battery life. LDO voltage regulators are typically packaged as an integrated circuit (IC) to provide generally fixed output voltages over varying loads with minimal voltage dropout on the output in a battery-powered device. Furthermore, performance of LDO voltage regulators is optimized by taking into consideration standby and quiescent current flow, and stability of the output voltage.
FIG. 1 is a schematic diagram of a conventional LDO voltage regulator 100 including a startup circuit 105 , a curvature corrected bandgap circuit 110 , an error amplifier 115 , a metal oxide semiconductor (MOS) pass device 120 , (e.g., a positive channel MOS (PMOS) pass device, a negative channel MOS (NMOS) pass device), resistors 125 , 130 , and a decoupling capacitor 135 having a capacitance COUT. The LDO voltage regulator 100 outputs an output voltage, V out , 145 .
The curvature corrected bandgap circuit 110 is electrically coupled to the startup circuit 105 and the error amplifier 115 . The startup circuit 105 provides the curvature corrected bandgap circuit 110 with current when no current is flowing through the LDO voltage regulator 100 during a supply increase or startup phase until the bandgap voltage is high enough to allow the curvature corrected bandgap circuit 110 to be self-sustaining. The curvature corrected bandgap circuit 110 generates a reference voltage 152 which is input to a positive input 150 of the error amplifier 115 , and a reference current 154 which is input to a reference current input 158 of the error amplifier 115 . Generally, the reference current 154 is a proportional to absolute temperature (PTAT) current generated by the curvature corrected bandgap circuit 110 .
The error amplifier 115 includes a positive input 150 coupled to the curvature corrected bandgap circuit 110 for receiving the reference voltage 152 , a reference current input 158 for receiving the reference current 154 , a negative input 155 , and an amplifier output 160 .
The MOS pass device 120 includes a gate node 165 , a source node 170 and a drain node 175 . The MOS pass device 120 may be either a PMOS or an NMOS pass device. The gate node 165 of the MOS pass device 120 is coupled to the amplifier output 160 of the error amplifier 115 . The source node 170 of the MOS pass device 120 is coupled to a supply voltage, V s . The drain node 175 of the MOS pass device 120 generates the output voltage, V out , 145 of the LDO voltage regulator 100 . The resistors 125 and 130 are connected in series to form a resistor bridge. One end of the resistor 125 is coupled to the drain node 175 of the MOS pass device 120 and the other end of the resistor 125 is coupled to both the negative input 155 of the error amplifier 115 and one end of the resistor 130 . Thus an error correction loop 180 is formed. The other end of resistor 130 is coupled to ground. The decoupling capacitor 135 is coupled between V out and ground.
In the conventional LDO voltage regulator 100 , a capacitance CMOS associated with the gate node 165 of the MOS pass device 120 and the decoupling capacitor 135 cause the slew rate and bandwidth of the error amplifier 115 to be limited. The conventional LDO voltage regulator 100 provides a fixed output voltage, but is constrained by others specifications such as voltage drop, gain and transient response. When a current step occurs, (due to the load of a circuit coupled to the output voltage, V out , 145 ), the output voltage, V out , 145 decreases first and, after an error correction loop delay Tfb occurs, the gate node 165 of the MOS pass device 120 is adjusted by the error amplifier 115 to provide the requested output current.
FIG. 2 shows a graphical representation of the output voltage, V out , 145 of the conventional LDO voltage regulator 100 shown in FIG. 1 during a maximum current step required by the load of a circuit coupled to the voltage output, V out , 145 . The delay Tfb corresponds to the minimum error correction loop delay to ensure voltage regulation. This delay is proportional to the bandwidth of the error amplifier 115 and may be calculated in accordance with the following Equation (1):
Tfb = 1 fu ; Equation ( 1 )
where Tfb is the delay and fu is the unity gain frequency of the error amplifier 115 .
The voltage drop during this delay may be approximated in accordance with the following Equation (2):
δ V = I max C out Tfb Equation ( 2 )
where δV is the voltage drop, I max is the maximum output current required by the load of a circuit coupled to the voltage output, V out , 145 , C out is the capacitance of the decoupling capacitor 135 and Tfb is the error correction loop delay.
Referring to FIGS. 1 and 2 , the error correction loop 180 provides voltage regulation after the Tfb delay and modifies the voltage of the gate node 165 of the MOS pass device 120 in order to switch on the MOS pass device 120 . The output voltage, V out , 145 is adjusted until the full load regulated value is reached. The time needed to recover the final value, T reg , may be approximated in accordance with the following Equation (3):
T reg = C OUT I pass - I max × V drop Equation ( 3 )
where C out is the capacitance of the decoupling capacitor 135 , I pass is the current of the MOS pass device 120 , I max is the maximum output current required by the load of a circuit coupled to the voltage output, V out , 145 , and V drop is the maximum voltage drop.
After T reg , the voltage of the gate node 165 of the PMOS pass device 120 , V gsmax , provides sufficient current through the PMOS pass device 120 to ensure output voltage stability. However, a significant voltage drop and a delay in reaching the final regulated output voltage occurs.
It would be desirable to modify the LDO voltage regulator 100 of FIG. 1 such that it is able to more rapidly set the voltage of the gate node 165 of the PMOS pass device 120 to the V gsmax voltage (or lower) in order to reduce output voltage drops and delays in reaching the final regulated output voltage, V out , 145 .
SUMMARY
The present invention is related to an LDO voltage regulator for generating an output voltage. The voltage regulator includes a startup circuit, a curvature corrected bandgap circuit, an error amplifier, a MOS pass device and a voltage slew rate efficient transient response boost circuit. The MOS pass device has a gate node which is coupled to the output of the error amplifier, and a drain node for generating the output voltage. The voltage slew rate efficient transient response boost circuit applies a voltage to the gate node of the MOS pass device to accelerate the response time of the error amplifier in enabling the LDO voltage regulator to reach its final regulated output voltage when an output voltage drop occurs in the LDO voltage regulator.
BRIEF DESCRIPTION OF THE DRAWINGS
A more detailed understanding of the invention may be had from the following description, given by way of example and to be understood in conjunction with the accompanying drawings wherein:
FIG. 1 is a schematic diagram of a conventional LDO voltage regulator;
FIG. 2 is a graphical representation of the output voltage transient response to a maximum output current step in the conventional LDO voltage regulator of FIG. 1 ;
FIG. 3 is a schematic diagram of an LDO voltage regulator with a voltage slew rate efficient transient response boost circuit configured in accordance with the present invention;
FIG. 4 is a graphical representation of the output voltage transient response of the LDO voltage regulator of FIG. 3 when a transient response boost voltage, Vb, is set to zero volts (ground);
FIG. 5 is a graphical representation of the output voltage transient response of the LDO voltage regulator of FIG. 3 when Vb is set to V gsmax ; and
FIG. 6 is a flow diagram of a process of regulating an output voltage implemented by the LDO voltage regulator of FIG. 3 .
DETAILED DESCRIPTION OF THE INVENTION
The present invention is incorporated in a novel voltage regulator which provides a simple solution to increase voltage regulator performance while reducing output voltage drop. This solution includes a voltage slew rate efficient transient response boost circuit that is configured in accordance with the present invention. The present invention can also be applied to any known voltage regulator structure by incorporating a voltage slew rate efficient transient response boost circuit which provides a simple solution to increase voltage regulator performance.
In one embodiment, the gate node of a PMOS pass device is rapidly set to the V gsmax voltage (or lower) in order to avoid voltage drops and to reduce delays between the output current step and the final regulated output voltage. When the output voltage falls below a predefined threshold, the gate node of the MOS pass device is coupled to V gsmax (or lower).
Referring now to FIG. 3 , a schematic diagram of an LDO voltage regulator 300 configured in accordance with the present invention is shown. The LDO voltage regulator 300 includes a startup circuit 305 , a curvature corrected bandgap circuit 310 , an error amplifier 315 , a MOS pass device 320 , a resistor bridge 325 including resistors 325 A, 325 B, 325 C, a decoupling capacitor 330 having a capacitance C out , a comparator 335 and a MOS switch device 340 . The LDO voltage regulator 300 generates an output voltage, V out , 345 . The resistor bridge 325 , the comparator 335 and the MOS switch device 340 form a slew rate efficient transient response boost circuit. The MOS pass device 320 may be either a PMOS or an NMOS pass device. The MOS switch device 340 may be either a PMOS or an NMOS switch device.
The curvature corrected bandgap circuit 310 is electrically coupled to the startup circuit 305 and the error amplifier 315 . The startup circuit 305 provides the curvature corrected bandgap circuit 310 with current when no current is flowing through the LDO voltage regulator 300 during a supply increase or startup phase until the bandgap voltage is high enough to allow the curvature corrected bandgap circuit 310 to be self-sustaining. The curvature corrected bandgap circuit 310 generates a bandgap reference voltage 352 which is input to a positive input 350 of the error amplifier 315 and a negative input 355 of the comparator 335 . The curvature corrected bandgap circuit 310 also generates a reference current 354 which is input to a reference current input 358 of the error amplifier 315 . Generally, the reference current 354 is a PTAT current generated by the curvature corrected bandgap circuit 310 .
The error amplifier 315 includes a positive input 350 coupled to the curvature corrected bandgap circuit 310 for receiving the bandgap reference voltage 352 , a reference current input 358 for receiving the bandgap reference current 354 , a negative input 360 for receiving an error correction voltage 359 from the resistor bridge 325 , and an amplifier output 365 .
The MOS pass device 320 includes a gate node 370 , a source node 372 and a drain node 374 . The gate node 370 of the MOS pass device 320 is coupled to the amplifier output 365 , which outputs a pass device control signal. The source node 372 of the MOS pass device 320 is coupled to a supply voltage, V s . The drain node 374 of the MOS pass device 320 generates the output voltage, V out , 345 of the LDO voltage regulator 300 . The resistors 325 A, 325 B, 325 C are connected in series to form a resistor bridge 325 . One end of the resistor 325 A is coupled to the drain node 374 of the MOS pass device 320 and the other end of the resistor 325 A is coupled to both a positive input 376 of the comparator 335 and one end of the resistor 325 B. The other end of the resistor 325 B is coupled to the negative input 360 of the error amplifier 315 and to one end of the resistor 325 C. The other end of the resistor 325 C is coupled to ground. The decoupling capacitor 330 is coupled between V out 345 and ground.
Still referring to FIG. 3 , the MOS switch device 340 includes a gate node 380 , a source node 382 and a drain node 384 . An output 378 of the comparator 335 is coupled to the gate node 380 of the MOS switch device 340 . The output 378 generates a switch device control signal. The drain node 384 is coupled to the output 365 of the error amplifier 315 and the gate node of the MOS pass device 320 . The source node 382 of the MOS switch device 340 is coupled to a transient response boost voltage, Vb, which may be generated, for example, by an output current monitoring unit coupled to the voltage output, V out , 345 .
The positive input 376 of the comparator 335 receives a threshold voltage, Vt, 326 from the junction between the resistors 325 A and 325 B. The value of Vt may be calculated in accordance with the following Equation (4):
Vt = V out - ( V drop - I max C out × τ de ) Equation ( 4 )
where Vt is the threshold voltage of the comparator 335 , V out is the regulated output voltage, V drop is the maximum voltage drop allowed, I max is the maximum output current, C out is the value of the decoupling capacitor 330 and τ de is the internal delay of the comparator 335 .
The MOS switch device 340 is a small and fast device having a drain node 384 coupled to the gate node 370 of the MOS pass device 320 and coupled to a transient response boost voltage, Vb, that is set to a “final value” between zero volts, (i.e., a ground value), and a maximum voltage, V gsmax . The purpose of the MOS switch device 340 is to rapidly set a final value on the gate node 370 of the MOS pass device 320 in order to permit the MOS pass device 320 to deliver the maximum output current to V out 145 .
As shown in FIG. 4 , the output voltage transient response of the present invention has the same error correction loop delay Tfb as that in the transient response of the conventional LDO voltage regulator 100 shown in FIG. 1 . By switching the MOS switch device 340 on, Vb is set to a ground value which results in a high output current and a fast output voltage rising edge. The comparator 335 then switches off the NMOS switch device 340 until the next voltage drop. The output 378 of the comparator 335 is either zero volts, (i.e., a ground value), which turns off the MOS switch device 340 , or V s which turns on the MOS switch device 340 . During this time, some oscillations may be present due to the multiple comparator switching but the maximum voltage drop is reduced. After the error correction loop delay Tfb, the error correction voltage 359 is provided by the resistor bridge 325 to the negative input 360 of the error amplifier 315 , which provides output voltage regulation and adjusts the output voltage on the gate node 370 of the MOS pass device 320 to the final value.
In another embodiment, the transient response boost voltage, Vb, is set exactly to V gsmax . The comparator 335 switches on the MOS switch device 340 , thus coupling the gate node 370 of the MOS pass device 320 to V gsmax , whereby the output current is exactly the same as the load current. Thus, output voltage, V out , 345 is immediately regulated, as shown in FIG. 5 . When the voltage drop exceeds Vt, the gate node 370 of the PMOS pass device 320 is immediately coupled to its final value and then the LDO voltage regulator 300 is set to a full load regulated voltage mode. By setting the voltage of the gate node 370 of the MOS pass device using the MOS switch device 340 , instead of waiting for the error amplifier 325 to do it, the error amplifier response time is increased and the voltage output 345 is regulated and the voltage drop of V out 345 is greatly reduced.
In accordance with the present invention, a process 600 of regulating an output voltage, V out , 345 is implemented using the LDO voltage regulator 300 . Referring to FIGS. 3 and 6 , a bandgap reference voltage 352 is received at the positive input 350 of the error amplifier 315 , a bandgap reference current 354 is received at the reference current input 358 of the error amplifier 315 , and an error correction voltage 359 derived from the output voltage, V out , 345 is received at the negative input 360 of the error amplifier 315 (step 605 ). The error amplifier 315 generates a pass device control signal which closes the pass device 320 based on the bandgap reference voltage 352 , the bandgap reference current 354 and the error correction voltage 359 to adjust the output voltage, V out , 345 to a full load regulated value (step 610 ). In step 615 , the transient response boost voltage, Vb, is generated. In step 620 , the bandgap reference voltage 352 is compared by the comparator 335 to a threshold voltage, Vt, 326 derived from the output voltage, V out , 345 . The comparator 335 generates a switch device control signal which closes the switch device 340 based on the comparison of step 620 to selectively apply the transient response boost voltage, Vb, to the pass device control signal to accelerate the rate at which the output voltage, V out , 345 is adjusted to the full load regulated value (step 625 ). The transient response boost voltage, Vb, is applied to the pass device control signal when a drop in the output voltage, V out , 345 occurs.
Although the features and elements of the present invention are described in particular combinations, each feature or element can be used alone without the other features and elements of the embodiments or in various combinations with or without other features and elements of the present invention. | A low-dropout (LDO) voltage regulator for generating an output voltage is disclosed. The voltage regulator includes a startup circuit, a curvature corrected bandgap circuit, an error amplifier, a metal oxide semiconductor (MOS) pass device and a voltage slew rate efficient transient response boost circuit. The MOS pass device has a gate node which is coupled to the output of the error amplifier, and a drain node for generating the output voltage. The voltage slew rate efficient transient response boost circuit applies a voltage to the gate node of the MOS pass device to accelerate the response time of the error amplifier in enabling the LDO voltage regulator to reach its final regulated output voltage when an output voltage drop occurs in the LDO voltage regulator. | 6 |
This application is a division of U.S. patent application Ser. No. 09/329,688, filed on Jun. 10, 1999 now U.S. Pat. No. 6,221,074 and entitled FEMORAL INTRAMEDULLARY ROD SYSTEM; the contents of which are hereby incorporated by reference.
FIELD OF THE INVENTION
The present invention is directed to techniques for treating bone fractures. Specifically, but not exclusively, the invention relates to a system for treating a variety of typical femoral fractures using a uniform intramedullary rod design.
BACKGROUND OF THE INVENTION
The femur generally comprises an elongated shaft extending from the hip to the knee. The proximal end of the femoral shaft includes a neck segment connected to a head portion. The head portion fits into a concavity of the hip bone to form a ball and socket joint at the hip. The distal end of the femoral shaft engages the upper end of the tibia to form the knee joint. Overall, the femur is one of the longest and strongest bones in the human body; however, portions of the femur are extremely susceptible to fracture.
Internal fixation of femoral fractures is one of the most common orthopedic surgical procedures. Many different types of femoral fractures are encountered in practice, including fractures of the femoral neck, midshaft, and distal regions. When the femur is fractured, treatment requires that the fractured bone be substantially immobilized and held together in an abutting relationship during the healing process. Any longitudinal, transverse, or rotational movement of one section of the fractured bone relative to the other can cause substantial delay in healing time or cause improper healing to occur. In general, two different internal fixation approaches have been used to immobilize the area surrounding the fracture site.
One approach involves driving metallic pins through the two sections of bone to be joined and connecting them to one or more plates bearing against the external surface of the bones. However, such an arrangement injures the flesh and muscle surrounding the bones and a large number of pins driven through the bone tend to weaken its hard outer layer. Plates also tend to stress the bone and are not always able to bear sufficient stress for many femoral fracture applications.
Further, bone beneath the plate does not always become as strong as it would in the absence of the plate. A second approach to treating femoral fractures involves the use of an intramedullary nail which is inserted into the medullary canal of the femur and affixed therein by a number of different methods. After complete healing of the bone at the fracture site, the nail may be removed through a hole drilled in the proximal end of the femur. A wide variety of devices have been developed over the years for use in the internal fixation of femoral fractures utilizing the method of intramedullar stabilization and immobilization. While there have been a number of technological advances made within the area of intramedullary fixation of femoral fractures, several problem areas remain.
One such problem arises from the fact that most intramedullary fixation systems currently available are adapted to a specific type of femoral fracture, resulting in a large number of highly specialized configurations. This has led to the disadvantageous consequence that hospitals and trauma centers have to keep a large inventory of incremental nail lengths with varying configurations and ancillary parts in order to accommodate a random and diverse incoming patient population. Maintaining such a high level of inventory to handle all expected contingencies is not only complex, but is also very expensive. Correspondingly, the possibility of error during selection and implantation of the fixation device by the surgeon is elevated. Likewise, the inventory costs associated with varying methods of intramedullary fixation are drastically increased and, in the case of smaller medical facilities, may necessitate switching to a less costly and potentially less effective method of treating femoral fractures.
Another problem may result from intramedullary rod systems used to specifically treat fractures of the neck or head of the femur. These devices typically include a transverse fixation member (nail, pin, screw, etc.) adapted to be positioned along the longitudinal axis of the femoral neck with its leading end portion embedded in the femoral head so as to grip the femoral head and thereby stabilize the fracture site. The fixation member is operably connected to the intramedullary rod to maintain a fixed relationship between the fixation member and the rod. Unfortunately, this structural connection does not always prevent rotational or translational movement of the fixation member relative to the intramedullary rod in response to forces commonly resulting from the normal activity of a convalescing patient. Additionally, the intramedullary rods used in these devices are typically specialized for use with this single fixation application and can not be used in other applications. Therefore, the costs associated with maintaining increased levels of inventory are substantially increased. Furthermore, if it is desired to vary the angle of the fixation member relative to the rod, substantial modifications must typically be made to either the fixation member or the rod member to accommodate for such an angular variation, again driving up inventory levels and associated inventory costs.
In still another problem area, on occasion, it is necessary to use transverse locking bone screws to lock the rod into position relative to the femur. In order to prevent the screws from backing out, locking nuts can be threaded onto the distal ends of the locking screws. Unfortunately, the installation of locking nuts onto the ends of the locking screws requires additional surgical incisions and commonly causes soft tissue irritation.
In yet another problem area, when an intramedullary rod is inserted into the medullary canal and anchored to the femur by two or more bone screws, despite the best efforts of the surgeon, the fracture site may have either been over-compressed or over-distracted as a result of the insertion of the rod. Unfortunately, with conventional intramedullary rods, it is virtually impossible to adjust the amount of distraction or compression without first removing one or more of the bone screws and manually distracting or compressing the fracture site. The intramedullary rod must then be re-anchored to the femur by reinserting the bone screws at different positions along the femur.
Thus, there is a demand for bone treatment techniques to address these problems. The present invention meets this demand and provides other benefits and advantages in a novel and unobvious manner.
SUMMARY OF THE INVENTION
The present invention is directed to techniques for treating bone fractures. Various aspects of the invention are novel, nonobvious and provide various advantages. While the actual nature of the invention covered herein can only be determined with reference to the claims appended hereto, selected forms and features of the preferred embodiment as disclosed herein, are described briefly as follows.
One form of the present invention includes treating a bone fracture with a nail that defines an opening and a transverse member including a bone engaging portion and a connection portion. The connection portion defines a through-hole and the nail is sized to pass through the through-hole. A pin is adjustably coupled to the transverse member to rigidly assemble the transverse member to the nail.
In a further form of the present invention, a method of treating a bone fracture includes forming a first hole in a femur transverse to the medullary canal and introducing a transverse member through the first hole. The transverse member includes a through-hole that is positioned relative to the medullary canal of the femur, and is preferably aligned therewith. The method further includes forming a second hole intersecting the medullary canal and inserting an intramedullary nail into the medullary canal via the second hole. The nail passes through the through-hole of the transverse member. The nail may include an opening aligned with the transverse member to facilitate rigid assembly to the transverse member by positioning a pin coupled to the transverse member in the nail opening.
In still another form of the present invention, a system for treating bone fractures includes a nail having a first end portion opposite a second end portion along a longitudinal axis. The first end portion defines an opening extending through the nail and has an angled surface oriented at an oblique angle relative to the longitudinal axis of the nail. Also included is a sleeve that includes a pair of apertures positioned on opposite sides of the sleeve. The apertures and the opening align to form a passageway when the sleeve is fitted over an end portion. A bone engaging member is received within the passageway in an abutting relationship with the angled surface.
In yet another form of the present invention, a bone fracture treatment apparatus includes an elongated nail having a longitudinal axis and a transverse axis generally perpendicular to the longitudinal axis. The nail defines a transverse opening extending along the transverse axis with the opening being bound by an upper surface and an opposite lower surface. At least one of the upper or lower surface defines a projection extending in a longitudinal direction to thereby narrow a dimension of the opening within the nail. The nail opening, and projection may be arranged to cooperate with one or more other members suitable to treat a particular type of bone fracture, such as a fracture of the femur.
According to another form of the present invention, a system for treating bone fractures includes a nail defining a longitudinal axis, a transverse axis and an opening extending along the transverse axis with the opening being bound by a bearing surface. Also included is a sleeve having a pair of apertures positioned on opposite sides thereof. The apertures and the opening are aligned to form a passageway when the sleeve is fitted over the nail. A bone engaging member is sized to pass through the passageway. Additionally, the system may include a means for biasing the sleeve in a longitudinal direction to clamp the bone engaging member against the bearing surface.
Still a further form of the present invention includes a technique for treating bone fractures with a nail that defines a longitudinal axis, an elongated opening extending therethrough, and a longitudinal passage intersecting the opening. A bone engaging member passes through the opening and a positioning device is provided that may be adjusted to change position of the bone engaging member along the longitudinal axis relative to the nail when the member is positioned through the nail opening. This device may be utilized to facilitate compression or distraction of a bone fracture.
Accordingly, one object of the present invention is to provide an improved bone fracture treatment system. Preferably, this system may be used to treat fractures of the femur.
Additionally or alternatively, another object is to provide an improved method of treating bone fractures, particularly fractures of elongated bones such as the femur.
Additionally or alternatively, still another object is to reduce the complexity and inventory costs associated with treating bone fractures.
Other objects, features, forms, embodiments, aspects, advantages and benefits of the present invention will become apparent to persons of ordinary skill in the art from the following written description and accompanying figures.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side view, partly in section, of a rod system of the present invention with a transverse member shown in an antegrade position.
FIG. 2 is a side view, partly in section, of the system of FIG. 1 with the transverse member in a retrograde position.
FIG. 3 is a partial side view of the proximal end portion of the rod of FIGS. 1 and 2.
FIG. 4 is a partial side view of the sleeve of FIGS. 1 and 2.
FIG. 5 is a partial, sectional side view of the proximal end portion of the rod shown in FIG. 3 and the sleeve of FIG. 4 assembled together with the locking member of FIGS. 1 and 2.
FIG. 6 is a side view, partly in section, of another rod system of the present invention implanted in the neck and head of a femur.
FIG. 7 is a partial, sectional side view of the proximal end portion of the system of FIG. 6 .
FIG. 8A is a side view of the fixed angle pin of FIG. 7 .
FIG. 8B is an end view of the fixed angle pin of FIG. 7 .
FIG. 9 is a partial, sectional side view of the proximal end of yet another system of the present invention having a variable angle pin positioned at 135 degrees relative to a rod.
FIG. 10A is a side view of the leading portion of the variable angle pin of FIG. 9 .
FIG. 10B is an end view of the leading portion of the variable angle pin of FIG. 9 taken along view line 10 B— 10 B of FIG. 10 A.
FIG. 11A is a side view of the trailing portion of the variable angle pin of FIG. 9 .
FIG. 11B is an end view of the trailing portion of the variable angle pin of FIG. 9 taken along view line 11 B— 11 B of FIG. 11 A.
FIG. 12 is a partial, sectional side view of the proximal end of the system of FIG. 9 showing the variable angle pin at 140 degrees relative to the rod.
FIG. 13 is a side view, partly in section, of still another rod system of the present invention illustrating implantation of an intramedullary nail inserted in a retrograde direction.
FIG. 14 is a partial, sectional side view of the proximal end portion of a farther system of the present invention.
FIG. 15 is a side view, partly in section, of another rod system of the present invention for performing distraction of a bone fracture.
FIG. 16 is a partial, sectional side view of the proximal end portion of the rod of FIG. 15 .
FIG. 17 is a partial, sectional side view of the proximal end portion of the system of FIG. 15, illustrating a first operational position.
FIG. 18 is a partial, sectional side view of the proximal end portion of the system of FIG. 15, illustrating a second operational position.
FIG. 19 is a side view, partly in section, of an additional intramedullary rod system of the present invention for performing compression of a bone fracture.
FIG. 20 is a partial, sectional side view of the proximal end portion of the system of FIG. 19, illustrating a first operational position.
FIG. 21 is a partial, sectional side view of the proximal end portion of the system of FIG. 19, illustrating a second operational position.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
For the purposes of promoting an understanding of the principles of the invention, reference will now be made to the embodiments illustrated in the drawings and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope of the invention is thereby intended, any alterations and further modifications in the illustrated embodiments, and any further applications of the principles of the invention as illustrated therein being contemplated as would normally occur to one skilled in the art to which the invention relates.
FIGS. 1-2 depict intramedullary system 10 according to one embodiment of the present invention. System 10 is shown implanted in femur 12 and includes an elongated intramedullary rod or nail 14 , sleeve 16 and bone engaging member 18 . System 10 also includes fasteners 20 and locking bone screws 22 a, 22 b. FIG. 1 illustrates system 10 as used in a first locking configuration with bone engaging member 18 placed in an antegrade direction within femur 12 . FIG. 2 illustrates a second locking configuration of system 10 ; where bone engaging member 18 is placed in a retrograde position within femur 12 . The tip of the greater trochanter 12 a, the neck 12 b, and the head 12 c of femur 12 are designated in FIGS. 1 and 2. Although system 10 is shown implanted in a human femur 12 , system 10 could also be used in conjunction with other bones as would occur to one skilled in the art, including, but not limited to, the tibia, humerus, radius, ulna and fibula.
Nail 14 includes a proximal end portion 14 a and a distal end portion 14 b. Nail 14 also defines a longitudinal centerline axis L 1 running along the length of nail 14 between proximal end portion 14 a and distal end portion 14 b. For application to an adult human femur, proximal end portion 14 a preferably has a diameter of about 11-13 millimeters. The diameter of the remainder of nail 14 may vary depending upon the requirements of the fixation procedure and the surgeon's preference. While nail 14 has a generally circular cross section, other suitable shapes are also contemplated as would occur to one skilled in the art.
Referring additionally to FIGS. 3-5, portion 14 b of nail 14 defines generally parallel transverse bores 24 a, 24 b, each sized to respectively receive locking bone screws 22 a, 22 b therein. Distal end portion 14 b also defines transverse bore 24 c, aligned generally perpendicular to transverse bores 24 a, 24 b and sized to receive locking bone screw 22 c (not shown). Proximal end portion 14 a defines an opening 26 and a threaded transverse bore 28 , both extending through nail 14 generally transverse to axis L 1 from a first side 14 c to a second side 14 d. Side 14 c generally opposes side 14 d. Proximal end portion 14 a also defines threaded longitudinal bore 29 generally extending along axis L 1 for receiving nail insertion and extraction instrumentation (not shown) used to guide nail 14 into and out of femur 12 . Nail 14 also defines a longitudinal passage 30 intersecting bore 29 and extending generally along axis L 1 to allow for the optional use of a guide wire (not shown) to aid in the insertion of nail 14 into femur 12 .
Referring more specifically to FIGS. 3 and 5, opening 26 is bound by lower surface 31 opposite upper surface 32 . Lower surface 31 includes a first angled surface 31 a oriented generally parallel to transverse axis T 1 . Upper surface 32 includes a second angled surface 32 a offset from first angled surface 31 a along axis T 1 . Angled surfaces 31 a, 32 a are generally parallel to transverse axis T 1 . Transverse axis T 1 is aligned at an oblique angle α 1 relative to longitudinal axis L 1 of nail 14 . Angle α 1 is preferably in a range of about 120-150 degrees, with the more preferred angle being about 135 degrees. First angled surface 31 a and second angled surface 32 a cooperate to define pathway 33 generally oriented at angle α 1 relative to axis L 1 . First pathway 33 is sized to receive bone engaging member 18 therethrough.
Lower surface 31 also includes a third angled surface 31 b aligned generally parallel to transverse axis T 2 . Upper surface 32 also includes a fourth angled surface 32 b generally offset from third angled surface 31 b along axis T 2 that is also generally parallel to transverse axis T 2 . Comparing to FIG. 2, transverse axis T 2 is also aligned at an oblique angle α 2 relative to longitudinal axis L 1 of nail 14 . Angle α 2 is preferably in a range of about 120-150 degrees, with the more preferred angle being about 135 degrees. Third angled surface 31 b and fourth angled surface 32 b cooperate to define pathway 34 generally oriented at angle α 2 relative to axis L 1 . Second pathway 34 is sized to receive bone engaging member 18 therethrough.
First angled surface 31 a and third angled surface 31 b cooperate to define a first projection 35 extending in a longitudinal direction which narrows a dimension of opening 26 within nail 14 along axis L 1 . Similarly, second angled surface 32 a and fourth angled surface 32 b cooperate to define a second projection 36 extending in a longitudinal direction generally opposite first projection 35 to further narrow a dimension of opening 26 within nail 14 along axis L 1 . In a preferred embodiment, each projection 35 , 36 defines an apex, resulting in a convergent-divergent throat 36 a about midway between sides 14 c and 14 d of nail 14 . However, first projection 35 and second projection 36 could alternatively define any other geometric configuration as would occur to those skilled in the art. For example, first projection 35 and second projection 36 could be rounded. Likewise, in other alternative embodiments, one or more of projections 35 , 36 may be absent. While angled surfaces 31 a, 31 b, 32 a, 32 b are generally concave to compliment member 18 , other shapes are also contemplated as would occur to those skilled in the art. For example, angled surfaces 31 a, 31 b, 32 a, 32 b could be flat or have other configurations corresponding to the outer surface of bone engaging member 18 .
Referring to FIG. 4, sleeve 16 of system 10 is illustrated therein. Sleeve 16 has a generally cylindrical shape and defines a proximal end 16 a, a distal end 16 b and a side wall 37 . Sleeve 16 is sized to fit over the proximal end of nail 14 as shown in FIG. 3 . Distal end 16 b is therefore open to allow for passage of proximal end portion 14 a therethrough. Sleeve 16 also defines an inwardly tapered edge 38 , terminating at distal end 16 b, to permit easy sliding of sleeve 16 through bone. Proximal end 16 a defines an opening 39 to permit access to threaded bore 29 , and thus allow for passage of nail insertion and extraction instrumentation (not shown). Side wall 37 defines offset apertures 40 a, 40 b positioned on opposite sides of sleeve 16 . Apertures 40 a, 40 b are generally circular and are aligned and sized to receive bone engaging member 18 therethrough. Side wall 37 further defines opposing transverse apertures 42 a, 42 b positioned on opposite sides of sleeve 16 . Apertures 42 a, 42 b are generally circular and are aligned and sized to receive fastener 20 therethrough.
Referring to FIG. 5, therein is illustrated bone engaging member 18 . Bone engaging member 18 includes a proximal end portion 18 a and a distal end portion 18 b. Bone engaging member 18 has a generally circular cross section and preferably has a diameter of about 5.5-6.5 millimeters for applications treating fractured adult human femurs. Distal end portion 18 b includes a means for fixedly engaging and gripping bone 44 . Bone engaging member 18 may be a bone screw having a threaded distal end portion 18 b as shown in FIG. 5, or a bone blade having distal end portion 18 b formed from a plate with a helical twist (not shown). Alternately, distal end portion 18 b may be otherwise configured for engaging bone as would occur to those skilled in the art.
As illustrated in FIG. 5, when sleeve 16 is fitted over proximal end portion 14 a of nail 14 , apertures 40 a, 40 b of sleeve 16 are positioned to align with opening 26 of nail 14 , and register with pathway 33 along transverse axis T 1 . Collectively, apertures 40 a, 40 b and opening 26 define passageway 50 coincident with pathway 33 . Passageway 50 is bound on one side by first angled surface 31 a and on another side by second angled surface 32 a. As bone engaging member 18 is slidably received within passageway 50 and guided along transverse axis T 1 , bone engaging member 18 forms an abutting relationship with either or both of first and second angled surface 31 a, 32 a. This relationship may be load bearing in nature. Bone engaging member 18 is sized relative to passageway 50 so that its rotational position about axis L 1 and its translational position along axis L 1 are generally fixed when positioned therethrough.
As illustrated in FIG. 5, when sleeve 16 is fitted over proximal end portion 14 a of nail 14 , apertures 42 a, 42 b of sleeve 16 are aligned with bore 28 of nail 14 . A fastener 20 is passed through aperture 42 a and threaded into bore 28 to thereby releasably secure sleeve 16 to nail 14 . Another fastener 20 is passed through aperture 42 b and threaded into bore 28 to further secure sleeve 16 to nail 14 . While two fasteners 20 are shown to releasably secure sleeve 16 to nail 14 , it is also contemplated that a single fastener may be used to sufficiently secure sleeve 16 to nail 14 . To avoid interfering with the optional use of a guide wire (not shown) to aid in the insertion of nail 14 into femur 12 , fastener 20 has a length which penetrates bore 28 far enough to secure sleeve 16 to nail 14 , but without obstructing longitudinal passage 30 . In still other embodiments, one or more of fasteners 20 , bore 28 , and apertures 42 a, 42 b may not be utilized at all.
Notably, by rotating sleeve 16 180 degrees relative to nail 14 , system 10 may be reconfigured from an antegrade orientation of bone engaging member 18 to a retrograde orientation, or vice-versa. Similarly, regardless of which locking configuration is used, the same components of system 10 can be used to treat either a left or right femur by simply rotating sleeve 16 180 degrees relative to nail 14 . As a result, apertures 40 a, 40 b of sleeve 16 are repositioned to align with pathway 34 through opening 26 of nail 14 along transverse axis T 2 . Collectively, apertures 40 a, 40 b and opening 26 define passageway 52 which is coincident with pathway 34 . Passageway 52 is bound on one side by third angled surface 31 b and on another side by fourth angled surface 32 b (see FIGS. 2 and 5 ). As bone engaging member 18 is slidably received within passageway 52 and guided along transverse axis T 2 , bone engaging member 18 forms an abutting relationship with either or both of the third and fourth angled surfaces 31 b, 32 b. Preferably, this relationship is suitable for load bearing, and generally fixes member 18 with respect to rotation about axis L 1 or translation along axis L 1 .
In other embodiments of system 10 , the angular alignment of bone engaging member 18 relative to axis L 1 may be varied by changing the configuration of sleeve 16 . More specifically, apertures 40 a, 40 b can be aligned at an angle other than α 1 . In these embodiments, first passageway 50 does not fall along transverse axis T 1 of nail 14 . Thus, as bone engaging member 18 is slidably received within first passageway 50 , bone engaging member 18 will contact either first projection 35 or second projection 36 , but will not form an abutting relationship with first angled surface 31 a or second angled surface 32 a. However, the alternative arrangement is still suitable to fix bone engaging member 18 axially and rotationally relative to nail 14 .
Referring again to FIGS. 1 and 2, a femur implantation procedure corresponding to system 10 is next described. The implant procedure generally includes forming a longitudinal hole into, and generally parallel with, the medullary canal from a position slightly medial to the tip of the greater trochanter 12 a. The longitudinal hole is sized to receive nail 14 therethrough. Preferably, the longitudinal hole is formed by drilling. Sleeve 16 is fitted over proximal end portion 14 a of nail 14 and sleeve 16 is secured to nail 14 by threading fasteners 20 into bore 28 . As discussed above, system 10 can be used in either a first or second locking configuration depending on the rotational orientation of sleeve 16 relative to nail 14 .
FIG. 1 illustrates system 10 in a first locking configuration corresponding to an antegrade configuration for the depicted femur 12 . In this first locking configuration, sleeve 16 is secured to nail 14 with apertures 40 a, 40 b positioned relative to opening 26 of nail 14 to define passageway 52 along transverse axis T 2 . Nail 14 , with sleeve 16 secured thereto, is inserted through the longitudinal hole and into the medullary canal. A transverse hole is formed through femur 12 across the medullary canal corresponding to transverse axis T 2 The transverse hole intersects the medullary canal and is sized to receive bone engaging member 18 therein. Preferably this transverse hole also is formed by drilling. Bone engaging member 18 is inserted into the transverse hole and through passageway 52 formed by nail 14 and sleeve 16 . As a result, member 18 is preferably secured against translation along axis L 1 or rotation about axis L 1 . When received in passageway 52 , member 18 generally extends between a femur entry point slightly lateral to the greater trochanter 12 a to a terminal point below the base of neck 12 b. Generally parallel bores are formed through femur 12 transverse to the medullary canal and generally perpendicular to axis L 1 to align with transverse bores 24 a, 24 b of nail 14 . Preferably these bores are also formed by drilling. Nail 14 is further locked into position by inserting locking bone screws 22 a, 22 b through femur 12 and into transverse bores 24 a, 24 b of nail 14 .
FIGS. 2 and 5 illustrates system 10 in a second locking configuration corresponding to a retrograde arrangement relative to the depicted femur 12 . In this second locking configuration, sleeve 16 is secured to nail 14 with apertures 40 a, 40 b positioned relative to opening 26 of nail 14 to define passageway 50 along transverse axis T 1 . The medullary canal is accessed in generally the same manner as described in connection with FIG. 1 . Nail 14 , with sleeve 16 secured thereto, is inserted through the longitudinal hole medial to the greater trochanter 12 a and into the medullary canal. A transverse hole is drilled into femur 12 across the medullary canal corresponding to transverse axis T 1 and sized to receive bone engaging member 18 therein. Bone engaging member 18 is inserted into the transverse hole through passageway 50 . So arranged, member 18 generally extends through neck 12 b into head 12 c. Generally parallel bores are formed through femur 12 transverse to the medullary canal and generally perpendicular to axis L 1 . These bores are generally aligned with transverse bores 24 a, 24 b of nail 14 . Nail 14 is further locked into position by inserting locking bone screws 22 a, 22 b through femur 12 and into transverse bores 24 a, 24 b of nail 14 .
Next, a preferred method of manufacturing nail 14 is described. This preferred method includes drilling a first bore through proximal portion 14 a in a direction corresponding to transverse axis T 1 (aligned at angle α 1 ). A second bore is then drilled through proximal portion 14 a corresponding to transverse axis T 2 (aligned at angle α 2 ) and intersecting the first bore at a point generally corresponding to the centerline of nail 14 . The first and second bores are each sized to receive bone engaging member 18 therethrough. The first bore thereby defines first angled surface 31 a and second angled surface 32 a, and the second bore thereby defines third angled surface 31 b and fourth angled surface 32 b. The remaining material between lower surface 31 and upper surface 32 may then be removed to form opening 26 through nail 14 , having projections 35 , 36 as depicted.
FIG. 6 depicts intramedullary system 100 according to another embodiment of the present invention; where like reference numerals represent like features previously described in connection with system 10 . System 100 is shown implanted in femur 12 and includes intramedullary rod or nail 14 , transverse member 102 , pin 103 , locking screw 104 and set crew 105 . System 100 also includes locking bone screws 22 a, 22 b. Although system 100 is shown implanted in human femur 12 , system 100 could also be used in conjunction with other bones as would occur to one skilled in the art, including the tibia, humerus, radius, ulna and fibula to name a few. While system 100 could be used to treat the same indications as system 10 in the second locking configuration, as illustrated in FIG. 2 and discussed above, it is preferably used for fractures of the proximal portion of femur 12 , and more preferably fractures between the neck 12 b and head 12 c. The same components of system 100 can be used to treat either a left or right femur by rotating transverse member 102 180 degrees relative to nail 14 .
FIGS. 7-12 provide additional details concerning the structure and assembly of system 100 . Referring to FIG. 7, various structural details of transverse member 102 and pin 103 are shown therein. Transverse member 102 defines a longitudinal centerline axis L 2 and includes a barrel connection portion 106 and a bone engaging portion 108 . Connection portion 106 is generally cylindrical and has a side wall 110 . Side wall 110 defines a passage 112 extending generally along axis L 2 . Connection portion 106 also includes a proximal portion 106 a and a distal portion 106 b. Proximal portion 106 a includes an internal threaded portion 114 extending along a portion of passage 112 . Distal portion 106 b defines an external inward taper 116 to promote ease of movement through bone when transverse member 102 is advanced into femur 12 . Distal portion 106 b also defines an inner retaining lip 118 for provisionally maintaining bone engaging portion 108 in sliding engagement with connection portion 106 , the operation of which will become apparent hereinafter.
A thru-hole 120 is formed through connection portion 106 . Thru-hole 120 is generally cylindrical and has a diameter slightly greater than the outer diameter of proximal portion 14 a of nail 14 . Alternately, thru-hole 120 could be elliptical or any other shape corresponding to proximal portion 14 a of nail 14 . Additionally, thru-hole 120 and portion 14 a of nail 14 could be asymmetrical and of similar profile to prevent rotational movement of transverse member 102 relative to nail 14 when proximal portion 14 a is received within thru-hole 120 . Similarly, if thru-hole 120 and portion 14 a of nail 14 where both tapered in the same direction and at about the same angle, the resulting tight engagement between transverse member 102 and nail 14 would aid in preventing rotational movement.
Thru-hole 120 is formed through connection portion 102 to provide a selected angular relationship with axis L 1 when nail 14 passes therethrough. This relationship corresponds to angle α 3 between axes L 1 and L 2 , and is preferably in a range of about 130-145 degrees. More preferably, for system 100 , angle α 3 is about 135 degrees and is equal to angle α 2 as depicted in FIG. 6 . As will become apparent from later discussion, angle α 3 corresponds to the angle of fixation between transverse member 102 and nail 14 .
Bone engaging portion 108 includes a proximal portion 108 a and a distal portion 108 b. A bone engaging and gripping thread 122 is formed on distal portion 108 b. Additionally or alternatively, a different bone gripping means may be utilized, such as a bone blade having distal portion 108 b formed from a plate with a helical twist, or such other means as would occur to those skilled in the art.
Proximal portion 108 a includes a hex recess 124 for receiving a driving tool (not shown), such as an Allen wrench, preferably suited to drive bone engaging portion 108 into neck 12 b and head 12 c of femur 12 . Bone engaging portion 108 defines a longitudinal passage 126 extending therethrough and generally along axis L 2 to allow for the optional use of a guide wire (not shown) to aid in the insertion of bone engaging portion 108 into bone. Proximal portion 108 a is sized to be received within passage 112 of connection portion 106 to allow slidable movement of bone engaging portion 108 generally along axis L 2 over a predetermined range. A keeper 128 is provided on, in association with, or integral to proximal portion 108 a to provisionally maintain bone engaging portion 108 and connection portion 106 in a telescopic sliding relationship. Keeper 128 is comprised of a cylindrical sleeve that is preferably laser welded onto shaft 130 of bone engaging portion 108 after it has been positioned within connection portion 106 . The outer diameter of keeper 128 is slightly smaller but in close tolerance with the inner diameter of passage 112 .
Pin 103 is shown positioned within passage 112 of connection portion 106 . FIGS. 8A and 8B additionally illustrate various structural details of pin 103 . Pin 103 has a longitudinal centerline axis L 3 and includes a leading portion 132 integrally connected to a trailing portion 134 . Leading portion 132 has a generally circular, elongated body and is sized to be received within opening 26 of nail 14 . Leading portion 132 also includes an angled, annular engaging surface 135 configured to co-act with a surface of nail 14 . Engaging surface 135 is aligned at an angle α 4 relative to axis L 3 . Angle α 4 is in a range of about 130-145 degrees. Most preferably, angle α 4 should be approximately equal to angle α 2 . Leading portion 132 additionally includes a tapered tip 136 . Trailing portion 134 is provided with an externally threaded portion 137 configured to threadedly engage threaded portion 114 of connection portion 106 . A hex recess 138 is defined by trailing portion 134 for receiving a driving tool (not shown), such as an Allen wrench, to advance pin 103 into portion 106 or remove pin 103 from portion 106 by turning in a corresponding rotational direction. In other embodiments, pin 103 additionally or alternatively has a different means for positioning relative to connection portion 106 , such as a ratcheting mechanism, a cabling arrangement, or any other method capable of advancing pin 103 along axis L 2 as would occur to those skilled in the art.
In order to prevent pin 103 from migrating once positioned in a desired position within passage 112 , system 100 includes locking screw 104 . Locking screw 104 is provided with external threads 142 configured to threadedly engage threaded portion 114 of connection portion 106 . A hex recess 144 is defined by trailing end 146 for receiving a driving tool (not shown), such as an Allen wrench, to rotationally advance locking screw 104 along connection portion 106 . Locking screw 104 is axially advanced along axis L 2 until it tightly engages trailing portion 134 of pin 103 . In other embodiments, system 100 additionally or alternatively includes another locking means as would normally occur to one skilled in the art to prevent pin 103 from migrating relative to connection portion 106 .
To further aid in preventing pin 103 from rotating, loosening or migrating once positioned in a desired axial position within passage 112 , system 100 includes set screw 105 . Set screw 105 includes a threaded portion 150 and an elongated stem portion 152 . Threaded portion 150 is configured to threadedly engage bore 29 of nail 14 . Threaded portion 150 also includes a hex recess 154 for receiving a driving tool (not shown), such as an Allen wrench, to rotationally advance set screw 105 along bore 29 . Elongated stem portion 152 is sized to be slidably received within longitudinal passage 30 of nail 14 . Stem 152 also defines a tapered or contoured end 156 conforming with an outer surface of leading portion 132 of pin 103 to provide improved mechanical interlocking between set screw 105 and pin 103 .
Referring generally to FIGS. 6, 7 , 8 A, and 8 B, another embodiment of a femur implantation procedure in accordance with the present invention is described with respect to system 100 . This femur implantation procedure generally includes forming a transverse passage into femur 12 that crosses the medullary canal and is sized to receive transverse member 102 therein. Preferably, this transverse passage is formed by drilling and begins at the lateral side of femur 12 , extends into neck 12 b and terminates in head 12 c to orient transverse member 102 as depicted in FIG. 6 . Also shown in FIG. 6, it is preferred that the transverse passage form an oblique angle approximately the same as angle α 3 with respect to axis L 1 or the medullary canal.
Next, transverse member 102 is introduced through the transverse passage with thruhole 120 positioned to at least overlap the medullary canal of femur 12 , and preferably to be generally centered with respect to the medullary canal of femur 12 . At least a portion of bone engaging portion 108 is threaded into femur 12 at this stage. Preferably, bone engaging portion 108 is threaded into a portion of head 12 c of femur 12 by engaging hex recess 124 with a suitable tool and turning portion 108 in a corresponding rotational direction generally about axis L 2 .
Notably, bone engaging portion 108 is telescopically received within passage 112 of connection portion 106 to allow axial movement of bone engaging portion 108 over a predetermined range along axis L 2 . Keeper 128 cooperates with inner retaining lip 118 to prevent disengagement of bone engaging portion 108 from connection portion 106 . The cooperation between inner retaining lip 118 and keeper 128 also acts to stabilize bone engaging portion 108 , thus aiding in the sliding motion of bone engaging portion 108 to provide the preferred telescopic functioning of transverse member 102 . Since connection portion 106 provisionally maintains bone engaging portion 108 in a captive, telescopic relationship, the alignment of bone engaging portion 108 along axis L 1 is always maintained. Thus, when the procedure includes turning thread 122 through neck 12 b of femur 12 and into head 12 c, head 12 c will become fixed in an angular relationship relative to transverse member 102 . By maintaining the angular alignment between neck 12 b and head 12 c, and allowing them to slide telescopically relative to one another, system 100 can accommodate for changes during patient movement and expedite the bone healing process.
After transverse member 102 is inserted, an opening is formed, preferably by drilling, into and generally along the medullary canal from a position slightly medial relative to the tip of the greater trochanter 12 a and sized to receive nail 14 therethrough. Nail 14 is inserted through the longitudinal and into the medullary canal. Nail 14 passes through thru-hole 120 of connection portion 106 . Thru-hole 120 of transverse member 102 receives nail 14 in a close sliding fit, thereby permitting limited axial and rotational movement of transverse member 102 along axis L 1 of nail 14 . Transverse member 102 is longitudinally positioned on nail 14 so that passage 112 of connection portion 106 registers with opening 26 of nail 14 . If desired, bone engaging portion is further advanced into the bone at this stage.
Next, pin 103 is axially advanced through passage 112 by engaging hex recess 144 with an appropriate tool and rotating in a corresponding direction. As threaded portion 137 of pin 103 engages threaded portion 114 of connection portion 106 , leading portion 132 is slidably received within opening 26 to engage one or more surfaces 31 b, 32 b. Even if passage 112 and opening 26 are misaligned, in many instances tapered tip 136 allows pin 103 to self-center, thereby aiding in the insertion of leading portion 132 within opening 26 . As pin 103 is slidably received within pathway 34 of opening 26 and guided along transverse axis T 2 , leading portion 132 forms an abutting relationship with one or both of angled surfaces 31 b, 32 b. Pin 103 thus becomes oriented at angle α 2 relative to axis L 1 , aiding in the fixation of transverse member 102 relative to nail 14 . As pin 103 is further advanced through passage 112 , engaging surface 135 is firmly pressed against nail 14 and transverse member 102 is pulled in a proximal direction. Correspondingly, an inner surface of transverse member 102 that borders thru-hole 120 is clamped against an outer surface of nail 14 while generally maintaining angle α 2 of transverse member 102 relative to axis L 1 .
After securely clamping transverse member 102 and nail 14 together, generally parallel passages are formed, preferably by drilling through femur 12 transverse to the medullary canal and aligned with transverse bores 24 a, 24 b of nail 14 . Nail 14 is further locked into position by inserting locking bone screws 22 a, 22 b through femur 12 and into transverse bores 24 a, 24 b of nail 14 .
Referring to FIG. 9, system 160 of another embodiment of the present invention is illustrated; where reference numerals like those of previous embodiments refer to like features. System 160 includes transverse member 102 ′ which is the same as transverse member 102 except that pin 103 ′ is utilized in place of pin 103 . FIGS. 10A, 10 B, 11 A and 11 B illustrate selected details of pin 103 ′. Pin 103 ′ includes a leading portion 162 and a non-integral trailing portion 164 . Leading portion 162 preferably has a generally circular, elongated body and is sized to be received within opening 26 of nail 14 . Leading portion 162 also includes an angled, annular engaging surface 165 configured to co-act with a surface of nail 14 . Engaging surface 165 is aligned at an angle α 4 relative to axis L 4 of pin 103 ′. Leading portion 162 additionally includes a tapered tip 166 .
Leading portion 162 is articulated to trailing portion 164 to facilitate pivotal movement of portion 162 relative to portion 164 . Trailing portion 164 includes externally threaded portion 167 configured to threadedly engage threaded portion 114 of connection portion 106 . A hex recess 168 is defined by trailing portion 164 for receiving a driving tool (not shown), such as an Allen wrench, to advance pin 103 ′ axially along connection portion 106 . In other embodiments, pin 103 ′ is alternatively or additionally configured with a different means to be axially advanced through connection portion 106 , such as a ratcheting mechanism or a cabling arrangement. In still other embodiments, techniques are utilized as would occur to one skilled in the art.
Leading portion 162 has a longitudinal centerline axis L 4 and trailing portion 164 has a longitudinal centerline axis L 5 . Unlike pin 103 , leading portion 162 and trailing portion 164 are not integral and are coupled to permit leading portion 162 to pivot relative to trailing portion 164 . This pivoting or articulation permits angular variation of portion 162 relative to axis L 2 . In one preferred embodiment, leading portion 162 includes a ball and socket joint 170 to provide the angular adjustment capability.
The rear portion of leading portion 162 defines a concave surface 174 generally centered about axis L 4 . Projecting proximally from concave surface 174 along axis L 4 is stem 178 . Stem 178 has a generally circular cross section, but also preferably defines a pair of parallel, opposing flats 180 a, 180 b. A ball member 182 is positioned at the end of stem 178 and is generally spherical-shaped. Trailing portion 164 defines a convex surface 184 generally centered about axis L 5 and configured to closely conform with concave surface 174 of leading portion 162 . Trailing portion 164 also defines a transverse socket 186 extending partially therethrough and aligned generally perpendicular to axis L 5 .
Transverse socket 186 has a diameter slightly larger than the diameter of ball member 182 . Transverse socket 186 terminates at concave bottom surface 188 . Concave bottom surface 188 substantially conforms with the outer surface of ball member 182 . Trailing portion 164 also defines a longitudinal bore 190 aligned with axis L 5 . Longitudinal bore 190 extends from convex surface 184 to transverse socket 186 . Longitudinal bore 190 is outwardly tapered with wide end 190 a intersecting convex surface 184 and narrow end 190 b intersecting transverse socket 186 , thus defining taper angle α 5 relative to axis L 5 . Preferably, taper angle α 5 is between about 5 degrees and 20 degrees. Most preferably, taper angle α 5 is about 10 degrees. Trailing portion 164 further defines a transverse slot 192 extending partially therethrough and substantially aligned with transverse socket 186 . Slot 192 has a width W extending along longitudinal bore 190 from convex surface 184 to transverse socket 186 . Slot 192 has a depth sufficient to intersect narrow end 190 b of transverse bore 190 . Height H of slot 192 is slightly greater than the distance between flats 180 a, 180 b of stem 190 . Collectively, socket 186 and slot 192 are configured to receive ball member 182 and stem 178 therein, respectively.
In another embodiment of pin 103 ′, a flexible, readily deformable intermediate section is positioned between leading portion 162 and trailing portion 164 that may be additionally or alternatively used to provide means for allowing angular variation between axis L 4 and axis L 5 . In still another embodiment, portion 162 is journaled to portion 164 by a shaft through a bore, permitting rotation of portion 162 relative to portion 164 . In other embodiments, another suitable means for providing angular variation between axis L 4 and L 5 may alternatively or additionally be utilized as would occur to those skilled in the art.
As illustrated in FIG. 9, pin 103 ′ operates generally in the same manner as pin 103 described in connection with system 100 . Although pin 103 ′ can be used in instances where angles α 2 and α 3 are substantially equal (as shown in FIG. 9 ), the more preferred application arises in configurations where angles α 2 and α 3 are different. The articulation of leading portion 162 relative to trailing portion 164 facilitates secure clamping to nail 14 despite a mismatch between the angled surfaces 31 a, 32 a, or 31 b, 32 b and the angular relationship of member 102 ′ to axis L 1 defined by thru-hole 120 . For example, referring additionally to FIG. 12, angles α 2 and α 3 are about 135 and 140 degrees, respectively, relative to axis L 1 . Preferably, the pivot range of leading portion 162 accommodates a range of different angular orientations of thru-hole 120 corresponding to α 3 . In one more preferred range, leading portion 162 pivots to accommodate a variation of angle α 3 from about 130 to about 145 degrees.
In one preferred implantation procedure, transverse member 102 ′ and nail 14 are implanted in accordance with the same procedure for inserting bone engaging member 108 , connection portion 106 and nail 14 , with the engagement of pin 103 ′ in place of pin 103 . For pin 103 ′, ball member 182 is inserted into socket 186 by aligning flats 180 a, 180 b of stem 178 with slot 192 and then guiding ball member 182 within transverse socket 186 until ball member 182 is positioned adjacent concave bottom surface 188 . A slight rotation or angulation of leading portion 162 relative to trailing portion 164 securely engages the two portions. As a result, leading portion 162 is rotatably coupled to trailing portion 164 by ball and socket joint 170 . Thus, leading portion 162 can rotate freely over a predetermined range within passage 112 as limited by taper angle α 5 . In one preferred embodiment, taper angle α 5 permits angular variation between leading portion 162 and trailing portion 164 of about 10 degrees in any direction. The assembly of leading portion 162 to trailing portion 164 may be performed during the implantation procedure just before insertion into passage 112 or in advance of the procedure as desired.
Once leading portion 162 and trailing portion 164 are assembled, Pin 103 ′ is advanced through passage 112 of connection portion 106 by engaging hex recess 168 and turning in the appropriate rotational direction. Pin 103 ′ is slidably received within pathway 34 of opening 26 and leading portion 162 is guided along transverse axis T 2 to form an abutting relationship with one or both of angled surfaces 31 b, 32 b. If, as mentioned above, thru-hole 120 is disposed in connection portion 106 in correspondence to a different angle α 3 relative to axis L 1 (such as 140 degrees), leading portion 162 is forced to pivot relative to trailing portion 164 and thereby aligns at angle α 2 (such as 135 degrees). As trailing portion 164 is tightened in connection portion 106 , a rigid, secure construct forms between transverse member 102 ′ and nail 14 as described in connection with the operation of system 100 , except that pin 103 ′ may pivot, contacting an inner surface of connection portion 106 as illustrated in FIG. 12 . Notably, like system 10 , system 100 and 160 may be reconfigured to accommodate either the left or right femur or an antegrade or retrograde application; however, in other embodiments of the present invention, rod 14 may be modified to define only one generally linear pathway therethrough.
Referring now to FIG. 13, system 195 according to another embodiment of the present invention is illustrated; where reference numerals of previously described embodiments refer to like features. Preferably, system 195 is implanted in femur 12 as shown, and includes intramedullary rod or nail 14 , set screw 105 , and locking bone screws 22 a, 22 b, 22 c. In other embodiments, system 195 may be used in conjunction with other bones as would occur to one skilled in the art, such as the tibia, humerus, radius, ulna, or fibula to name a few. Additionally, the same components of system 195 can be used to treat either a left or right femur by simply rotating nail 14 180 degrees relative to longitudinal axis L 1 . Unlike systems 10 , 100 and 160 ; system 195 positions nail 14 with the proximal and distal end portions reversed within femur 12 corresponding to implantation of nail 14 in a retrograde direction. Unlike existing systems, nail 14 need not be modified to operate in a retrograde direction. Indeed, nail 14 may be used in either an antegrade direction, as illustrated in connection with systems 10 , 100 , and 160 , or a retrograde direction as illustrated in FIG. 13 .
One preferred implant procedure for system 195 includes forming a longitudinal hole along femur 12 , intersecting the medullary canal from a point generally central to distal end portion 12 d. The longitudinal hole is sized to receive nail 14 therethrough and is preferably formed by drilling into femur 12 . Nail 14 is inserted through the longitudinal hole and into the medullary canal. A pair of generally parallel, transverse passageways are formed, preferably by drilling, through femur 12 transverse to and intersecting with the medullary canal. These passageways are in registry with opening 26 and transverse bore 28 , respectively. Nail 14 is locked into position by inserting locking bone screws 22 a, 22 b into the transverse passageways and correspondingly through opening 26 and transverse bore 28 . Another transverse passageway is drilled through femur 12 across the medullary canal and intersecting therewith that is generally aligned with transverse bore 24 c formed in distal portion 14 b of nail 14 . Nail 14 is further locked into position by inserting locking bone screw 22 c into this distal transverse passageway and correspondingly through transverse bore 24 c. Although system 195 does not require a sleeve to lock bone screws 22 a, 22 b into position relative to nail 14 , as discussed below, such a feature may optionally be utilized.
Referring now to FIG. 14, shown is bone treatment system 200 according to yet another embodiment of the present invention; where reference numerals of previously described embodiments refer to like features. System 200 is shown implanted in femur 12 and includes intramedullary nail 14 , sleeve 202 , bone engaging members 204 , 205 and biasing sleeve 202 . Preferably, system 200 is utilized to treat fractures of the human femur, but may be used in conjunction with any other bone as would occur to those skilled in the art. Additionally, while system 200 can be used with any nail and sleeve configuration, it is preferably used in conjunction with retrograde implantation of nail 14 as described in connection with FIG. 13 herein.
In FIG. 14, opening 26 extends generally along transverse centerline axis T 3 and transverse bore 28 extends generally along transverse centerline axis T 4 . Opening 26 is bounded by a bearing surface 26 a and bore 28 is bounded by a bearing surface 28 a. Sleeve 202 has a generally cylindrical shape and defines a proximal end 202 a, a distal end 202 b, and a side wall 208 . Sleeve 202 is sized to fit over proximal end portion 14 a of nail 14 . Distal end 202 b is therefore open to allow for passage of proximal end portion 14 a. Sleeve 202 defines an inwardly tapered edge 210 , terminating at distal end 202 b, to facilitate movement of sleeve 202 through bone. Proximal end 202 a is also open to allow for the passage of nail insertion and extraction instrumentation (not shown). The interior surface of side wall 208 immediately adjacent proximal end 202 a defines a threaded portion 211 . Side wall 208 also defines two sets of opposing apertures 212 a, 212 b and 214 a, 214 b. Apertures 212 a, 214 a oppose apertures 212 b, 214 b in a direction along axes T 3 , T 4 , respectively. Aperture sets 212 a, 212 b, and 214 a, 214 b are generally circular and are aligned and sized to respectively receive bone engaging members 204 , 205 therethrough. Apertures 212 a, 212 b define circumferential engaging surfaces 213 a, 213 b, respectively, and apertures 214 a, 214 b define circumferential engaging surfaces 215 a, 215 b, respectively.
Bone engaging member 204 includes a proximal end portion 204 a opposite a distal end portion 204 b. Bone engaging member 204 has a generally circular cross section and preferably has a diameter of about 5.5-6.5 millimeters for a femur application. Distal end portion 204 b includes thread 216 for engaging and gripping bone. Alternatively or additionally, member 204 may include a different bone engaging or gripping means such as a bone blade having distal end portion 204 b formed from a plate with a helical twist or an expansion device. Bone engaging member 205 includes a proximal end 205 a and a distal end 20 b and is preferably configured the same as bone engaging member 204 .
System 200 includes biasing end cap 220 . End cap 220 is generally circular and includes a first threaded portion 222 configured to threadingly engage threaded portion 211 of sleeve 202 . A second threaded portion 224 is configured to threadingly engage longitudinal bore 29 of nail 14 . End cap 220 proximally terminates in an enlarged, flat end portion 226 having protruding flange 228 . Flat end portion 226 also defines hex recess 230 for receiving a driving tool (not shown).
System 200 is utilized in accordance with one preferred femur implantation procedure by inserting nail 14 as described in connection with FIG. 13, except, proximal end 14 a also carries sleeve 202 thereon by loosely threading end cap 220 into sleeve 202 and rod 14 .
Accordingly, protruding flange 228 of flat end portion 226 bears against proximal end 202 a of sleeve 202 . With sleeve 202 so oriented, apertures 212 a, 212 b are generally in alignment with transverse bore 28 along axis T 4 to define passageway 232 . Correspondingly, apertures 214 a, 214 b are generally aligned with opening 26 along transverse axis T 3 to defined passageway 234 .
Once the nail 14 and sleeve 202 are in place within femur 12 , two transverse passages are formed through the bone that are in registry with passageways 232 , 234 . Next, bone engaging members 204 , 205 are received through the bone and passageways 232 , 234 , respectively. Once bone engaging members are in place. Sleeve 202 is biased by further tightening of end cap 220 . As end cap 220 is tightened, is moves sleeve 202 and nail 14 in opposite directions along axes L 1 . Correspondingly, surfaces 213 a, 213 b move to bear against bone engaging member 204 and engaging surfaces 214 a, 214 b bear against bone engaging member 205 . In turn, bone engaging member 204 is tightly clamped against bearing surface 26 a of opening 26 and bone engaging member 205 is tightly clamped against bearing surface 28 a of bore 28 . The tight engagement between bone engaging members 204 , 205 and bearing surfaces 26 a, 28 a thereby clamps bone engaging members 204 , 205 into position relative to nail 14 and prevents lateral migration. Locking nuts, which have in the past been used to prevent such lateral migration, are generally not needed for system 200 , so that additional surgical incisions normally required to engage locking nuts onto the bone engaging members need not be made and soft tissue irritation commonly associated with the presence of the locking nuts is also eliminated. Preparations and implantation of one or more bone engaging members may optionally be performed at distal end 14 b of nail 14 .
In an alternative embodiment, end cap 220 does not include first threaded portion 222 . Thus, as threaded portion 224 engages longitudinal bore 29 of nail 14 , flange 228 of flat end portion 226 contacts proximal end 202 a of sleeve 202 to advance sleeve 202 in a distal direction relative to nail 14 . In still another embodiment, end cap 220 does not include second threaded portion 224 . Thus, as threaded portion 222 engages threaded portion 211 of sleeve 202 , flat end 222 a of threaded portion 222 is forced into contact with the proximal end of nail 14 , thereby advancing sleeve 202 in a proximal direction relative to nail 14 . In yet another embodiment of system 200 , the biasing means consists of a spring member operably captured between nail 14 and sleeve 202 . The spring member is configured to urge sleeve 202 , nail 14 , or both to clamp bone engaging members 204 , 205 .
Referring now to FIG. 15, intramedullary system 300 according to still another embodiment of the present invention is illustrated; where reference numerals of previously described embodiments refer to like features. System 300 is shown implanted in femur 12 and includes elongated intramedullary nail 302 , positioning device 304 , bone engaging member 306 and locking bone screw 308 . Femur 12 includes a fracture site 301 , separating femur 12 into two portions 12 f, 12 e. Fracture site 301 is shown in a compressed state (i.e., portions 12 f, 12 e are being pushed together). Although system 300 is shown implanted in femur 12 , system 300 could also be used in conjunction with other bones such as the tibia, humerus, radius, ulna and fibula to name a few. Additionally, the same components of system 300 can be used to treat either a left or right femur by simply rotating nail 302 180 degrees relative to axis L 6 . Although FIG. 15 illustrates nail 302 implanted within femur 12 in a retrograde direction, it is understood that system 300 could also be implanted with nail 302 in an antegrade direction.
FIGS. 15 and 16 show various structural details of nail 302 . It should be understood that nail 302 can take on a number of configurations, including that of nail 14 illustrated and described above. However, in a preferred embodiment, nail 302 is configured as described below. Nail 302 includes a proximal end portion 302 a and a distal end portion 302 b. Nail 302 also defines a longitudinal axis L 6 running along the length of nail 302 between proximal end portion 302 a and distal end portion 302 b. Proximal end portion 302 a preferably has a diameter of about 11-12 millimeters for an adult human femur application. The diameter of the remainder of nail 302 can be varied depending upon the requirements of the fixation procedure and the surgeon's preference. While nail 302 has a generally circular cross section, other suitable shapes are also contemplated as would occur to one skilled in the art.
Nail 302 defines a passage 309 extending therethrough along axis L 6 line to allow for the optional use of a guide wire (not shown) to aid in the insertion of nail 302 in femur 12 . Distal end portion 302 b defines parallel transverse bores 310 b, 310 c, each sized to receive locking bone screw 308 . Distal end portion 302 b also defines transverse bore 310 a, aligned generally perpendicular to transverse bores 310 b, 310 c and also sized to receive locking bone screw 308 .
Proximal end portion 302 a defines an elongated, longitudinal opening 312 bounded by side walls 313 and sized to receive bone engaging member 306 therein. Opening 312 laterally extends through nail 302 and is elongated in the direction of longitudinal axis L 6 . Opening 312 has a first end portion 312 a and an opposing second end portion 312 b. Proximal end portion 302 a of nail 302 also defines a longitudinal passage 314 extending generally along axis L 6 and having a generally circular cross-section. Longitudinal passage 314 intersects opening 312 and terminates in a generally concave bottom surface 316 . A threaded portion 318 is defined about a portion of longitudinal passage 314 . Proximal end portion 302 a also defines a transverse bore 320 extending through nail 302 generally perpendicular to axis L 6 and aligned with opening 312 . Bore 320 is sized to receive bone engaging member 306 therein.
Referring to FIG. 17 therein is shown nail 302 , positioning device 304 and bone engaging member 306 as assembled within system 300 . Positioning device 304 is shown positioned within longitudinal passage 314 and includes a first portion 322 and a second portion 324 . First portion 322 includes a head 326 and a threaded stem 328 extending therefrom generally along longitudinal axis L 6 . Head 326 is substantially circular and has an outer diameter generally corresponding to the outer diameter of nail 302 . Head 326 also includes a hex recess 330 for receiving a driving tool (not shown), such as an Allen wrench. The diameter of threaded stem 328 is less than the diameter of head 326 , thereby defining an annular shoulder 332 .
Second portion 324 defines a generally circular, elongated body 333 having a diameter slightly less than the diameter of longitudinal passage 314 . Second portion 324 also defines an internally threaded portion 334 extending generally along longitudinal axis L 6 and configured to threadedly engage threaded stem 328 of first portion 322 . Threaded portion 334 has a depth slightly greater than the length of threaded stem 328 . The end of second portion 324 opposite threaded portion 334 terminates into a generally convex outer surface 336 that substantially corresponds to concave bottom surface 316 of longitudinal passage 314 . Second portion 324 also defines a transverse opening 338 extending therethrough generally perpendicular to longitudinal axis L 6 . Opening 338 is bounded by inner surface 339 and is sized to receive bone engaging member 306 therein.
FIG. 17 illustrates a first operational position of system 300 . Positioning device 304 (including first and second portions 322 , 324 ) is shown inserted within longitudinal passage 314 of nail 302 . Opening 338 of second portion 324 is positioned adjacent second end portion 312 b of opening 312 and generally aligned with opening 312 to define a passageway 40 . Bone engaging member 306 is shown inserted through passageway 340 . Threaded stem 328 of first portion 322 is partially threadedly engaged within threaded portion 334 of second portion 324 . First portion 322 can be rotated by placing a driving tool (not shown) within hex recess 330 and turning in a clockwise or counterclockwise direction as appropriate. Second portion 324 is prevented from rotating in correspondence with first portion 322 because of engagement between bone engaging member 306 against sidewalls 313 of opening 312 . In one embodiment, threaded stem 328 and threaded portion 334 each have right-handed threads. In this embodiment, as first portion 322 is rotated in a clockwise direction, shoulder 332 of head 326 bears against nail 302 , and second portion 324 correspondingly moves toward first portion 322 generally along longitudinal axis L 6 . As the position of second portion 324 is adjusted along axis L 6 , inner surface 339 of opening 338 bears against bone engaging member 306 and correspondingly adjusts the position of bone engaging member 306 along the length of opening 312 .
FIG. 18 illustrates a second operational position of system 300 in which first portion 322 is rotated in a clockwise direction until bone engaging member 306 is positioned adjacent first end portion 312 a of opening 312 . It should be understood, however, that bone engaging member 306 can be variably positioned anywhere along the length of opening 312 . It should further be understood that the terms “first operational position” and “second operational position” are not necessarily indicative of the initial position and adjusted position of bone engaging member 306 . For example, bone engaging member 306 could originate in a position adjacent first end portion 312 a and be variably positioned anywhere along the length of opening 312 .
In other embodiments of system 300 , nail 302 defines a keyway extending along the length of longitudinal passage 314 generally parallel with axis L 6 . Additionally, second portion 324 defines a key along its length which generally corresponds to the keyway defined in nail 302 . Preferably, the key is radially positioned so that when it is slidably received within the keyway, opening 338 of second portion 324 will correspondingly align with opening 312 of nail 302 . Alternatively, the key could be defined along the length of second portion 324 and, correspondingly, the keyway could be defined along the length of longitudinal passage 314 of nail 302 .
Having described selected structural and operational features of nail 302 and positioning device 304 , the operational characteristics of system 300 will now be described in further detail. Referring back to FIG. 15, nail 302 is shown implanted in femur 12 . Distal end 302 b of nail 302 is anchored to portion 12 e of femur 12 by inserting locking bone screw 308 into portion 12 e and through transverse bore 310 a (not shown) of nail 302 . Proximal end 302 a of nail 302 is anchored to portion 12 f of femur 12 by inserting bone engaging member 306 into portion 12 f and through passageway 340 (defined by aligning opening 338 with opening 312 ). Preferably, bone engaging member 306 is initially positioned adjacent or near second end portion 312 b of opening 312 . As first portion 322 of positioning device 304 is rotated in a clockwise direction, bone engaging member 306 is correspondingly repositioned along the length of opening 312 , and more specifically is transferred toward first end portion 312 a. Because bone engaging member 306 is anchored to portion 12 f of femur 12 , portion 12 f is correspondingly moved in the direction of arrow “A”, while portion 12 e of femur 12 remains stationery, securely anchored to distal end 302 b of nail 302 . Thus, portion 12 f of femur 12 is repositioned away from portion 12 e, thereby distracting fracture site 301 .
One preferred procedure for implanting system 300 within femur 12 includes forming a longitudinal hole along the medullary canal from a point generally central to the distal end portion 12 d of femur 12 . Preferably this hole is formed by drilling sized to receive nail 302 therethrough. Positioning device 304 is inserted in longitudinal passage 314 of nail 302 and nail 302 is inserted through the longitudinal hole and into the medullary canal. It should be understood that positioning device 304 could alternatively be inserted in longitudinal passage 314 after nail 302 has been implanted in femur 12 . A first passage is formed through femur 12 transverse to the medullary canal and generally aligned with transverse bore 310 a (not shown) formed in distal portion 302 b of nail 302 . A second passage is formed through femur 12 transverse to the medullary canal and generally aligned with passageway 340 . Preferably, these transverse passages are formed by drilling. Locking bone screw 308 is threaded into the first passage, passing through transverse bore 310 a. Bone engaging member 306 is threaded into the second passage, passing through passageway 340 . At this point, fracture site 301 can be distracted by following the operational procedure described above. Dashed line 301 a of FIG. 15 corresponds to the position of the fractured end of portion 12 f after distraction in accordance with one embodiment of the present invention.
Referring now to FIG. 19, intramedullary system 400 according to yet another embodiment of the present invention is illustrated; where like reference numerals of previously described embodiments refer to like features. System 400 is shown implanted in femur 12 and includes elongated intramedullary nail 302 , positioning device 304 ′, bone engaging member 306 and locking bone screw 308 . Femur 12 includes a fracture site 301 ′, separating femur 12 into two portions 12 f, 12 e. Fracture site 301 ′ is shown in a distracted state (i.e., portion 12 a, 12 b are spaced apart relative to one another). Although system 400 is shown implanted in femur 12 , system 400 could also be used in conjunction with other bones as would occur to one skilled in the art, including the tibia, humerus, radius, ulna and fibula, to name a few. Additionally, the same components of system 400 can be used to treat either a left or right femur by simply rotating nail 302 180 degrees relative to axis L 6 . Although FIG. 19 illustrates nail 302 implanted within femur 12 in a retrograde direction, it is understood system 400 may also be implanted with nail 302 in an antegrade direction.
Referring to FIG. 20, therein is shown nail 302 , positioning member 304 ′ and bone engaging member 306 as assembled within system 400 . Positioning member 30 ′ is shown positioned within longitudinal passage 314 and includes a first portion 402 and a second portion 404 . First portion 402 includes a threaded upper portion 406 and an elongated lower portion 408 extending therefrom along longitudinal axis L 6 . Upper portion 406 is configured to threadedly engage threaded portion 318 of longitudinal passage 314 . Upper portion 406 also includes a hex recess 410 for receiving a driving tool (not shown), such as an Allen wrench. Lower portion 408 has a generally circular body having an outer diameter slightly less than the diameter of longitudinal passage 314 . A transverse passage 412 extends through lower portion 408 and is aligned generally perpendicular to axis L 6 . The end of lower portion 408 opposite its threaded portion terminates in a generally flat surface 414 .
Second portion 404 has a circular body having an outer diameter generally corresponding to the outer diameter of lower portion 408 of first portion 402 . Second portion 404 defines an internally threaded portion 416 extending generally along axis L 6 for engaging insertion instrumentation (not shown). One end of second portion 404 defines a generally flat surface 418 , corresponding to surface 414 of lower portion 408 . The opposing end of second portion 404 terminates in a generally convex outer surface 420 substantially corresponding to concave bottom surface 316 of longitudinal passage 314 . Second portion 404 also defines a transverse opening 422 extending therethrough generally perpendicular to axis L 6 . Opening 422 is bound by inner surface 424 and is sized to receive bone engaging member 306 therein.
FIG. 20 illustrates a first operational position of system 400 . Positioning device 304 ′ including first and second portions 402 , 404 ) is shown inserted within longitudinal passage 314 of nail 302 . Opening 422 of second portion 404 is positioned adjacent first end portion 312 a of opening 312 and generally aligned with opening 312 to define a passageway 426 . Bone engaging member 306 is shown inserted through passageway 426 . Upper portion 406 of first portion 402 is partially threadedly engaged within threaded portion 318 of longitudinal passage 314 . First portion 402 can be rotated by placing a driving tool (not shown) within hex recess 410 and turning first portion 402 in a clockwise or counterclockwise direction. In one embodiment, threaded upper portion 406 and threaded portion 318 each have right-handed threads. In this embodiment, as first portion 402 is rotated in a clockwise direction, it will be advanced through longitudinal passage 314 generally along axis L 6 . As first portion 402 is advanced, surface 414 will engage surface 418 of second portion 404 , thereby correspondingly advancing second portion 404 through longitudinal passage 314 generally along axis L 6 . As the position of second portion 404 is adjusted along axis L 6 , inner surface 424 of opening 422 bears against bone engaging member 306 and correspondingly adjusts the position of bone engaging member 306 along the length of opening 312 .
FIG. 21 illustrates a second operational position of system 400 in which first portion 402 is rotated in a clockwise direction until bone engaging member 306 is positioned adjacent second end portion 312 b of opening 312 . It should be understood, however, that bone engaging member 306 can be variably positioned anywhere along the length of opening 312 . It should further be understood that the terms “first operational position” and “second operational position” are not necessarily indicative of the initial position and adjusted position of bone engaging member 306 . For example, bone engaging member 306 could originate in a position adjacent second end portion 312 b and be variably positioned anywhere along the length of opening 312 .
When bone engaging member 306 is positioned adjacent second end portion 312 b of opening 312 , transverse passage 412 of upper portion 406 will become aligned with transverse bore 320 of nail 302 , thereby defining a passageway 430 . A second bone engaging member 306 can then be inserted through passageway 430 to prevent further rotational movement of first portion 402 relative to nail 302 . However, if transverse passage 412 and transverse bore 320 cannot be aligned to form passageway 430 , a second bone engaging member 306 cannot be used. In this case, in order to prevent first portion 402 from rotating and migrating relative to nail 302 , a locking set screw can be threadedly advanced along threaded portion 318 of nail 302 until it tightly engages upper portion 406 .
Having described selected structural and operational features of positioning device 304 ′, the operational characteristics of system 400 will now be described in further detail. Referring back to FIG. 19, nail 302 is shown implanted in femur 12 and is anchored to portions 12 a and 12 b in substantially the same manner as described above in system 300 . Preferably, bone engaging member 306 is initially positioned adjacent or near first end portion 312 a of opening 312 . As first portion 402 of positioning device 304 ′ is rotated in a clockwise direction, bone engaging member 306 is correspondingly repositioned along the length of opening 312 , and more specifically is transferred toward second end portion 312 b of opening 312 . Because bone engaging member 306 is anchored to portion 12 f of femur 12 , portion 12 f is correspondingly moved in the direction of arrow “B”, while portion 12 e of femur 12 remains stationary, securely anchored to distal end 302 b of nail 302 . Thus, portion 12 f of femur 12 is repositioned toward portion 12 e, thereby compressing fracture site 301 ′. Dashed line 301 b of FIG. 19 corresponds to the fractured end of portion 12 f after compression in accordance with one embodiment of the present invention.
One preferred procedure for implanting system 400 within femur 12 is substantially identical to the procedure for implanting system 300 , except a compression operation as described above is performed instead of the distraction operation as described in connection with system 300 .
The components of systems 10 , 100 , 165 , 195 , 200 , 300 and 400 may be fabricated from any suitably strong, bio-compatible material such as stainless steel, titanium, chrome-cobalt, or any other material which would occur to those skilled in the art.
While the invention has been illustrated and described in detail in the drawings and foregoing discussion, the sane is to be considered as illustrative and not restrictive in character, it being understood that only the preferred embodiments have been shown and described and that all changes and modifications that come within the spirit of the invention are desired to be protected. | A femoral intramedullary rod system capable of treating a variety of femoral bone fractures using a uniform intramedullary rod design. The system generally comprising an intramedullary rod defining an opening having an upper surface and a transverse member including a bone engaging portion and a connection portion defining a thru-hole with the nail sized to pass therethrough. A pin is selectively coupled to the transverse member to rigidly assemble the transverse member to the nail when the nail is passed through the thru-hole and the pin is received within the opening. | 0 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims the priority, under 35 U.S.C. §119, of German Patent Application DE 10 2009 047 963.5, filed Oct. 1, 2009; the prior application is herewith incorporated by reference in its entirety.
BACKGROUND OF THE INVENTION
Field of the Invention
[0002] The present invention relates to a device and a method for determining register deviations on printing material in multi-color printing presses during production, using a computing unit which takes into consideration the influence of ghosting effects when measuring the deviations on the printing material.
[0003] In lithographic offset printing and other additive printing processes, a number of color separations of a printed image are printed on top of each other to produce a multi-colored printed image. The positioning of the individual color separations with respect to each other is referred to as the color register. The positioning of the superimposed color separations with respect to a predetermined margin on the printing material is referred to as the lateral register. If the positioning of the color separations is correct in both of those respects, the product may be referred to as an in-register print. In the following description, “register” is understood to include both the color register and the lateral register. In order to determine register deviations, it has become known to use register measuring devices which measure register marks pertaining to the lateral and color register on the printing material to be measured for the purpose of determining deviations. However, due to disruptions in the operation of a lithographic offset printing press, so-called ghosting effects may occur, which likewise cause the individual color separations to become offset or shifted relative to each other. That means that a conventional register measuring device does not exclusively determine register deviations, but also superposed deviations caused by ghosting. Thus, the important issue is to distinguish between deviations caused by ghosting and true register deviations, because otherwise the control drives for the compensation of register deviations cannot be appropriately controlled and deviations would persist.
[0004] The problem of ghosting effects is also known, for example, from Published German Patent Application DE 38 00 877 A1, corresponding to U.S. Pat. No. 4,878,753. In that document, a method of measuring offset caused by ghosting in printing presses is described. In accordance with that method, a test halftone pattern is printed onto a printing material and sensed by two sensors. Those sensors feed the gray values of the test pattern to a ghosting detection device. Ghosting effects can be detected based on the measurements and the geometric relation between the test strips. That method is likewise suitable for use in a printing press, allowing the detection of ghosting effects during a print run. The sensors substantially determine ghosting offsets, which are characterized by the fact that next to a fresh, solidly colored halftone dot there is a ghosting shadow which is matt and frequently of smaller diameter.
[0005] Published European Patent Application EP 0 000 328 A1, corresponding to U.S. Pat. No. 4,606,633, discloses a measuring process and a device for determining defects on printing material. In accordance with that method, remission values on a printing material are determined and evaluated by computation. Ghosting effects are determined and taken into consideration in order to calculate the correct halftone value on the printing material. If desired, the ghosting effects are displayed on a screen for a printing press operator to examine them.
[0006] A disadvantage of the prior art is that although the existing measuring devices can be used to determine ghosting effects, they are only taken into consideration with respect to a correct evaluation of halftone values. So far, register measuring devices are incapable of taking ghosting effects into consideration, thus leading to correspondingly erroneous results when determining register deviations.
SUMMARY OF THE INVENTION
[0007] It is accordingly an object of the invention to provide a method and a device for determining register deviations on printing material through recursion analysis, which overcome the hereinafore-mentioned disadvantages of the heretofore-known methods and devices of this general type, which take the influence of ghosting effects into consideration when measuring register deviations on printing material and which need only one measuring process to determine the deviations.
[0008] With the foregoing and other objects in view there is provided, in accordance with the invention, a method for determining color register and lateral register deviations on printing material during production in multi-color printing presses. The method comprises taking an influence of ghosting effects into consideration in a computing unit when measuring the deviations on the printing material. The ghosting effects of at least a preceding and/or a succeeding printed image are taken recursively into consideration in the computing unit, when measuring on the printing material.
[0009] With the objects of the invention in view, there is also provided a device for measuring deviations relating to color register and/or lateral register on printing material during production in printing presses. The device comprises a computing unit configured to take an influence of ghosting effects into consideration when measuring the deviations on the printing material. The computing unit is configured to take the ghosting effects on at least one preceding or/and on at least one succeeding printed image into consideration when determining deviations on the printing material.
[0010] In accordance with another mode of the method of the invention, the register deviations including the ghosting effects contained therein as they are determined on a printing material through the use of a register measuring device in a measuring process are fed to a computing unit. This computing unit then determines the proportion of the ghosting effects in the measured deviations by recursively taking into consideration at least the ghosting effects of a preceding and/or succeeding printed image. This means that the method not only includes the determining of ghosting effects in a printed image on a printing material as in the prior art, but also the taking into consideration of ghosting effects of a number of succeeding printed images on a number of printed sheets or on a web of printing material. This approach is based on a model in which the calculation of the ghosting effects is done through recurring to the resultant register fluctuations on a number of printed images. In this manner, it is possible to distinguish the ghosting effects caused by vibrations from register deviations and to separate the superimposed effects so that it is possible to factor out the proportion of the register deviations and to suitably correct only these deviations by giving adjustment commands to register control drives in the printing press. If the ghosting effects were not factored out, erroneous adjustment values would be supplied to the register adjustment drives in the printing press, and the control system would not work properly. Nevertheless, the method and device of the invention do not require a second measurement to determine the ghosting effects. Instead, it is sufficient to measure out the printed image through the use of a register measuring device without requiring the use of special measuring devices for determining ghosting effects. The present invention is suited in particular for use in sheet-fed rotary printing presses.
[0011] In accordance with a further particularly advantageous embodiment of the invention, the ghosting effects of up to 5 preceding and/or succeeding printed images are taken into consideration. This number has proved to be sufficient in practice. In this context, if the printing material is in the form of sheets, it is of particular importance to measure the sheets in the correct order in which they are successively produced in the printing press. This is, in particular, the case if the sheets are measured by a separate measuring device after they have been removed from the printing press. If, in contrast, the measuring device is disposed in the printing press downstream of the last printing unit, the measuring of the printing material is guaranteed to be in the correct order.
[0012] In order to be able to separate the influences of ghosting effects from register deviations, the present invention makes use of a recursion analysis. The recursion analysis takes into consideration color shifts of halftones in the Lab color space. These color shifts can be used to calculate the system behind the ghosting effects and thus to separate the influence of the ghosting effects from the register deviations.
[0013] In accordance with an added embodiment of the invention, the line width of register marks on the printing material is determined to detect register deviations under the assumption that the prints transferred from printing plate to printing material or intermediate print carrier are identical. In lithographic offset printing, the intermediate print carrier is usually a rubber blanket. In this context, the line width of the register marks is at first not known as an absolute value, but may be calculated from a recursion analysis under the assumption indicated above. The method of the invention may be applied during continuous printing and prior to the actual printing operation during the start-up phase of the printing press.
[0014] In accordance with a concomitant mode of the invention, the device may be a conventional hand-held register measuring device. This conventional register measuring device either may include a computing unit to carry out the recursion analysis or it may be connected to a suitable computing unit. Moreover, a register measuring device of this kind may be integrated into a color measuring device. A considerable advantage of this aspect is that only one measuring process is required to establish both color measurement values and register measurement values. If, in particular, such a combined measuring device is disposed in the last printing unit of the printing press, it is thus possible to establish color measurement values and register measurement values in each printed image.
[0015] Other features which are considered as characteristic for the invention are set forth in the appended claims.
[0016] Although the invention is illustrated and described herein as embodied in a method and a device for determining register deviations through recursion analysis, it is nevertheless not intended to be limited to the details shown, since various modifications and structural changes may be made therein without departing from the spirit of the invention and within the scope and range of equivalents of the claims.
[0017] The construction and method of operation of the invention, however, together with additional objects and advantages thereof will be best understood from the following description of specific embodiments when read in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING
[0018] FIG. 1 is a diagrammatic, partly perspective and partly elevational view of a combined register and color measuring device which is connected to a computing unit, that is in turn connected to a printing press;
[0019] FIG. 2 is a diagram illustrating a simple example for color shifts in the Lab color space;
[0020] FIG. 3 is a perspective view illustrating the formation of ghosting shadows around halftone dots;
[0021] FIG. 4 is a flow diagram illustrating a printing process including three process colors with ink build-up on a blanket of a lithographic offset printing press;
[0022] FIG. 5 is a flow diagram illustrating a printing operation in a start-up phase of a printing press without disrupting influences;
[0023] FIG. 6 is a flow diagram illustrating a printing operation in a start-up phase of a printing press with disruptions concerning sheet travel; and
[0024] FIG. 7 is a flow diagram illustrating a stationary printing operation during a continuous print run upon a disruption concerning sheet travel.
DETAILED DESCRIPTION OF THE INVENTION
[0025] Referring now to the figures of the drawings in detail and first, particularly, to FIG. 1 thereof, there is seen a combined register and color measuring device 10 , which has a measuring bar 1 with a combined measuring head 8 . The measuring head 8 is driven electrically to move across the entire extent of a printed image on a sheet-shaped printing material 3 resting on the measuring device. In the process, the measuring bar 1 moves in a direction X whereas the measuring head 8 in the measuring bar 1 moves in a direction Y. Thus, the measuring head 8 is capable of sensing any desired image dot on the sheet 3 . In order to carry out the measuring process, the sheet 3 is placed underneath the measuring bar 1 on a measuring table 2 . A printed measuring mark 9 can be seen on a margin of the sheet 3 . This measuring mark 9 may include both color measuring patches and register marks which are sensed by the measuring device. The measuring device 10 feeds measured color and register values to a computing unit 4 .
[0026] However, an inherent problem with the measured register values is that they include proportions of ghosting effects. Those influences of ghosting effects are filtered out in the computing unit through the use of the recursion analysis explained below, in order to determine actual register deviations. Based on the actual register deviations that have been determined in this way, the computing unit 4 may calculate correction values for a lithographic offset printing press 7 connected to the computing unit 4 . As an alternative to fully automatic control, these correction values may be displayed to the operating staff on a screen 5 . An operator may then use a keyboard 6 or a computer mouse 11 connected to the computing unit 4 to release the correction values and to feed them to the printing press 7 . The correction values may be converted at the printing press to corresponding actuating commands for register adjustment drives in the printing press 7 to counteract register deviations that have been determined.
[0027] By way of example, FIG. 2 illustrates a shift of a color location of a halftone dot on the printing material 3 in the Lab color space. The color location F of a halftone dot can be seen to have been shifted to a color location F′ due to ghosting effects. This shift or displacement from the correct color location F to the color location F′ caused by ghosting, may be expressed by a color location shift vector dF.
[0028] This color location shift dF is created by a so-called ghosting shadow illustrated in FIG. 3 . Ghosting shadows are created when non-dried image dots on the sheet 3 are reprinted onto a rubber blanket in downstream printing units of a printing press 7 under the influence of sheet travel disruptions, for example caused by vibrations in the printing press. Due to those disruptions, halftone dots which have been reprinted in the downstream printing units and are visibly weaker in color, are not printed exactly on top of each other but rather with a slight degree of offset. That effect becomes visible as a ghosting shadow which enlarges the image dot. In the upper region of FIG. 3 , a halftone dot D 1 having a diameter of 100 μm is shown as having a ghosting shadow DS 1 that is 80 μm in diameter. In the lower half of the image, a halftone dot D 2 having a diameter of 50 μm is shown as having a ghosting shadow DS 2 that is 40 μm in diameter. This representation is based on the realistic assumption that the size of the ghosting shadow is approximately 80% of that of the original halftone dot D 1 , D 2 . In the first column, the ghosting shadow disappears behind the halftone dot because the offset between halftone dot and ghosting shadow is 0 μm . In the second column, halftone dot and ghosting shadow are offset by 10 μm relative to each other. In the third column, this offset has increased to 30 μm . As can be seen in the figure, such a degree of offset visibly affects print quality and produces erroneous measurement results when halftone dots are measured to determine register deviations.
[0029] FIG. 4 illustrates an ink build-up of a halftone dot on the rubber blanket in three printing units of the printing press 7 during the printing operation. A first printing unit DW 1 prints the color black, a second printing unit DW 2 prints the color cyan, a third printing unit DW 3 prints the color magenta. In the first printing unit DW 1 , only black dots are created on the blanket because only unprinted sheets 3 from the feeder reach this printing unit. When the color cyan is printed onto the printing material in the second printing unit DW 2 , black portions are printed onto the blanket as the blanket rolls on the printing material 3 . These black portions are reprinted from the blanket onto the sheet 3 . In the same manner, black and cyan portions from the upstream printing units DW 1 and DW 2 are reprinted onto the printing material 3 in the third printing unit DW 3 in addition to the magenta portion since cyan and black portions have likewise been deposited on the blanket in the third printing unit DW 3 and are printed onto the sheets 3 from there.
[0030] FIG. 5 illustrates the printing operation in the first three printing units of the printing press 7 during the start-up phase without any sheet travel disruption.
[0031] FIG. 6 likewise illustrates the printing operation in the start-up phase. However, in FIG. 6 a sheet travel disruption occurs between the first and second printing units DW 1 and DW 2 after the second sheet. As a result, in the downstream printing units DW 2 and DW 3 , the reprinted halftone dots are offset and corresponding ghosting effects occur.
[0032] FIG. 7 illustrates a stationary printing operation during a continuous print run, likewise with a sheet travel disruption. The figure shows that in this case ghosting effects likewise occur due to an offset of the reprinted halftone dots on the blanket. This offset causes the halftone dots of the color black, for example, to be overprinted on subsequent sheets 3 by the halftone dots reprinted in printing units DW 2 and DW 3 on the blankets. Since these halftone dots are not located precisely on top of each other, the black dots receive a ghosting shadow. Thus, the ghosting shadow is created because ink from upstream printing units is present on the blanket of downstream printing units and because these superimposed halftone dots are not located precisely on top of each other, i.e. are offset relative to each other due to sheet travel disruptions. Those ghosting shadows are factored out through the use of the recursion analysis according to the invention described below, so that correct measuring of register deviations is possible even when ghosting effects occur.
[0033] When a number of color separations A_j, j=1 . . . m (m=number of printing units) are printed together, the desired color impression F=f( . . . ,A_j, . . . ), j=1 . . . m is created with paper white and as a result of the autotypical ink mixing of the color separations that are printed on top of one another. This color impression may be identified unequivocally through the use of a metric as an ordered triple (L, a, b) in the Lab color space (also refer to FIG. 2 ). Due to influencing or disruptive factors (such as the color density of the individual separations, the topology and ink accepting properties of the printing material, etc.) the desired color impression shifts to a color impression F′=(L′, a′, b′). The difference between the two states is described by a vector dF=(L′-L, a′-a, b′-b). Through the use, for instance, of an IT 8.7/3 color chart, a multiplicity (number I) of different halftone patches with color impressions F_k, k=1 . . . I are printed. If a disruption occurs at the sheet transfer between printing units j and j+1, for example, depending on the printing order, a number o of the I halftone patches will experience a characteristic tonal shift dF_j, j=1 . . .o.
[0034] Further elements are conceivable as an alternative to the IT 8.7/3 color chart. A halftone dot that is subject to ghosting effects experiences an area coverage gain which depends on its absolute size because it is a “fringe effect.” A certain minimum register deviation is necessary for the ghosting shadow to become visible beyond the original image (refer to FIG. 3 ). If the halftone dot is large, the area coverage gain is smaller than if the halftone dot is small. Thus, the tonal shifts to be expected can be influenced by choosing suitable halftone dot sizes.
[0035] The influence of an individual color separation A_j or of a transfer Ü_j/j+1 on a color impression F of the I halftone patches may be described by a model:
[0036] F_k=f( . . . ,A_j, Ü_j/j+1), k=1 . . . I. If all I halftone patches are measured and the actual color impressions F′ are determined, due to dF=(L′-L, a′-a, b′-b) the result is a characteristic shift patch of the color hues in the Lab color space. As described above, the values for the o halftone patches that are concerned is different than zero. The magnitude of the disruption that has caused the effect may be determined by reverse calculation. This reverse calculation may also be done by using a model that has been empirically determined and by using recursion analysis.
[0037] In a manner analogous to current methods used by register measuring devices, it is additionally possible to determine an overall shift/ghosting value for each color separation and to integrate this value as additional information into the model described above, yet without directional information.
[0038] The model on which the calculation is based, in particular takes into consideration the instant at which a color dot is being printed. For this reason, it is imperative that the sheets 3 be measured in a defined order.
[0039] The method described above gives information on both the quality and the quantity of a disruption in the image or sheet transport at a certain location in the printing operation. A certain memory effect is inherent in the printing process: a disruption in the front region of the printing press 7 has an effect on the succeeding printing processes (refer to FIGS. 5 to 7 ), i.e. on the printing processes carried out in downstream printing units after the disruption has occurred. Consequently, the color impression and thus the measured values to be established on a sheet j are affected by disruptions that occurred when the sheets j−1, j−2 were printed. In turn, the sheet j has an influence on the values of the following sheets j+1, j+2. In general, the influence is limited to approximately −/+5 adjacent sheets 3 .
[0040] Allowing for this fact, a recursive improvement of the measured results may be achieved. Just as in current methods, as a first step, a measured value for the position of the color separations is determined as a starting value for the recursion. As soon as a second sheet 3 is measured or rather as soon as a second measured value is available, information on a possible variation between sheet j and sheet j+1 is available. Through the use of the model described above, an estimation of the ghosting influence affecting the measurement may be made. This is then used to improve ghosting shadow correction of the sheet j+1. If precisely the value of ghosting shadow correction is output separately in addition to the register measuring value, a further important piece of information is obtained by one measurement per image dot on the sheet 3 , namely information on the magnitude of the ghosting effect, which directly correlates with the visual impression.
[0041] A further factor is the line width of the measuring mark 9 , which is not known at first as an absolute value. Based on the assumption that the original image is always printed identically from the printing plate to the blanket, the line width may likewise be obtained from the recursion. | A method and a device for determining color register and lateral register deviations on printing material during production in multi-color printing presses, include a computing unit which takes into consideration the influence of ghosting effects when measuring the deviations on the printing material. The ghosting effects of at least one preceding and/or one succeeding printed image are recursively taken into consideration in the computing unit, when measuring on the printing material. | 1 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a non-provisional application claiming the filing priority benefit of U.S. Provisional Patent Application Ser. No. 61/630,912, filed Dec. 22, 2011, in the name to the current inventors and the contents of which are incorporated in their entirety herein be reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to shock absorbing spacers or bumpers for connecting a boat or other vessel from a mooring, such as a dock, and more particularly to a spacer having a bag, bladder or other enclosure containing a fluid under pressure for protecting a vessel from impact with a dock, buoy or other mooring structure when the vessel is subjected to forces caused by waves, wind, tide and the like.
[0004] 2. Brief Description of the Related Art
[0005] U.S. Pat. No. 6,431,104, issued on Aug. 13, 2002, in the name of John T. Webb, the contents of which are also incorporated in the entirety herein by reference, is directed to a shock absorbing spacer which functions to separate a boat tied to a mooring from impacting the mooring. The spacer uses a resilient length of cord, sometimes referred to as a “bungee cord” to act as a buffer or shock absorber as two cylinders are forced toward one another as a vessel secured to the spacer moves toward a mooring due to ambient conditions. One of the cylinders is attached to mooring such as a dock and the other is attached to a vessel such as a boat. The two cylinders are in telescopic relationship with one other and when the boat is subjected to the forces mentioned above, the inner cylinder slides into the outer cylinder thereby shortening the effective overall length of the spacer. The sliding is resisted by the bungee cord so that the spacer is never short enough to allow the boat to come into contact with the mooring.
[0006] In U.S. Pat. No. 4,043,545, issued Aug. 23, 1977, in the name of Darrell D. Dial et al, another form of cushioning unit or bumper for positioning between a boat or ship and a mooring, such as a dock, is disclosed wherein a piston rod is connected to a piston plate that is movable within a buffering cylinder and divide the buffering cylinder into separate interior portions. As ambient conditions urged a vessel towards its mooring, the piston plate is driven inwardly of the buffering cylinder such that compression of fluid within the buffering cylinder acts as a buffer on the forces being directed between the vessel and the mooring. During this compression period, compressed fluid is bled from the buffering cylinder through a plurality of ports which communicate with the interior of a secondary high pressure cylinder within which the buffering cylinder is mounted. As forces increase within the high pressure cylinder, they will act in an opposite direction to urge the piston face toward an opposite end of the buffering cylinder such that the piston rod is restored to its originally extended position relative to the vessel.
[0007] Other examples of cushioning or bumper devices used to dissipate forces tending to direct vessels either toward or away from mooring devices are disclosed in U.S. Pat. No. 4,063,526 to Ueda wherein inner and outer pressurized cylinders are used and U.S. Pat. No. 4,066,030 to Milone, wherein a hydraulic cylinder arrangement is provided with a male portion of the arrangement being vertically movable within a vertical guide track so that relative vertical movement of a vessel and a dock or mooring structure is accounted for simultaneously with the buffering of compressive and expansion forces. Another buffering or cushioning device for allowing for vertical movement between a vessel and a mooring structure is disclosed in U.S. Pat. No. 5,014,638 to Ilves et al.
SUMMARY OF THE INVENTION
[0008] A first embodiment of shock absorbing, cushioning device or docking spacer of the present invention for use in securing a boat or similar vessel to a mooring, such as a dock, includes an elongated body having a pair of sections movable longitudinally of each other in telescopic relationship to define a variable effective overall length. One of the sections is adapted to being attached to the boat while the other section is adapted to being attached to the dock. An airtight bag or bladder containing a pressurized fluid, and preferably a gas, is disposed within one section while a connecting rod extends from the bag to the other section. The connecting rod advances toward the bag upon impact of the boat with the shock absorber or docking spacer.
[0009] In a second embodiment of the invention, as opposed to a rod extending from one section and being connected to a pressurized bag or bladder in the other section, the shock absorbing, cushion device or docking spacer has one section having one end connected to one of a vessel or a mooring structure and another end connected to a first sealed end of a pressurized bag or bladder mounted within a second section of the shock absorber. In this embodiment, as the section connected to the vessel moves toward the mooring device, the first end of the bag or bladder is moved toward a second end thereof thereby building up pressure within the bag or bladder which build up of pressure buffers the force of the vessel moving toward the mooring structure. In this embodiment, a bumper device or resilient material may be provided on an inner end face of the movable section to thereby provide a resilient stop should the forces driving the sections toward one another cause an impact there between.
[0010] In both embodiments of the invention, the shock absorbing or spacer devices may be mounted to a slidable base secured to a vertical guide track structure which is mounted to a vertical post or other portion of the mooring device so that water levels change relative to the mooring structure, the slidable base will automatically be vertically adjusted. In this manner, transverse stresses on the sections of the shock absorbing or spacer devices will be reduced thereby allowing smoother reciprocal motion between the telescoping sections of the devices.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] A better understanding of the shock absorbing devices or docking spacers of the present invention will be had with reference to the accompanying drawings in which:
[0012] FIG. 1 is a side elevation view, primarily in section, of a shock absorbing device or docking spacer of a first embodiment of the present invention;
[0013] FIG. 2 is a front perspective view of the shock absorbing device or docking spacer of FIG. 1 attached to a mooring structure by way of a vertically movable base;
[0014] FIGS. 3 a and 3 b are illustrational views of the shock absorbing device or docking spacer with adjustable base of FIG. 2 and showing the relationship between a vessel and the mooring structure at high and low tides, respectively, and illustrating how the sections of the shock absorbing device remain horizontally aligned; and
[0015] FIG. 4 is a side elevation view, primarily in section, of a shock absorbing device or docking spacer of a second embodiment of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0016] With reference to FIG. 1 , a first embodiment of shock absorbing device or docking spacer 10 includes first and second hollow sections or cylinders, 11 and 12 , respectively, which are moveable longitudinally of each other in a telescopic relationship along axis A-A of the first section with resulting changes in the effective overall length of the docking spacer. A bushing 14 is disposed between an inner wall 15 of the first section and the outer wall 16 of the second section for reducing friction between the two walls as they slide relative to each other.
[0017] The first section 11 is connected to a cleat 17 which is attached to a dock 18 while the second section is connected to a cleat 20 which is attached to a boat 21 . Alternatively and with reference to FIGS. 2 , 3 a and 3 b , the first section may be connected to a base slider 22 which is mounted to slide vertically on a track or guide channel such as an I-beam 24 . The I-beam is fastened to a vertical post 26 which is provided adjacent to, or which forms part of, the dock 18 . The docking slider 22 allows the docking spacer 10 to move vertically so that the boat to which the docking spacer is attached is free to move up and down with the tide. This vertical adjustment reduces vertical transverse forces which can be created between the first and second cylinder sections 11 and 12 and the sections remain generally horizontally aligned regardless of the water level as shown in FIGS. 13A and 13B . Thus the sections will not bind when reciprocally moving relative to one another regardless of wave action.
[0018] Mounted within the first section 11 is a fluid-containing airtight bag or bladder 32 . A valve 34 is attached to the bag to allow fluid under pressure to flow into the bag and for bleeding the fluid from it. A pressure gauge (not illustrated) measures the pressure within the bag. As shown, the valve 34 extends out from a proximal end of the first section.
[0019] The fluid flows to the bag from a high pressure cylinder (not illustrated). For reasons of economy, air is the preferred fluid and the air is contained in one or more conventional air cylinders. Other gases such as nitrogen or inert gases may also be used but generally are less suitable than air because of their cost. Liquids such as water can also be used but are generally not very suitable because of the cost of compressing them.
[0020] Attached to the distal end 35 of the bag which faces the second section 12 is a coupling 36 having a threaded socket 37 which receives one of two threaded ends 39 of a connecting rod or like connector 38 . The opposite end of the connecting rod is threadably attached to a proximal end wall 40 of the second section, relative to the cleat 20 . The connecting rod is also supported in a distal end wall 41 of the second section 12 .
[0021] In use of the first embodiment, a hooked end member 42 connected to the proximal end of the first section 11 is secured, such as by a rope 43 , to the cleat 17 of the dock 18 and a proximate hooked end member 44 connected to the proximal end of the second section 12 is secured to the cleat 20 of the vessel 21 , also such as by a rope 45 . The pressure within the air bag 32 is adjusted to provide a preferred buffering resistance to movement of the connecting rod 28 as ambient conditions force the second section 12 to move reciprocally relative to the first section. Such ambient conditions include forces caused by waves, wind, tide and the like. The greater the pressure within the air bag the less the buffering resistance to movement of the second section as such higher pressure resists compression of the air bag that is necessary to allow a buffered compression of the air bag to absorb the forces directed from the vessel toward the mooring dock.
[0022] Also, as shown in the drawings, in some forms of the first embodiment, some clearance 47 may be provided between the air bag 32 and the inner walls of the first section to allow for some initial expansion of the air bag without resistance from the walls of the first section.
[0023] With reference to FIG. 4 , a second embodiment of shock absorbing device 90 for connecting between a boat 20 and a mooring device such as a dock 18 is shown including outer and inner cylindrical sections, 91 and 92 , respectively. Spaced bushings 94 and 96 are disposed in an annular gap between the two sections. The bushings act not only to close the gap but also act as guides for ensuring that the direction of the sliding motion of the second section 92 is along a longitudinal axis B-B of the first section 91 . The outward movement of the second section relative to the first section is limited by a circular plate 98 at the distal end of the second section. The plate defines a forward or distal wall of the second section. The plate engages bushing 94 when an effective length of the mooring spacer is greatest. The inward movement the second section is limited by a bumper 100 which contacts proximal end wall 102 of the first section. When contact occurs, the effective length of the mooring spacer is the least.
[0024] An airtight bag 104 for compressed fluid is disposed within the first section. The bag is closed except for an opening defined by an edge 105 which is attached to plate 98 . Thus as the second section slides inward toward end wall 102 of the first section, the plate draws the circular edge 105 and the air bag 104 inward toward the end wall 102 with resulting compression of fluid within the bag. Fluid may be introduced into the bag or bled from it through a valve 108 adjacent to the proximal end wall 102 of the first section.
[0025] In use of the second embodiment, a hooked end member 42 connected to the proximal end of the first section 91 is secured, such as by a rope, not shown, to the cleat 17 of the dock 18 and a proximate hooked end member 44 connected to the proximal end of the second section 92 is secured to the cleat 20 of the vessel 21 , also such as by a rope, not shown. The pressure within the air bag 104 is adjusted to provide a preferred buffering resistance to movement of the second section 92 toward the proximal end 102 of the first section 91 as ambient conditions force the second section 92 to move reciprocally relative to the first section 91 . Such ambient conditions include forces caused by waves, wind, tide and the like The greater the pressure within the air bag, the less the buffering resistance to movement of the second section as such higher pressure resists compression of the air bag that is necessary to allow a buffered compression of the air bag to absorb the forces directed from the vessel toward the mooring deck.
[0026] Also, as shown in the drawings, in some forms of the second embodiment, some clearance 115 may be provided between the air bag 104 and the inner walls of the first section 91 to allow for some initial expansion of the air bag without resistance from the walls of the first section.
[0027] It will be understood, of course, that modifications can be made in the structure of the shock absorbing devices and docking spacers of the invention without departing from the scope and purview of the invention as defined in the claims that follow. | A shock absorbing docking spacer for connecting a vessel to a mooring structure and which includes first and second sections relatively telescopically movable longitudinally relative to one another so as to define a variable effective overall length for the docking spacer and wherein one section contains an airtight air bag and the air bag is connected to the other section such that as the first and second sections move relatively inwardly relative to one another the air bag provides a buffer for absorbing impact forces between the first and second sections brought about by ambient conditions. | 1 |
BACKGROUND OF THE INVENTION
The present invention concerns a device for withdrawing the shafts on which textile pieces have been rolled during their weaving or knitting.
The pieces finally obtained from a weaving or knitting machine are rolled on a shaft. When the roll of textile obtained reaches a sufficiently large dimension, the amount carried by the metal shaft around which the piece of cloth is rolled is taken from the machine. It is then necessary to extract the metal shaft to re-mount it on the machine. Generally this operation is manual. The extraction of the shaft is particularly delicate when it is a question of a knitted piece, for, in effect, this is made up of deformable stitches which strongly grip the shaft upon which it is rolled. Moreover, the fibres which make up a knitted piece slide badly. Thus, when an operator applies a longitudinal force to extract the shaft, the latter only comes out with great difficulty, whilst the roll of cloth held by a second operator is deformed.
The present invention has the aim of avoiding these disadvantages, and of creating a simple device for mechanisin the extraction of the roller shafts from woven or knitted textile pieces.
SUMMARY OF THE INVENTION
A machine according to the invention is characterized in that it comprises stops attached to the fixed frame, a traction cable of constant length, fitted at one of its ends with a harness able to be firmly attached to the shaft, whilst a pneumatic circuit feeds at least one double-action jack, of which the movement controls the displacement of the traction cable, of which the path is defined by return pulleys, means being provided to position the roll against the stops, so that traction on the cable is ensured by the re-entry of the stem of the jack and causes the extraction of the shaft attached to the harness, the roll of cloth being held motionless against the stops, whilst finally a system is provided so that the cable remains constantly taut during this operation.
According to another characteristic, the harness fitted to one end of the cable includes a yoke capable of fitting around one of the ends of the shaft which projects on each side from the roll of cloth, whilst the attachment of the yoke to the shaft is carried out by engaging a peg in radial openings drilled respectively in the yoke and in the shaft.
The shaft to be withdrawn may for example be tubular.
According to another characteristic, the stem of the double-action jack carries at its free end a pulley situated on the path of the extraction cable between a fixed return pulley and the free end which is immobilized during extraction, so that the movement of the piston carries with it the pulley and modifies the path of the cable which is of constant length, so that the position of the pulley determines that of the extraction harness.
According to a first manufacturing method a machine known as the horizontal model is fitted with stops arranged in a vertical plane and fixed to a horizontal table. One of the ends of the cable is attached to the harness, the opposite end being fixed to a counterweight. The tension system of the cable comprises the counterweight which slides or travels along a ramp inclined to the horizontal, fitted at its upper end with a stop to immobilize the counterweight, hence the corresponding end of the cable. The mechanism includes finally a double-action jack arranged horizontally under the table in such a way that the pulley attached to the stem acts on the cable at a point situated between two return pulleys rotating about fixed axes. The first pulley is, for example, mounted at the end of the table on which the roll of cloth is positioned, whilst the second pulley is mounted at the upper end of the inclined ramp. In this construction, the axis of the roll of cloth, the axis of the pneumatic jack, the inclined ramp, the return pulleys and the path of the cable are situated in the same vertical longitudinal plane.
Following another manufacturing method a machine known as the vertical model comprises a pneumatic positioning system to bring the roll to bear against the lower face of horizontal stops attached to a vertical support. One end of the traction cable is anchored to the frame. This cable then passes over the pulley attached to the double-action jack positioned vertically, then around at least one return pulley carried by the upper part of the frame, whilst the harness fitted to the other end of the cable constitutes, by the simple effect of gravity, the cable tensioning device.
Following another characteristic, the pneumatic circuit of the vertical machine is fitted with limit contacters operated respectively by the pneumatic means utilised to apply the roll against the stops and by the stem of the jack when the extraction of the shaft is completed.
It hence suffices to vary, by the aid of a pneumatic jack, the path of a constant-length cable to extract the shaft on which cloth is rolled, the roll of textile being held bearing over all its transverse surface against the fixed stops between which is provided a space sufficient to allow the passage of the shaft to be withdrawn.
The attached drawings, given by way of non-limiting example, will allow the characteristics of the invention to be better understood:
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a general view of a machine according to the invention for drawing the shafts from rolls of cloth,
FIG. 2 represents the pneumatic control circuit of the double-action jack for a horizontal machine,
FIG. 3 is a view in perspective at the level of the bearing stops of the horizontal table,
FIG. 4 is an exploded view of the pegging system between the traction harness and the end of the shaft,
FIG. 5 is a view illustrating in particular the path of the traction cable,
FIG. 6 is a view of the system for tensioning the traction cable,
FIG. 7 illustrates the attachment of the cable to the shaft to be withdrawn,
FIGS. 8 to 11 show the successive phases of operation and the position of the pneumatic control components for the corresponding stages,
FIG. 12 is a view of an extraction machine operating vertically,
FIG. 13 is the pneumatic control diagram for the machine in FIG. 12,
FIGS. 14, 16, 19 and 21 show the operation of the pneumatic circuit with an inflatable cushion,
FIGS. 15, 17, 18 and 20 correspond respectively to the stages shown in FIGS. 14, 16, 19 and 21. They show the operation of the vertical machine during one cycle of the withdrawal of the shaft from a roll of cloth,
FIG. 22 is a variant of a vertical machine with two double-action jacks,
FIG. 23 is a schematic view of the pneumatic circuit of the machine with two jacks.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
There is shown in FIG. 1 a machine according to the invention of the horizontal model. It comprises an upper plate or table 1 to which the stops 2 are fixed. It is a matter of separating the roll of cloth 3 from the shaft 4 on which it is rolled. For this a cable 5 is used, one end of it being fitted with a harness 6. This cable then passes over a first return pulley 7, over a pulley 8 fixed to the end of the stem of a pneumatic jack 9 and over a second return pulley 10 carried by the end of a lower plate 11 on which is mounted the body of the jack 9. Finally the other end of the cable 5 is anchored to a component 12 which slides along an inclined ramp 13. The weight of the component 12 keeps the cable 5 taut. The upper part of the ramp 13 is fitted with a stop system 14 able to block the counterweight 12.
The jack 9 is a double-action pneumatic jack, each of the two chambers of the cylinder 17 being able to be either fed by compressed air or open to the exhaust. According to the distribution of the air the piston 15 moves, carrying with it the stem 16 and the pulley 8, modifying the path of the cable between the return pulleys 7 and 10. The jack 9 is mounted on the horizontal plate 11 which constitutes a runway for a caster-wheel 18 fixed near to the end of the stem 16.
The pneumatic circuit is illustrated in FIG. 2. The circuit is controlled from two push-buttons 19 and 20 fixed to the table 1 and positioned respectively near to the support stops 2 and near to the end of the table and the return pulley 7 (FIG. 1). This pneumatic circuit comprises a distributor 21 which swings according to the action of the pneumatic signal sent by the operation of one of the buttons 19 or 20. Each distributor includes two outputs, each linked to one of the chambers of the jack 9 through output limiters 22 and 23. Each of these outlets 24 and 25 can communicate either with an exhaust opening 26 or 27 or with the pressure feed 28. The chamber fed under pressure is determined by the operation on the buttons 19 and 20 which allow the sending of a pneumatic signal causing the distributor 21 to swing (FIG. 2). Referring to FIG. 3, the stops 2 are constituted for example by two L-shaped brackets 2a and 2b. These two brackets are fixed to the table 1 so that their vertical arms lie in the same transverse plane. They are separated from each other by a distance which allows the engagement between them of the shaft 4, whilst the roll 3 comes to bear against the brackets. It is known that the shaft 4 projects at each end from the roll of cloth 3. This shaft is for example tubular and drilled, near to its end, with two openings diametrically opposite. The table 1 carries, near to the stops 2, one of the control buttons 19 of the pneumatic circuit (FIG. 1).
FIG. 4 illustrates the harness attached to one end of the cable 5. A yoke 33 pivots about a retainer pin 34 carried by a rectangular tube member 30. The tube member further has two opposed mounting holes 31 through which is mounted a retainer peg or dowel 42 which is used to mount the tube 30 to the shaft 4 upon which the cloth is rolled. For this purpose, a hole 41 is provided in the end of the shaft. Locating the end of the shaft 4 with respect to the tube member 30 is provided by the stop plate 32. The cable 5 is attached to the closed end of the yoke 6. FIGS. 5 and 6 illustrate the traction cable path.
From the harness 6, the cable 5 passes successively through a stop and support 35, around the return pulley 7, mounted free to rotate about its transverse horizontal axis, around the pulley 8 carried by a yoke fitted to the free end of the stem 16, around a second return pulley 10 fitted at the rear end of the lower plate 11 and finally through an opening in the stirrup type stop device 14. The second end of the cable 5 is attached to the component 12 which slides along the inclined ramp 13 (FIG. 5). The stop device 14 is for example constituted by a saddle fixed to the lateral walls of the ramp 13 with U section. The center of the transverse part of this saddle is drilled with an opening 36 through which passes the cable 5, the end of which is firmly attached to the component 12. The U ramp 13 serves as a slideway and a means of guiding for this component 12 of which the extreme positions are defined by the stirrup 14 and the free length of the cable when the harness 6 butts against the stop 35. (FIGS. 5 and 6).
Naturally, the construction shown in the figures is given only as an example. The scope of the invention will not be exceeded by modifying details of manufacture.
OPERATION
The operation is as follows:
At rest, the stem 16 of the jack 9 is extended. The run of the cable between the pulleys 7 and 10 is at its mimimum. The weight of the component 12 draws down the rear end of the cable towards the lowest part of the inclined ramp until the harness 6 butts against the support 35. A roll 3 is placed on the table 1 in front of the stops 2 and it is slid so that the shaft 4 enters between the vertical plates 2a and 2b (FIGS. 1 and 3). The jack 9 is in the position shown in FIG. 2. The rear chamber 17a is connected to the exhaust, whilst the front chamber 17b is in communication with the compressed air supply. The rockers controlled by the buttons 19 and 20 are both in the exhaust position, so that no signal is being sent to the distributor 21.
The first operation is manual as illustrated in FIG. 7. It consists of attaching the harness 6 to the shaft to be withdrawn 4. For this, the harness is pulled according to the arrow 40. The cable 5 passes around the pulleys 7, 8 and 10. The counterweight 12 remounts the inclined ramp 13 and keeps the cable taut. The tube 30 of the harness 6 is engaged on the end of the shaft 4. The stop plate 32 facilitates the positioning of the openings 31 in the tube 30 opposite the opening 41 of the shaft 4. A peg or dowel 42 is then engaged in these openings to attach the shaft 4 and the cable 5 (FIG. 4). During this manual operation, the stem 16 of the pneumatic jack remains stationary (FIG. 7).
FIGS. 8 and 9 show the second phase of operation. The button 19, situated near to the stops 2, is pressed. The corresponding rocker sends a signal 43 to the distributor 21 of which the valves are displaced so as to put the chamber 17b in connection with the exhaust and to supply the chamber 17a of the jack 9. The resultant thrust 44 causes the stem 16 of the jack to be drawn into the distributor (arrow 45). The longitudinal displacement of the pulley 8 modifies the run of the cable 5, which has the following effect:
first, of applying the counterweight 12 against the stirrup 14, so that then the end 37 of the cable 5 is stationary; and
second, to increase the length of cable between the pulleys 7 and 10, this lengthening being compensated by a reduction of the length between the support 35 and the harness 6.
Thus, during the re-entry of stem 16 into jack 9, the shaft 4 is drawn towards the right (arrow 46) whilst the piece of rolled cloth is held by the stops 2 (FIG. 8).
FIGS. 10 and 11 illustrate the final phase of operation. When the harness 6 comes to bear against the support 35, the shaft 4 is completely withdrawn from the roll 3. The dowel 42 is then taken out to uncouple the shaft from the harness and the button 20 situated near the stop support 35 is pressed. This button controls the corresponding rocker which sends a signal 47 to the distributor 21. The valves of this distributor swing to put the chamber 17a in connection with the exhaust and the chamber 17b with the compressed air supply (FIG. 12). The extension of the stem 16 causes the displacement of the pulley 8 according to the arrow 48. The harness 6 is held by the support 35 so that the counterweight 12 is released from the saddle 14 and slides along the ramp 13 keeping the cable 5 taut (FIG. 11). The rest position is thus regained; the jack stem extended as shown in FIG. 1.
During these re-entry and extension movements of the jack 9, the stem 16 is supported by a castor-wheel 18 running along the plate 16 which carries the jack 9 positioned longitudinally.
There is shown in FIG. 12 a machine according to the invention working in a vertical position. The roll of cloth 3 is placed vertically on an inflatable cushion 50, the stops 52 are fixed to a vertical support 51. The cable 55 carries a harness 56 capable of being pegged to the shaft 54 to be extracted. The extraction cable passes successively around guide pulleys 57 and 60, attached to the upper support plate 65, and around a pulley 58 moving with the stem 66 of the jack 59 arranged vertically. The other end of the cable 55 is connected to the upper part of the frame by a tensioning device 62 of any known type. Finally this vertically operating machine is fitted with a pneumatic circuit 73 set out in detail in FIG. 13 and controlled from two buttons 69 and 70. FIG. 12 corresponds to the rest position of the machine. The stem of the jack is extended and the cushion on which the roll of cloth rests is deflated.
The rest position is obtained when the components of the pneumatic circuit are in the position shown in FIG. 13. The buttons 69 and 70 prevent the passage of compressed air which circulates only through a conditioning system 74 comprising for example a filter, a pressure reducing valve and a lubricator, to feed the distributor 71 from which the movements of re-entry and extension of the jack 59 are controlled. In the position of FIG. 13 it is seen that the distributors 67 and 68 are not supplied, so that the cushion 50 remains deflated. The control circuit in addition comprises limit rockers 63 and 64 controlled respectively by the inflation of the cushion 50 and the re-entry of the stem 66.
first phase of operation is illustrated in FIGS. 12, 14, and 15.
With the machine at rest the roll 3 is placed on the deflated cushion 50 (FIG. 12). Then a button 69 (FIG. 14) is pressed: to allow passage of compressed air (arrow 80). The signal 81 swings the distributors 67 and 68 and the inflatable cushion or air chamber is supplied with compressed air. The pressure in the chamber 50 balances the weight of the roll of cloth which rises according to the arrow 53 (FIG. 15) to come to bear under the fixed stops 52. The harness and the shaft are attached by a peg as described previously. The cable is kept constantly taut owing to the tensioning device 62 fixed near to the anchor point of its outer end to the frame (FIG. 15). During this operation the upper chamber of the jack 59 remains connected to the exhaust through the distributor 71.
When the roll 3 is pressed against the stop 52 it operates the limit rocker 63 FIGS. 16 and 17 illustrate the compressed air distribution following the arrow 82 can pass and a signal is sent:
(a) in one direction following the arrow 83 towards the distributor 67 (FIG. 14) which swings to the exhaust position. The admission of air to the chamber 50 (FIG. 14) is cut off. However, the exhaust opening of the distributor is closed, so that pressure is maintained in the inflated chamber 50 and
(b) in another direction towards the distributor 71 (arrow 84) which swings. The lower chamber is opened to the exhaust 85 and the stem of the jack re-enters (arrow 61).
The re-entry of the jack draws down the pulley 58, and causes the extraction of the shaft 54 (FIG. 17).
FIGS. 18 and 19 show that, when the jack has re-entered, the pulley 58 operates the limit rocker 64 which sends a signal 86 to the distributor 68: the swing of the valve of this distributor connects the chamber 50 to the exhaust. The roll of cloth re-descends as its support deflects, whilst the shaft 54 remains bearing against the upper support 65 of the frame.
FIGS. 20 and 21 illustrate the rest or starting position for a new extraction cycle is reached by operating the button 70. A signal is sent to the distributor 71 which swings and connects the upper chamber of the jack to the exhaust. The stem 66 extends. The tension on the cable diminishes and the shaft 54 may be detached. (FIGS. 20 and 21).
FIG. 22, illustrates another embodiment for the support cushion. The inflatable support cushion 50 is replaced by a metal plate 90 able to move along the uprights of the frame under the action of an auxiliary double-action jack 91. The pneumatic circuit of this method of manufacture is shown schemmatically in FIG. 23. This embodiment of the vertical model machine presents several advantages:
the mobile plate 90 constitutes a more stable support for the roll of cloth;
the placing, then removing, of the piece of cloth are facilitated;
the successive stages of a cycle of extraction are all brought about pneumatically and controlled from a single button 92.
At the beginning of the operation, the principal extraction jack 93 and the auxiliary positioning jack 91 have their stems extended as shown in FIG. 22. The stem 91a acts upon cables 96 suspending the mobile plate 90 guided according to double arrow 94 along the frame. The stem 93a operates the extraction cable 95.
The components of the pneumatic circuit are initially in the position shown in full lines in FIG. 23. The operation is then as illustrated in FIGS. 22 and 23:
The piece of cloth 3 with its shaft 4 is placed on the plate 90. The control button 92 is pressed. (The chamber 91i is connected to the exhaust). The distributors d 1 , d 2 and d 3 swing; the chamber 91 s is put under pressure and the piston of the jack 91 retracts under the effect of the signal 100. The stem draws the cables 96. The support plate 90 rises until it applies the piece of cloth 3 against the fixed stops 52 (FIG. 22, position shown in broken lines). The limit contacter 97 is then operated and sends a pneumatic power signal 101. The distributors return to their original position. The feed to the auxiliary jack 91 is then cut off, the button 92 likewise returning to the exhaust position.
The harness 56 is attached to the upper end of the shaft 4.
The button 92 is again operated. The distributors d 1 , d 4 and d 5 , feeding the principal jack 93, swing under the action of the pneumatic control power signals passing through an upper limit contacter 98 s , and a distributor 99. The stem 93a of the extraction jack retracts (the upper chamber is under pressure) and causes the extraction of the shaft 4 by traction of the cable 95.
At the end of its travel, the stem acts on a rocker 98; which allows the passage of a signal 103 to order the removal of the feed of the auxiliary jack. The signal 100 feeds, after the swing of d 2 and d 3 the lower chamber 91: The stem extends, the plate 90 and the piece of cloth 3 redescend, whilst the signal 101 is cut off (the limit contacter 97 swings).
The piece of cloth 3, removed from its shaft 4, is then taken from the machine.
Another operation of the control button 92 reverses the pneumatic feed of the principal jack 93 of which the stem extends and allows the shaft 4 to redescend; this may then be taken from the machine after having been detached from the harness 56.
It will be seen that the horizontal and vertical models operate in the same way, that is, by applying the roll of cloth against fixed plates, attaching the shaft on which it is rolled to a harness fixed to a taut cable, and finally drawing on this cable with the aid of a pneumatic jack to extract the shaft from the roll mechanically.
The vertical machine proves valuable because of its small floor space, which is particularly interesting for knitting sheds which are often very crowded.
Naturally the preceding constructions have been described only by way of example. The scope of the invention will not be exceeded by modifying the constructional details of the machine's components. | The present invention relates to a machine for extracting the metal shaft of a roll of knitted or woven textile cloth. The roll is mounted on a frame structure against a fixed stop. A traction cable is guided by a series of pulleys and on one end utilizes a harness to attach the cable to the shaft. At the opposite end of the cable, a tensioning means keeps the cable and tension during its operational load. Actuating device is attached to a pulley communicating with the traction cable to provide the necessary power to extract the shaft from the roll of textile cloth. | 8 |
FIELD OF THE INVENTION
The present invention relates to an extensible vehicle, in particular a motor bicycle which, under resting conditions, assumes a contracted configuration and which at the time of use unfolds to assume an extended configuration of operation.
PRIOR ART
At present there are folding vehicles in trade and in particular motor bicycles in which the chassis is formed of articulated or telescopic parts which can be folded or can contract so as to allow their transport by another means of locomotion, such as an automobile, e.g. in extraurban ways, and their use in urban traffic as an alternative to said automobile.
In some cases the tubular rods of the handle bars are articulated and can be folded back on the central part of the chassis, in relation with which the seat can also be raised or lowered.
In other cases the fork itself, which supports the front wheel, is articulated and can be laid over the central part of the chassis.
Vehicles of this type and particularly folding motor bicycles are not very practical because they require rather laborious operations for folding and unfolding and because in the rest configuration they are difficult to handle.
SUMMARY OF THE INVENTION
The object of the present invention is an extensible vehicle, and particularly an extensible motor bicycle, which would not have the shortcomings of the known ones, which are folding, but which would be functional and occupy little space. Another object of the invention is an extensible vehicle which would have a particularly compact and manageable configuration at rest and could be made usable simply and quickly.
A further object of the invention is an extensible vehicle which would be an optimized solution from the viewpoint of performance and also attractive in appearance.
In accordance with the invention, there has been conceived an extensible vehicle, in particular an extensible motor bicycle, comprising at least one power unit, wheels and associated suspensions, handle bars, and a seat, the vehicle being characterized in that it is equipped with a body which has substantially the structure of a geometric solid and is capable of housing within itself, at least partially, in rest conditions, at least the said power units, wheels and associated suspensions.
In accordance with a preferred embodiment, said body also houses within itself first actuating means operatively connected at least to said wheels to control their lowering and rising from the rest condition, at least partially retracted inside said body, to the operating condition, at least partially extracted outside of said body, and vice versa.
In accordance with another preferred embodiment, said body also houses within itself at least partially the rods of said handle bars and second actuating means are operatively connected to said rods to control rising and lowering thereof from the rest condition, at least partially retracted inside said body, to the operating condition, at least partially extracted outside of said body, and vice versa.
In accordance with another preferred embodiment, said body is of the monocoque type with incorporated frame and is substantially in the form of a suitcase and has a handle.
Advantageously said seat is incorporated in said body. The proposed vehicle is particularly practical, because under rest conditions, it can disappear even entirely in its own body and is easy to transport by another means of locomotion; then, when it is needed, it be can made usable simply and quickly.
Further scope of applicability of the present invention will become apparent from the detailed description given hereinafter. However, it should be under stood that the detailed description and specific examples, while indicating preferred embodiments of the invention, are given by way of illustration only, since various changes and modifications within the spirit and scope of the invention will become apparent to those skilled in the art from this detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
Characteristics and advantages of the invention will now be explained with reference to FIGS. 1-16 wherein are represented as nonlimiting examples preferred embodiments of said invention.
FIGS. 1-4 are a side, rear, front and perspective view respectively of the vehicle in accordance with the invention in a rest condition.
FIG. 5 is a transparent view in enlarged scale of the vehicle of FIG. 1.
FIG. 6 is a schematic view of some components of the vehicle shown in FIG. 5.
FIGS. 7-10 are a side, rear, front and perspective view respectively of the vehicle in operating conditions.
FIGS. 11-13 show some accessories of the vehicle illustrated in FIGS. 1-10, and
FIGS. 14-16 show a modified embodiment of the vehicle represented in FIGS. 1-10.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
In FIGS. 1-4 reference number 10 indicates the overall extensible motor bicycle made in accordance with the invention and represented in rest condition and reference number 11 indicates the overall body which functions as a frame and can be of the monocoque type with the frame incorporated thereon or with the frame mounted separately. The body 11 has the structure of a geometric solid, substantially that of a parallelepiped with rounded edges, of the suitcase type, but without the bottom wall, and with an opening side wall, for maintenance.
The body 11 with a suitcase structure is preferably made of a suitable plastic, optionally reinforced with glass or carbon fibres, and has an optimized design to obtain the necessary resistance to operating stresses.
The body 11 incorporates in the top wall a seat indicated by reference number 12, in the smaller side walls a headlight 13 and a taillight 14, and in the larger side walls pairs of extractible pedals 15. The body 11 has a handle, indicated by reference number 16. Handle 16 allows lifting of the motor bicycle 10. A housing 17 for a key and a control button 18 are also provided on body 11. The control button 18 and an electromagnet 36 comprise a control device.
In the top wall of the body 11 there is a pair of rectangular openings indicated by reference number 19.
As shown in FIG. 5, inside the body 11 are housed in rest position the members and components necessary for motion of the motor bicycle 10.
Reference number 20 indicates the entire power unit comprising an internal combustion motor, e.g. a one-cylinder 2-stroke motor, or an electric motor, and a transmission, e.g. consisting of gears and a chain.
Reference numbers 21 and 22 indicated the front and rear wheels of the motor bicycle and 23 and 24 indicate as a whole the associated suspensions made up of the forks integral with the rods 25 and 26 of two pistons 27 and 28 which are also shown in FIG. 6. The pistons 27 and 28 slide in the cylinders 29 and 30 which are fixed to the body 11. The variable volume chambers 31 and 32 of the cylinders 29 and 30 are connected as shown in FIG. 6, by ducts 33 and 34 to a slide valve actuated by an electromagnet represented schematically by blocks 35 and 36. The valve 35 is controlled by the electromagnet 36 and by a suitable spring, not shown, to slide between two stop positions in which it provides communication between the ducts 33 and 34 and a duct 37 for supplying of a pressurized fluid and alternatively a duct 38 for discharging said fluid.
Reference numbers 39, 40 and 41 indicate respectively the accumulator of the fluid under pressure, the tank for said fluid and a pump or feed compressor depending on whether the fluid under pressure is oil or air.
Reference numbers 42, 43 and 44 indicate the ducts connecting them. In the variable volume chambers 45 and 46 of the cylinders 29 and 30 are arranged respective compression springs 47 and 48 engaged with pistons 27 and 28 respectively. In the place of or even in combination with the springs, the chambers 45 and 46 could be connected by ducts to a slide valve similar to 35 capable of providing communication between them and alternatively the tank 40 and the accumulator 39. Any shock absorbers operatively connected to the wheels 21 and 22 are not shown.
Reference number 49 indicates two tubular rods bent at the ends to form handle bars 50 of the motor bicycle and reference number 51 indicates two actuating levers connected to said handle bars. Handle bars and levers are not described in detail because they are known.
Each rod 49 is integral with the rod 52 of a respective piston 53 which slides in an associated cylinder 54. The cylinders 54 are connected to the body 11 in such a manner as to be able to rotate around a substantially vertical axis, not shown, which constitutes the axis of rotation of the rods 49 of the handle bars 50 during steering. Each variable volume chamber 55 of a cylinder 54 is connected through a duct 56 to the slide valve 35, which is capable of putting it in communication alternatively with the ducts 37 and 38.
In the variable volume chamber 57 of each cylinder 54 is arranged a compression spring 58 which engages with the associated piston 53. In this case also, in the place of, or in combination with the spring 58, the chamber 57 could be connected by means of a duct to a valve similar to 35 to be put in communication alternatively with the tank 40 and with the accumulator 39.
The rod 52 of each piston 53 has a pin 59 sliding in a partially helical groove 61 of a respective tubular sheath 60 which surrounds said rod 52.
With this connection each rod 52 can slide vertically and simultaneously rotate around its own axis, causing corresponding rotations of the rods 49 during their rising and falling strokes in such a manner that the handle bars 50 rotate from the rest position, shown in FIG. 5, arranged in planes parallel to the longitudinal plane of the body 11 and turned rearward, to the operative position shown in FIGS. 8-10, where they are arranged in a transverse plane of said body 11 and turned outward.
The tubular sheaths 60 are connected to the body 11 in such a manner as to be able to rotate around said substantially vertical axis, which constitutes the axis of rotation of the rods 49 during steering.
The sheaths 60 and the fork of the suspension 23 are operatively interconnected by motion transmission members in such a manner that the rotations of the handle bars during steering control rotations of the wheel 21 around its steering axis, which consists of the substantially vertical axis of said fork.
For example the sheaths 60 and the rod 25 can be connected by two engaging gears shown schematically by the block indicated as a whole by reference number 62, providing that a gear can be rotated jointly with the sheaths 60 and the other gear can rotate jointly with said rod 25, while allowing vertical slidings, as would be possible by means of a splined coupling.
Alternately, there could be used a mechanism consisting of two cranks and a rod pivoted thereon.
The handle bars 50 and the rods 49 control the steering of the wheel 21 through the rods 52, the pins 59 engaged with the grooves 61, the tubular sheaths 60 and to the gears 62.
The two rods 49 could be controlled by a single piston 53 whose rod 52 would be integral with both rods; in this case the associated cylinder 54 would be fastened to the body 11 while the rod 52 would slide in a single tubular sheath 60 supported in a rotating manner in the body 11 and operatively connected to the wheel 21 to control steering, e.g. by means of gears as those of the block 62. The rods 49 would then have handle bars 50 which in the rest position would be directed in the opposite direction, forward and rearward, with reference to FIG. 5, and which with the coming out of the body 11, through an opening provided for this purpose, such as those indicated by reference number 19, would assume the operative position turned outward.
In FIG. 5 the blocks 63 and 64 represent schematically a battery and a generator of electrical energy operatively connected to the power unit 20. The battery 63 is in turn operatively connected to the various electrical devices of the motor bicycle including the electromagnet 36 of FIG. 6, which is controlled to be energized and deenergized by the closing and opning of the switch 65, which is opoerated by the pushbutton 18.
Blocks 66 and 67 show schematically a starting device and the fuel tank, connected to the carburettor, not shown, which supplies the engine of the power unit 20.
Reference number 68 indicates the motor bicycle stand.
As shown in FIG. 11, the seat 12 is connected to the body by pins 69 and can be locked by a lock and key 70 operated by the housing 17. Beneath the seat 12 is housed the filler 71 of the tank 67 with its cap.
Inside the seat 12 there is a drawer 72 designed for housing tools or accessories.
In FIGS. 7-10 reference number 73 indicates a rearview mirror fixed to a handle bar 50.
By pressing the push-button 18 from the rest position to the operative position, the switch 65 is closed and the electromagnet 36 is energized, so that the slide valve 35 is commanded to move to the operative position and put in communication the chambers 31, 32, 55 of the cylinders 29, 30, 54 with the duct 37 supplying fluid under pressure.
Under the effect of the fluid under pressure the pistons 27, 28, 53 perform an expansion stroke, pushing the wheels 21 and 22 to lower and the rods 49 of the handle bars 50 to rise and simultaneously rotate, coming out of the openings 19. Thus wheels and handle bars are extracted automatically from the interior of the body 11 and the motor bicycle assumes the extended operating configuration, as illustrated in FIGS. 7-10.
By returing the push-button 18 to the rest position, the switch 65 opens and the electromagnet 36 is deenergized so that the slide valve 35 returns to the rest position and puts in communication the chambers 31, 32, 55 of the cylinders 29, 30, 54 with the discharge duct 38 of the fluid under pressure.
Under the action of the springs 47, 48, 58, or even of said fluid under pressure, the pistons 27, 28, 53 perform a contraction stroke and push the wheels 21, 22 to rise and the rods 49 of the handle bars to rotate and lower simultaneously, so as to be retracted automatically in the interior of the body 11 and the motor bicycle returns to the rest configuration of FIGS. 1-4.
The power unit 20 is operatively connected to the wheels 22 by a transmission comprising preferably a chain so that the lowering and rising strokes of said wheel are allowed; or said unit 20 can be connected to the wheel 22 and to the body 11 so that it can move together with said wheel.
In substitution for the fluid actuators the lowering and rising strokes of the wheels 21, 22 and the rods 49 of the handle bars could be controlled by electromechanical actuators consisting of helical and worm gears or rack and pinions, and reversible electric motors energized by a commutator and the push-button 18.
In FIGS. 12 and 13, a luggage rack 74 and an antitheft device 75 are shown with which the motor bicycle can be equipped.
One of the side walls of the body 11 could be made up of two layers connected along the edges by a bellows to form a parcel bag usable by opening special hooks designed to hold the two layers together.
In FIGS. 14-16, there is illustrated a motor bicycle indicated as a whole by reference number 100 which represents a modified embodiment of the one indicated by reference number 10 described above.
In this case the body 111 is formed of two telescopic parts 112 and 113 which are connected by a bellows 114 of appropriate material so that said body is optionally estensible or shortenable.
In the motor bicycles 10 and 100 the wheels 21 and 22 could be retracted only partially inside the body 11 or 111 under rest conditions and could be extracted only partially from said body in operating conditions.
Instead of a motor bicycle inside the body 11 or 111 could be housed an extensible bicycle.
The proposed extensible vehicle being contained in its body in the form of a suitcase has various advantages such as great ease of handling, rapidity and facility of use, small space requirements and an attractive appearance.
The invention being thus described, it will be obvious that the same may be varied in many ways. Such variations are not to be regarded as a departure from the spirit and scope of the invention, and all such modifications as would be obvious to one skilled in the art are intended to be included within the scope of the following claims. | An extensible motor bicycle is equipped with a body virtually in the form of a suitcase. The body houses within itself, at least partially, several mechanical members necessary for motion and an actuating device operatively connected to the members and capable of automatically controlling coming out and return within the body. | 0 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a fuel/air regulating device for controlling the incoming fuel/air in piston driven, reciprocating, internal combustion engines.
2. Description of the Related Art
As described in U.S. Pat. No. 5,243,934 and the patents discussed therein, reed valves are used in internal combustion engines to control air and or air/fuel intake. In two-stroke engines, reed valves have improved efficiency of the engine by improving transfer of the air and fuel from the crankcase to the combustion chamber while simultaneously sealing against back flow of the incoming fuel/air charge. Reed valves have also been employed in four stroke engines to control air intake and have improved engine performance.
As disclosed in the aforementioned patents, while reed valves have improved the performance of engines, such valves, themselves, introduce problems of operating life and wear. More specifically, multi-staged reeds have been subjected to greater stress on certain petals undergo material fatigue and breakage.
Prior art solutions to these problems included protective coatings, use of a cage to modify intake passages upstream from the reed, joining reed petals together, use of thicker and different reed valve materials and the use of wider reed valve ports and petals.
The present invention is a structure which eliminates the sources of the present state of the art reed valve design problems by replacing the petal style reed with a spring loaded diaphragm that will both regulate and improve the distribution and atomization of the fuel/air charge to the combustion chamber.
SUMMARY OF THE INVENTION
The present invention provides an intake valve, which is mounted in the intake manifold of internal combustion engines, between the output of the carburetor and the input of the combustion chamber.
A principal object and advantage of the invention is the provision of an intake manifold valve for internal combustion engines which provides a diffuser screen for improved atomization of the fuel/air mixture for a more complete combustion.
Another object and advantage of the invention is the provision of an intake manifold valve, which provides an increased plenum volume when compared prior art designs.
Still another object and advantage of the invention is the provision of an intake valve which is more durable than prior art designs.
Another object and advantage of the invention is the provision of an intake valve, which provides improved distribution of the incoming fuel/air charge.
A further object and advantage of the invention is the provision of an intake valve that provides an increase in velocity of the incoming fuel/air charge as it passes through the valve assembly.
Another object and advantage of the invention is the provision of an intake valve, which provides an increase in density of the incoming charge.
A further object of the invention is the provision of an intake valve, which recycles the unspent gases of the previous cycle back into the slipstream of the incoming charge.
A further object and advantage of the invention is the provision of an intake valve, which will improve engine deceleration. A further object of the present invention is the improved scavenging of the crankcase gases of two stroke engines.
A further object of the valve is to direct the incoming fuel/air.
A still further advantage of the present invention is the provision of both internal and external adjustable valve diaphragm-tensioning systems allowing torque curve adjustments.
The above objects are realized with the present invention when it is placed between the output of the engine's fuel/air supply and the plenum area before the combustion chamber.
The valve assembly is comprised of a diffuser screen positioned across an intake manifold that attaches to a lightweight hollow spherical body. The valve body's shape works in conjunction with an adjustable spring loaded, conically shaped diaphragm with a built in vortex generator. This is clearance fitted on a centrally located guide shaft that is secured by a retaining clip at the apex of the mounting plates' bracing. The valve diaphragm seals along its circumference where it contacts the converging inner wall of the valve body. The aft section of the assembled valve has a vectoring skirt and vent holes around its circumference.
The foregoing, as well as further objects and advantages of the invention will become apparent to those skilled in the art from a review of the following detailed description of my invention, reference being made to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a rear view of the diaphragm valve;
FIG. 2 is a cutaway rear view of the exterior diaphragm tensioning adjuster;
FIG. 3 is a front view of the diaphragm valve;
FIGS. 4 and 6 are right side sectional views of the diaphragm valve assembly in its sealed position; and
FIG. 5 is a right side sectional view of the diaphragm valve assembly in an open position.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
In the drawings, the following table sets forth each reference numeral set forth in the drawings:
1
mounting plate
2
mounting holes
3
slotted engagement
4
venturi
5
diffuser screen
6
guide shaft bracing
7
diffuser screen retaining screw and shaft alignment guide
8
tensioning adjustment notches
9
coil spring
10
valve diaphragm
11
valve body
12
guide shaft
13
vortex generator
14
vector skirt
15
valve seat
16
guide shaft retaining clip
17
o-ring
18
o-ring
19
adjuster access
20
plenum area
21
intake port
22
worm gear
23
engagement splines
24
threaded receiver
25
spring seat
26
guide shaft head
27
recess
28
low pressure vortex
29
diaphragm alignment guide
30
bleed-off holes
FIG. 1 is a rear view of the regulating valve. The valve includes a mounting plate 1 . The mounting plate has several holes 2 to enable it to be mounted in the path of the incoming fuel/air and the combustion chamber of the intended engine. The mounting plate 1 provides a fixed base for the guide shaft bracing 6 . The mounting plate 1 also serves as a receiver for the valve body 11 . The mounting plate also serves as a housing for the worm gear 22 , a component of the external diaphragm tensioning system of FIG. 2 . This view also gives a good illustration of the vent holes 4 located in the valve body's circumference.
The engine's intake port 21 is formed between inner walls of the intake of mounting plate 1 and the adjoining portions of valve body 11 .
FIG. 2 displays the exterior diaphragm tension system. It includes a worm gear 22 with its slotted engagement 3 housed in the mounting plate 1 . Numeral 23 denotes a portion of the worm gear's engagement splines. These splines allow the valve body 11 to be rotated from the exterior thereof, using its threaded portion 24 , better shown in FIG. 4 to guide the movement.
FIG. 3 is a front view of the valve assembly showing the diffuser screen 5 that is held in place with a retaining screw 7 , best shown in side view of FIG. 4 . The retaining screw 7 is attached by its threaded portion at the apex of the valve guide shafts bracing 6 . The outer edge of the diffuser screen 5 is held at the junction point of the mounting plate 1 and the valve body 11 . Also shown in FIG. 3 is retaining clip 16 for guide shaft 12 and the worm gear 22 o-ring seals 18 .
FIG. 4 is a right side view of the valve assembly in its closed position with its diaphragm 10 sealed against its valve seat 15 . This view also best illustrates the relationship between the converging walls of the joined intake port of the mounting plate 1 and the valve body 11 . The opposing walls of the valve's diaphragm 10 narrow thus forming a funnel like nozzle that is responsible for the increased velocity of the fuel/air charge. FIG. 4 also shows the threaded receiver 24 of the mounting plate 1 engaging the valve body's threaded portion. Also shown is the o-ring seal 17 that gives this junction a hermetic seal.
FIG. 5 is a right side view of the valve assembly in an opened position with illustrated incoming fuel/air flow. The moveable element of the valve assembly includes a lightweight diaphragm 10 , with its clearance fitted diaphragm alignment guide 29 , mounted on its guide shaft 12 . Shaft 12 is slip fitted through the diffuser screen retainer screw 7 , exposing the valve's internal tension adjustment notches 8 . The retaining clip 16 attaches the guide shaft allowing variable preload tension on the valve diaphragm 10 . Held in position by the guide shaft 12 , is the valve's diaphragm 10 , which is tensioned against the valve body seat 15 by a compression spring 25 that is captured between the diaphragm's spring seat 25 and the guide shaft head 26 . Near the aft end of the valve body 11 is a recess 27 with a plurality of vent holes 4 , best shown in FIG. 1, formed about the periphery of the valve body providing a means to ventilate the plenum area 20 around the exterior of the valve body. The ventilators are positioned to siphon the unspent gases of the previous cycle back into the slipstream of the fresh incoming fuel/air charge. Also shown in FIG. 4, is the vectoring skirt 14 that cooperates with the diaphragm's vortex generator 13 to shape and direct the charge. Numeral 28 represents the low pressure vortex caused by the vortex generator 13 formed on the interior edge of the diaphragm 10 . This vortex 28 is also responsible for atomization of the fuel/air charge.
In operation, the valve diaphragm 10 , FIGS. 4-6, is actuated by the alternating pressure caused by the engine's reciprocating piston. With an advancing piston, a vacuum is created in the plenum area. This vacuum causes the diaphragm to be drawn away from the valve seat 15 , FIGS. 4-5 on the valve body 11 . This permits the carbureted fuel/air to be pulled through the diffuser screen 5 , FIG. 3, to initiate atomization of the fuel/air charge. The charge also passes through the funneled opening formed by the converging walls of the valve body 11 , FIGS. 4-5, and the diaphragm 10 . This process forms the atomized fuel/air charge into a dense, homogenized charge that will have gained velocity. This charge is then shaped and directed to the combustion chamber by the combination of a vector skirt 14 , FIGS. 4-5, venting holes 4 shown in FIG. 1, and the vortex generator 13 , shown in FIG. 4 . The charge is then further atomized by the circulation caused by the siphoning action of venturi 4 and the low pressure vortex 28 , FIG. 5, caused by the concave shape of the diaphragm 10 with its attached vortex generator 13 .
Conversely, with a retreating piston, the increased crankcase pressure developed causes the valve diaphragm 10 to be closed against its valve seat 15 . This seating action will seal the plenum area thereby decreasing backflow through the carburetor, while promoting the scavenging of the previous cycles' fuel/air charge into the combustion chamber.
As shown in FIGS. 1 and 4, valve diaphragm 10 may have bleed off holes 30 formed therein at an angle of approximately 30° with respect to the vertical. These holes serve to aid in the circulation of the flow in the areas behind the valve diaphragm 10 .
It should be understood that the shape of the diaphragm valve, and the size, location, and configuration of the valve structure as an assembly will be based on the function of the configuration of the connecting structure that best serves its intended applications performance as seen fit by those skilled in the art.
Having thus described the invention in detail, it is to be understood that the foregoing description is not intended to limit the spirit and scope thereof. What is desired to be protected by Letters Patent is set forth in the appended claims. | A diaphragm valve assembly includes a diffusing screen, and a generally spherical lightweight membrane that provides a 360° circular seal. Spring loading enables variable resistance to be placed on the seal to allow the operator to adjust the internal pressures in an engine by metering the intake and exhaust cycles to obtain maximum performance characteristics from the subject engine. | 8 |
This is a continuation of copending application Ser. No. 07/601,545 filed on Oct. 22, 1990 now abandoned.
This invention relates generally to printing on composite media, and more specifically to cutsheet film with a backing sheet which is used on automatically loaded printers.
It is very typical for the same cutsheet media to be used in both hand-loaded printers and automatically loaded printers. This avoids keeping two separate inventories of media. However, it was found that certain types of composite film media designed for use in hand-loaded printers sometimes were not satisfactory for automatic stack-loading printers.
More specifically, a composite media of film plus backing sheet of the "Lead-Edge" design was developed to be suitable for use with a conventional hand-loaded printer. Such hand-loaded printers typically allow a user to feed each individual sheet into the printer in a manner similar to feeding a sheet of paper into a conventional typewriter. However, problems developed when a stack of the same composite cutsheet media was used in an improved printer which provided automatic stack loading in lieu of hand-loading. In some environments having diverse combinations of temperature and relative humidity conditions, the leading edge of the composite media in the stack would curl, thereby interfering with the automatic loading and causing misfeeds.
It therefore became necessary to develop a different type of lead edge composite media suitable for automatic printer loading, which would also continue to be suitable for hand feeding into a printer.
OBJECTS AND BRIEF SUMMARY OF THE INVENTION
It is an object of the present invention to modify existing composite printing media such as the type formed by a laminate of film and backing in order to facilitate the automatic loading of printers by preventing misfeeds. A related object is to provide a composite printing media which can be satisfactorily fed into a hand-loaded printer as well as into an automatically loaded printer.
The invention provides a lateral slit through the backing sheet of a composite media in a middle portion of the leader region where the film is adhered on both sides of the lateral slit to the backing sheet. This allows the backing sheet to expand or contract at a different rate as compared to the adjacent film without causing excessive curling, thereby preventing printing misfeeds in extreme environmental conditions. In a preferred embodiment of the invention, the slit is displaced from the terminal edge of the finished film and also displaced from the leading edge of the film leader so as to be intermediate therebetween. By keeping the slit narrow, and by having the leading edge of the backing approximately flush with the leading edge of the film, and by providing adhesive on both sides of the slit and extending the adhesive continuously between the slit and the leading edge, the composite acts like a unitary laminant when picked up from the stack by a loading mechanism while at the same time providing an expansion/contraction joint along the full lateral width of the leader portion of the backing paper.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a typical hand-loaded ink-jet printer which uses composite media of the type having a leader for insertion into a feeding mechanism;
FIG. 2 shows a typical ink-jet printer capable of automatic loading of composite media from a stack tray;
FIG. 3 shows the specification sheet for a preferred embodiment of composite media incorporating the expansion/contraction features of the present invention; and
FIG. 4 shows a enlarged schematic cross-sectional enlargement of the composite media of FIG. 3, in order to illustrate the relative positioning of the film and backing in the vicinity of the leader portion of the composite media cutsheet.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
As shown in FIG. 1, a typical hand-loaded ink-jet printer 10 includes a manual roller knob 12 for initially feeding a sheet of transparent film 14 into the printer. In order to maximize the printing area at the top of a film sheet, a leader 16 is provided which preferably has a sealed leading edge 18 where the film sheet and underlying backing sheet are joined together to facilitate proper feeding into the printer.
In FIG. 2 a different printer 20 is shown which allows for either manual feeding or automatic feeding of cutsheet film into the printer. Such an ink-jet printer typically includes a power switch 22, a flip-up protective window 24, an ink cartridge carrier 26, and an operator control panel 28. Sheets can be manually fed into the printer, or alternatively a tray cover 30 is removed so that a stack of sheets such as composite film transparencies can be automatically fed from a media tray 32 into the printer.
The specifications for a preferred form of the invention are set forth in FIG. 3. More specifically, an elongated film sheet 38 is scored along a lateral line 54 to provide a finished film portion 40 of a predetermined length. A backing sheet 44 preferably extends along the entire film sheet 38, and includes a leader backing portion 46. A layer of suitable adhesive 48 connects the leader backing portion 46 to the overlying leader film 42 and also provides an adhesive layer removably connecting a forward strip of film 50 with its adjacent underlying backing. Thus at the end of the printing operation, the finished film portion 40 can be manually removed from the leader film 42 and backing sheet 44 by separating the forward strip of film 50 from its adhesive connection to the backing sheet.
In order to prevent undesirable curling of the leader prior to the cutsheet transparency being automatically fed into the printer, a paper slit 52 is provided across the entire width of the leader backing portion 46 in an intermediate location displaced between the leading edge and the film scoring 54. In the preferred embodiment, such a paper slit is preferably narrow so as to be 1.6 mm or less. To assure proper lamination between the two layers, no creases or wrinkles in the backing sheet are allowed. For typical printing conditions, an image coating is applied only to the externally exposes face of the film, while the uncoated surface is against the backing sheet directly or adhered to the backing sheet through a layer of suitable adhesive. The edges of the film and backing paper are preferably cut to be flush within 0.8 mm, particularly where the leading film edge 58 and the leading backing edge 60 are sealed together at the forward boundary of the cutsheet. As best shown in FIG. 3, the various primary dimensions A, B and C of the currently preferred embodiment of the media sheet are set forth in the following table:
______________________________________ A B CSIZE (mm) (mm) (mm)______________________________________A (ENGLISH) 213.4 279.4 304.8A4 (METRIC) 210 297 322.4______________________________________
In the preferred version of FIG. 3, the B dimension can tolerate variations of +1 mm/-3 mm from the table; the backing sheet portion 56 above the slit 52 is 12 mm wide with tolerable variations of +2 mm/-2 mm; and the adhesive strip underlying the forward strip of film 50 is 9.5 mm wide.
Of course, other laminating materials other than transparent film and paper backing may be used to implement the advantages of the invention in a composite laminant, all depending on the media required and the type of printer being used.
The actual dimensional thickness of the film, adhesive and backing are exaggerated in the schematic illustration of FIG. 4 in order to show the relative positioning of the slit 52 (which goes completely through the paper backing but not through the film) and the scoring 54 (which goes completely through the transparent film but not through the backing). The continuous layer of adhesive 48 is also shown to provide the adequate connection for creating a laminant which has no loose ends or edges which might otherwise cause a misfeed.
It will be appreciated by those skilled in the art that the improvement provided by the invention solves the problem of curling for automatic feeding into a stack-loaded printer while at the same time allowing the same composite media to still be used satisfactorily in the hand-loaded printers. While the invention is specifically suited and designed for ink-jet printers, it is also applicable to other printers which use composite media which is automatically loaded, as by a stack tray.
While a preferred exemplary embodiment of the invention has been shown and described, it is to be understood that various changes and modifications can be made without departing from the spirit and scope of the invention as defined by the following claims. | In order to avoid misfeeds from tray-loaded film, a lateral slit is provided through a backing sheet of composite media in a middle portion of a leader region where the film is adhered on both sides of the lateral slit to the backing sheet, thereby allowing the backing sheet to expand or contract at a different rate than the adjacent film. | 8 |
BACKGROUND OF THE INVENTION
Field of the invention
The field of the invention is the field relating to apparatus for pumping blood of a living person, or of a living animal, to replace one or more pumping functions of the human or animal heart in case of disability thereof. The heart replacement may be partial or complete. While the pumps provided according to the invention are provided principally for pumping blood, it will be apparent that the pumps may be employed in other instances for pumping other materials. The pumping equipment provided by the invention has rotating fluid accelerators or rotators. The pumps are adapted for pumping of blood and other delicate fluid materials without any pronounced physical effect on the blood or other fluid being pumped. The pumps do not impose sudden pressure changes, impacts, rapid changes in direction of flow, in order to prevent injury to or destruction of the pumped material and its components.
Description of the prior art
In the prior art, artificial heart pumps heretofore employed have been of the positive displacement type. Because of the relatively delicate nature and structure of blood, it has been found that use of centrifugal pumps invariably results in physical disruption of the blood and at least some of its components. Although it has been shown that a pulsating movement of blood through the body is not necessary to sustain life, the prior art has not afforded a solution to the problems involved in utilization of centrifugal pumps for pumping blood, since at least partial destruction of the blood has always resulted when centrifugal pumps were used. This invention solves these problems, by providing rotative pumping means for pumping blood, without any significant destruction of the blood and its components resulting from the pumping.
SUMMARY OF THE INVENTION
The invention is of rotative pumps which are suitable for use in primary blood for circulation through the body passages, veins, arteries, etc., of a living person or animal. The pumps are adaptable for use disposed within a body cavity, as replacements for either or both of the pumping functions of the heart. The pumps herein provided may also be used for pumping blood externally of the body. The pumps are adapted to pump without producing severe pressure changes, physical impacts, and the like, so that none of the blood components is subjected to treatment which will destroy it for use. The pumps do not require the use of valves, such as those of the heart, but valves may be provided if desired.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a cross sectional view of one preferred form of pump according to the invention.
FIG. 2 is a partial cross sectional view showing a modification of the pump of FIG. 1.
FIG. 3 is a cross sectional view of a three-stage pump, according to the invention.
FIG. 4 is a cross sectional view of a modified form of pump according to the invention.
FIG. 5 is a partial cross sectional view taken at line 5--5 of FIG. 4.
FIGS. 6-8, 8A, and 9-12 show different forms of fluid accelerators or rotators which may be employed in pumps according to the invention; FIG. 9, in addition, shows a built-in drive motor for the accelerator or rotator.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Blood is a complex and delicate fluid. It is essentially made up of plasma, a pale yellow liquid containing microscopic materials including the red corpuscles (erythrocytes), white corpuscles (leukocytes), and platelets (thrombocytes). These and the other constituents of blood, as well as the nature of suspension of these materials in blood, are fairly readily affected by the manner in which blood is physically handled or treated. Blood subjected to mechanical shear, to impact, to depressurization, or the like, may be seriously damaged. The balance between the blood constituents may be affected. Commencement of deterioration may result from physical mishandling of blood. Blood which has been damaged may be unfit for use.
The heart pumps blood through the body in a circulating, cyclic, fashion. The blood passes repeatedly through the heart. A pump for replacing one or more pumping functions of the heart should therefore be capable of repeatedly pumping the same blood, time and time again, without damaging the blood, at least not more than to the extent where the body can function to repair or replace the blood components and eliminate damaged and waste materials therefrom.
Blood also contains dissolved and chemically combined gases, which may be seriously affected by improper physical handling of the blood. It has, for example, been established that subjecting blood to negative or subatmospheric pressures of, say, minus 300 millimeters of mercury, is detrimental, even when the reduced pressures are only temporary.
The blood pressure is the pressure of the blood on the walls of the arteries, and is dependent on the energy of the heart action, the elasticity of the walls of the arteries, the peripheral resistance in the capillaries, and the volume and viscosity of the blood. The maximum pressure occurs at the time of the systole of the left ventricle of the heart and is termed maximum or systolic pressure. The normal systolic pressure may be from about 80 millimeters of mercury (mm. Hg) to about 150 mm. Hg. the pressure ordinarily increasing with increasing age. Pressures somewhat outside this range are not uncommon. The minimum pressure is felt at the diastole of the ventricle and is termed minimum or diastrolic pressure. The diastolic pressure is usually about 30 to 50 mm. Hg lower than the systolic pressure.
The preferred embodiments of the invention shown and described have in common that the blood or other delicate fluid is handled gently, without shear, shock, vibration, impact, severe pressure or temperature change, or any other condition or treatment which would unduly damage the blood or other fluid. Essentially non-turbulent flow is maintained through the pumps, and the pumped fluid is accelerated gradually and smoothly.
The pumping action obtained may be described as radially increasing pressure gradient pumping, or in some cases more specifically as forced vortex radially increasing pressure gradient pumping. In centrifugal pumps, the fluid acted on by the vanes of the impeller is positively driven or thrown outwardly (radially) by the vane rotation. The fluid as it moves from the vanes to the ring-shaped volute space beyond the tips of the vanes is reduced in velocity, and as the velocity decreases the pressure increases according to Bernoulli's theorum. On the other hand, in the pumps provided according to this invention, the pumped fluid is not driven or thrust outwardly but instead is accelerated to circulate in the pumping chamber at increasing speeds as it moves farther and farther from the center. As the outer periphery of the accelerator or rotator, the speed of the fluid is maximum.
The action of the fluid in the pumps may be clarified by analogy to a glass of water turning about its vertical axis without sideways motion or wobble. Because of its contact with the sides and the inherent potential shear force of the water in the glass, the water will rotate, in the form of a forced vortex, without much clip or shear between radially adjacent particles of water, and the water radialy away from the center of rotation will be moving faster than water nearer the center. If water is introduced through a tube at the axis of the glass and water is removed through one or more holes through the side of the glass, water will be pumped by the rotation of the glass. In the pumps afforded by this invention, while rotators are provided, in a number of different forms, the rotators are designed such that they act to increase the swirling speed of the liquid passing through the pump, but do not act to drive or throw the liquid toward the periphery or volute of the pump chamber, but instead only increase the rotational speed of the liquid. As the rotative speed of the liquid is increased, it achieves a higher "orbit" about the center of the accelerator and moves toward the periphery of the chamber.
Referring first to the apparatus shown in FIG. 1 of the drawings, a housing 15 has parallel spaced circular walls 16, 17. At the center of wall 16, an offset chamber 19 is formed which terminates outwardly in an inlet passage 20. Wall 17 has at its periphery circular formations 22, 23 joined by peripheral wall 24 between which is formed a peripheral ring-shaped chamber 27. Formation 22 is internally shaped to provide a flow-direction flaring surface 28. Wall 16 is connected to formation 22 by a plurality of circularly spaced screws 29.
A rotative circular vane 31, forming one side of the accelerator or rotator 30, has at one side a flared inlet formation 32 which extends into chamber 19 and is sealed to the wall of chamber 19 by O-ring 34 and which rotates in bearing 35 disposed within chamber 19. The interior wall of inlet 32 is flush with the wall inlet 20. An O-ring 36 around the periphery of flat vane or disc 31 seals with the inner side of formation 22. The inner side of vane 31 is flush with the beginning of curved surface 28 so that fluid flowing through the pump introduced through entrance 20 flows smoothly from entrance 20 to entrance passage 32, through the pump chamber, and smoothly past the intersection of the periphery of vane 31 and surface 28.
Vane 31 is connected to a second rotating vane 38, forming the other side of accelerator or rotator 30, which is concentric and parallel to vane 31, by circularly spaced pins or rods 39. Vane 38 has O-ring 40 about its periphery to seal with the inner side of formation 23. An outlet passage 41 is provided at one side of wall member 17, it being possible to provide any number of such outlets circularly spaced about the pump as is desired. Wall 17 has at its center a central passage 43 containing bearing 44 which is in contact with rotating shaft 45 connected to, or forms a part of, vane 38. Vane 38 has at the center of its inner side the rounded projection 38a, which guides incoming fluid to flow smoothly along the vanes.
The pump shown in FIG. 1 operates in the following manner: The fluid to be pumped flows inwardly through passage 20 into passage 32 to the space between rotating accelerator vanes 31, 38. Shaft 45 is driven rotatively by means not shown, and vanes 31, 38 rotate together (in either direction) because of their connection at pins or rods 39. The pump operates on a forced vortex principal, there being no impeller surfaces in the pump for impelling blood or other fluid material being pumped radially outwardly toward the periphery of the pump chamber. A forced vortex pump operates on the principal that a rotating chamber causes rotation of its contents, with creation of a vortex, so that a body of circulating fluid is maintained within the pump chamber by rotation of the vanes 31, 38 at opposite sides of the chamber, whereby the rotational speed of liquid in the pump is increased from the center to the periphery of the chamber of the pump. The liquid is withdrawn through the outlet 41, and as has been stated before, a plurality of outlets 41 may be provided if desired.
It will be seen that the blood or other fluid passing through the pump is not submitted to any substantial agitation by the rotation of the vanes, or by any other portion of the pump apparatus. There are no sudden changes in direction of the flow through the pump, all joints between surfaces being smooth and all surfaces over which the fluid flows being smooth.
Referring now to FIG. 2 of the drawings, there is shown a portion of a pump identical to that shown in FIG. 1 except that the flow outlet is of modified form. The outlet 41a from the pump chamber is shown to be disposed radially from the pump chamber instead of parallel to the pump axis as in FIG. 1. The wall elements 16a, 17a are like those shown in FIG. 1 except that the curved surface 28 is omitted at the interior of formation 22a and the peripheral chamber 27a is of rectangular cross section. The vanes 31, 38 are as shown in FIG. 1, as is also the remainder of the pump, only the peripheral portions of the pump elements being modified as shown. The operation of the pump in FIG. 2 is the same as that of the pump of FIG. 1, except that the pumped fluid exists from the pump radially instead of in line with the pump inlet. Plural outlets 41a may be provided if desired.
Referring now to FIG. 3 of the drawings, there is shown a pump 50 having three serially disposed pumping stages, whereby the pressure of blood (or other fluid) pumped may be higher than the pressure obtained in a single stage of pumping, such as by the pumps shown in FIGS. 1 and 2. The pump housing is made up of housing elements 51, 52, 53 and 54. The housing elements are joined at peripheral bolt flanges 55-56, 57-58, 59-60, the bolts not being shown.
The pump of FIG. 3 has three pumping chambers 61a, 61b, 61c, and two return chambers 62a, 62b through which the fluid pumped by the first two pumping stages is returned to the center of the pump for the next pumping stage.
The rotator or accelerator 63 in pumping chamber 61a includes a flat circuit vane 64, having peripheral flange 65, and sealed to the housing for rotation therein by O-ring seals 66, 67, and a flat circular vane 68 spaced from vane 64 and supported by plural circularly spaced pins or rods 69, and mounted at its center on shaft 70.
The return chamber 62a is formed between circular plate 71 and housing wall 52a, plate 71 being supported by wall 52a through plural circularly spaced pins 72, and sealed to the periphery of vane 68 by O-ring 73. Vane 68 and plate 71 are of the same diameter. Shaft 70 is disposed for rotation through plate 71 at O-ring seal 74.
The rotator or accelerator 75 in pumping chamber 61b includes vanes 76, 77 which are identical with vanes 64, 68, respectively, except that shaft 70 extends completely through vane 77 as shown. The seals 66, 67 and rods 69 are provided as before. Rotator 75 differs from rotator 63, however, in that a plurality of relatively thin flat plates or sheets 78a-78c are spaced parallelly between the facing sides of vanes 76, 77 within the pumping chamber. Plates 78a-78c are circular and may be of the same or different diameters. They are supported at perforations therethrough by the pins 69 extending between vanes 76, 77. Any number of these plates may be provided, so long as the spacings therebetwen do not become small. The spacings between the adjacent vanes and plates should not be less than about 1/4 inch. If the vanes and plates are spaced more closely, the shear stresses imposed on the blood or other fluid become excessive, with resulting trauma of blood and harmful physical effects in the case of other fluids. In Transactions of the ASME, July 1963, page 205, it is stated in the second complete paragraph of column 2, that in pumps therein termed "shear-force pumps," that "Due to the necessity for very close spacing of the shear surfaces, the pump" (ed) "fluid must be essentially free of suspensions." It should be made clear at this point that the utilization of very close spacings is not contemplated by this invention, so that the invention is distinguished over the apparatus described in the aforementioned article, and also is distinguished over apparatus of the type or kind proposed in Patent No. 1,061,206 to Tesla. In such apparatus, the emphasis is on very high rotational velocities and very close spacings, which make them unfit for use insofar as the contemplation of this invention is concerned. According to this invention, the emphasis is on gentle, non-turbulent handling of the pumped fluid, as is illustrated by the aforementioned rotating glass of water with nothing to rotationally accelerate the water but the smooth side of the glass. Yet, the water after a time rotates with the glass and continues the rotation as long as the glass continues to rotate.
Return chamber 62b is identical with return chamber 62a, and includes elements 71a, 53a, 72a, 73a, 74a, respectively identical with elements, 71, 52a, 72, 73, 74 heretofore described.
The rotator or accelerator 80 is made up of vanes 81, 82 which are respectively identical in form with vanes 64, 76 and 68, 77. The rods 69 are omitted, and the vanes 81, 82 are connected by plural vanes 83, radially disposed and arcuately spaced. The vanes 83 may be flat as shown, or may be curved end-to-end and twisted like the vanes shown in FIG. 9. Any suitable number of vanes 83 may be provided. Each vane 83 extends from near the axis of the pumping chamber to terminate the line with the inner face of vane 82, as shown.
Within housing element 54, there is a ring-shaped chamber 85 disposed between circular walls 86, 87, 88, walls 87, 88 being aligned with the sides of the annular opening between vanes 81, 82. Outflow opening 89 is provided through wall 88, and plural such openings may be provided if desired.
Shaft 70 is rotated by means not shown to rotate the vanes of the three rotators.
The flow inlet to the pump is provided through nipple 51a and circular opening 64a aligned flushly therewith.
It will be realized that pumps may be supplied according to the invention with any number of pumping stages, and may include individual pumping stages of any of the types mentioned herein in any combination.
Referring now to FIGS. 4 and 5 of the drawings, there is shown a pump 110 having a housing made up of members 112, 113 identical with the corresponding housing members of FIG. 2 except that bearings 135 is in a different disposition than bearing 35 (see FIG. 1). Elements of FIGS. 1-2 which are the same as indicated by the same reference numerals in FIGS. 4-5. The accelerator 119 includes a flat circular vane 120 and a second flat circular vane 121. The vanes 120, 121 are connected by the full-radius curved vanes 125, and the shorter curved vanes 126, 127, and 128. As best shown in FIG. 5 of the drawings, the vanes 125 extend from the center of the accelerator to its periphery, the vanes 126 extend from a point spaced from the center of the accelerator to its periphery, and the vanes 127, 128 extend from about the centers of vanes 126 to the periphery of the accelerator. Four of each type of vanes are shown in the drawing.
The objective of this configuration of the vanes is that the impetus of the vanes in thrusting the pumped fluid outwardly is minimal, only four of the sixteen vanes acting on the blood, or other fluid, as it emerges from the entrance into the pump chamber, and, as the blood progresses through the blood chamber, from its center toward the periphery, additional vanes take action to move the blood in its spiral motion, with increasing velocity, toward the periphery of the pumping chamber.
The rotator 119 has a flared entrance 130 which merges smoothly into the face of vane web 120. The interior of entrance 130 blends smoothly with the interior of entrance 20 which is formed in the offset space 19 at a side of the housing.
At the opposite side of the housing, wall 113 has at one side a cylindrical formation 134 through which rotative shaft 135 is disposed within bearing 136, and O-ring seal 137 is disposed about the outer periphery of vane 121 to seal between the vane and housing.
The housing has at one side the radially disposed outlet 138 having outflow passage 139 therethrough. Any number of similar outlets may be provided.
A ring shaped screen 140 is disposed around the ring shaped space 27a of the apparatus of FIGS. 4-5, the screen dividing the space into inner and outer annular portions. The screen may be omitted. Any porous or perforate divider may be substituted for the screen, e.g. a plate having one or more openings, spaced bars, etc. The screen serves to create two distinct annular flow zones within space 27a, an inner zone in which the fluid moves circularly as accelerated by the rotator, and an outer zone reached by the fluid by outflow through the screen, over its complete circular length, the fluid flow through the screen reducing its circular velocity. Thus, the outer zone is a zone of slower velocity from which the fluid moves in the outlet 139, whereby eddy currents and turbulence at the outlet is reduced.
Referring now to FIGS. 6-12, there are shown a number of forms of rotators or accelerators which may be used in the pumps, these being shown more or less schematically. The rotators 141, 142 shown in FIGS. 6 and 7 are similar, each having a pair of curved blades or vanes 150-151 and 153-154, respectively. The views shown are cross sections taken at right angles to the axis of rotation of each rotator, and the rotator shown in FIG. 6 has a flat side plate or vane 155 which is circular, and similarly the accelerator shown in FIG. 7 has a side vane or plate 156, also circular. In most cases there will be another plate 155 or 156 at the other, or near, side of the vanes. The rotators, therefore, are enclosed at their sides by these plates. The rotator of FIG. 6 has central openings 158 where the liquid to be pumped enters, and a pair of flow passageways between the vanes indicated by reference numerals 159, 160 which are of constant cross section from the center to the periphery of the rotator. Fluid passing through this rotator does not have opportunity for volume expansion, as the flow passages, through which it moves are of constant size from their beginning to their end. The rotator of FIG. 7, on the other hand, has the pair of flow passages 162, 163 extending from the center to the outside of the rotator which increase in cross section from their central entrance to their peripheral outlet ends.
The rotator shown in FIG. 8 consists of a hollow, drum-like, body 165, having a cylindrical tube 166 between central openings at each of its sides, and having a curved peripheral wall 167. The tube 166 and wall 167 have plural openings 168, 169, respectively, any suitable numbers and spacings of these being provided, four of each being shown circularly equally spaced. Fluid enters through tube 166 and flows into the drum through openings 168. The drum is rotated and the fluid therein is caused to rotate, the rotator giving the fluid circular motion but no outward radial motion. Centrifugal force resulting from circular motion of the fluid, however, causes the motion of the fluid to be spiral instead of circular, so that the fluid after moving spirally through the space within the drum flows outwardly through the openings 169 into the pumping chamber space annularly around the rotator, from which the fluid exits through one or more outflow passages of any suitable form. A pair of O-ring seals 170, 171 disposed in suitable grooves around the opposite edges of the body 165 seal between the rotator and the pump housing in the manner shown in other drawing figures.
In FIG. 8A, a rotator is shown which is a modification of that shown in FIG. 8, and to which the description of FIG. 8 applies to the elements indicated by the reference numerals of FIG. 8, the modification residing in the addition of the tubes 173, each of which extends between one of the inner holes 168 and one of the outer holes 169 at the same side of the rotator. The tubes 173 may be straight and radial as shown in the drawing, or may be curved or angular, by proper positions of the holes 168, 169 and shaping of the tubes. In this rotator, the fluid would pass from tube 166 through tubes 173 to exit at the periphery, upon rotation of the rotator.
Referring now to FIG. 9 of the drawings, a rotator 175 is shown which has a plate or disc 176 at each of its sides which may be identical or of different form or size, only one being shown in the drawing, and between which there are provided the equally circularly spaced curved blades 177a-177h, each curved from its inner end to its outer end as shown and each having a twist throughout its length similar to the twist of a propeller. The blades or vanes, may extend beyond the outer edges of the discs 176. Each blade 177a-177h carries a winding 178, which is covered by an impervious layer or membrane 179. The blade windings are connected to contact elements of a commutator 180. The surrounding pump housing is provided with the circularly spaced magnets or coils 181, which are separated from the pumping chamber by an impervious layer or membrane 182. The commutator rotates with the rotator in the usual manner of an electric motor. The rotator windings and housing magnets or coils constitute an internal electric motor for driving the rotator to pump fluid. The electric motor thus provided may be of any of the known types, AC or DC, with or without commutation powered by electrical conductors leading thereto from any suitable AC power source or from a battery, located either internally or externally of the body. The conductors may be disposed through the outer body wall from the exterior of the body, installed surgically. The power source may include capacitance connections, across the body wall, with both of its plates beneath the skin, or with one plate interior of the skin and the other exterior of the skin. A battery power source may be disposed within the body, and replaced periodically by surgery, or recharged inductively from the exterior of the body. Batteries capable of operation for periods in excess of one year are available, so that surgery for their replacement would need to be done either annually or at longer intervals.
While the self contained drive motor is herein shown and described in connection with the rotator of FIG. 9, it will be understood that it may be provided in conjunction with all of the other forms of rotators disclosed herein.
The descriptions concerning power supplies to the motor of FIG. 9 will, of course, relate also to power sources for motors connected to pump shafts external of the pump housings.
Referring now to FIG. 10 there is shown a rotator in the form of a plate 185, the peripheral edge 186 of which is of corrugated formation. The radial corrugations each extend narrowingly to the center opening 187 of the plate. The curved corrugation surfaces are adapted for acceleration of fluid circularly as the rotator is rotated, in either direction, about its center. This form of plate may be used alone as a rotator, or plurality as the flat plates of the second stage of the pump shown in FIG. 3. Similarly, the flat vane surfaces, such as in FIGS. 1 and 2, may be corrugated to enhance their accelerative purpose. Rotators of this form present only smooth surfaces to the blood or other fluid being pumped.
In FIG. 11, there is shown an accelerator or rotator having spaced parallel circular plates 190, 191 at the inner side of each of which are provided circularly spaced radial vanes 192 and 193. The vanes 192, 193 are staggered as shown, the vanes of each plate 190-191 being alternately disposed and extending only partway toward the opposite plate 190 or 191.
Referring now to FIG. 12 of the drawings, the rotator therein shown has a pair of opposite sides vanes or plates 197, only one being shown, between which are disposed a plurality of circularly spaced curved vanes 198. These vanes are of a shape, when rotated in the direction of arrow 202, serve to pick up blood from the entrance 203 to move it into the rotative path of the vanes, and then the concave curves of the vanes act to accelerate the fluid circularly while restraining somewhat outflow toward the periphery of the rotator, and at the same time lengthening the flow paths of the fluid from the center to the periphery of the rotator.
In each of the pumps shown in FIGS. 1-5, and pumps wherein use is made of rotators (or accelerators) of the different forms shown in FIGS. 6-12, it will be noted that the rotators are designed to avoid turbulence and to avoid rapid pressuring and depressuring of the blood or other fluid being pumped, and also to avoid any physical grinding or abrasive action upon the fluid. As has been made clear, these rotator designs are made in this manner in order that blood or other delicate liquids or gases being pumped, some containing solids in suspension, will not suffer detriment and will not be destroyed by the pumping operation.
In contrast to centrifugal pumps, the revolutions per minute of the rotators employed with the pumps herein shown and described are kept minimal. The several rotator designs presented are each of a form adapted to progressively increase the circular fluid velocities as the rotator turns and as the fluid advances toward the periphery of the rotator. In each pump presented, an annular fluid circulation space is provided, which is entirely unobstructed and regular so that fluid can circulate therein without turbulence or baffle effects.
As hereinbefore indicated, pumps may be made according to the invention incorporating features from one or more of the preferred embodiments shown and described herein, any particular feature not being confined to use only with the other features in connection with which it is herein shown and described.
The pumps and their parts may be constructed of any materials compatible with their intended use, including metals, mineral materials, plastics, rubbers, wood, or other suitable materials. When blood is to be pumped, consideration must be given to biological compatibility so that trauma to the blood will not result. Teflon has been successfully used in contact with blood, without traumatic effects, and may be used in construction of the pumps for blood pumping adaptations. Non-corrosive metals and alloys may be used in the pumps where required.
In the embodiment of FIG. 9, Teflon may be used for the membranes 179, 182 covering the windings of the electric motor structures.
The housings and rotators may be constructed of suitable material so that the housing may be rigid, semi-rigid, or elastic in whole or in part. The non-rigid constructions can be used for imparting pulse configurations to blood in heart simulation pumps.
While the rotators shown herein may in some cases perform better when rotated in one direction, it should be understood that they may be rotated in either direction, i.e. reversed, without other modification of the pumps. Each of the rotators presents surfaces to the fluid being pumped, to cause accelerating circular fluid motion in the pumping chamber. In some cases, the surfaces are parallel to the fluid flow; in other cases parallel and non-parallel surfaces are provided. Each of these surfaces, of whatever form, will accelerate the fluid regardless of the direction of rotation of the rotator. Each rotator should be rotated at a speed such that essentially no fluid turbulence occurs, and differences in the rotator designs affects the maximum speed at which a particular rotator may be rotated. The physical and flow properties of the fluid pumped will, of course, also affect the maximum speeds of rotation at which the rotators may be operated without turbulence and other objectionable effects, such as cavitation, vapor binding, and the like. It is, therefore, not possible to set forth exact rotational speed ranges for the rotators. But, the speeds of rotation will always be lower and will usually be substantially lower than those of centrifugal pumps and blowers, wherein turbulence always occurs at the impellers thrust the fluid radially outwardly against the periphery of the pumping chamber, and those of the aforementioned multiple disc pumps and compressors. To the end of achieving reduced rotator speeds, pumps provided according to this invention may be of larger size than other pumps, for the same pumping capacity. As internally placed heart pumps, the pumps may be as large as five inches in diameter, and, with removal of a lung, even larger.
According to the precepts of this invention, the forms of the rotators may vary considerably. For example, the rotators may be constructed entirely or partly of porous or perforate materials, i.e. the vanes of the rotator which accelerate the fluid circularly may be made of screen, of perforate plates or sheets, of spaced rods, or the like, and will still ably perform their fluid accelerating function. Rotators may be of axially extended form, so that the fluid is accelerated axially or axially and radially. Designs of this nature would extend the flowpath from inlet to outlet so that acceleration would be at a slower rate. In the rotator of FIG. 7, the vanes could be made to become closer together, instead of farther apart, toward the periphery of the rotator. In each of the pumps shown and/or described, one or more tangential outlets could be provided, disposed in the direction of fluid flow inside the peripheral wall of the pump. In multi-stage pumps, such as that shown in FIG. 3, the several rotators, which may be alike or unlike, may be driven at different rotational speeds. The axes of multi-stage rotators may be offset and in other positions out of alignment.
While preferred embodiments of apparatus according to the invention have been shown and described, many modifications thereof may be made by a person skilled in the art without departing from the spirit of the invention, and it is intended to protect by Letters Patent all forms of the invention falling within the scope of the following claims: | The disclosure is of pumps which are capable of use as heart pumps, that is, for pumping blood in connection with the maintenance of the life function in a human or animal body to replace one or more pumping functions of the heart. | 0 |
BACKGROUND OF THE INVENTION
This invention relates to vacuum servo booster devices such as vacuum servomotors or the like, which are particularly adapted for use in hydraulic braking system of a vehicle.
Conventional vacuum servomotors comprise a housing defined by a front shell and rear shell, a valve body slidably supported by the rear shell and incorporating therein a valve mechanism, a flexible diaphragm connected to the circumference of the valve body and extending in the radial direction toward the circumference of the housing so as to divide the interior of the housing into a front chamber and a rear chamber, and a piston plate mounted on the valve body and extending contiguous to the diaphragm. When a vacuum servomotor of the aforesaid kind is used in a vehicle hydraulic braking system, a master cylinder is rigidly secured to the front shell by means of bolts or the like, and the rear shell of the servomotor is rigidly connected to a toe-board (a plate partitioning a driver's compartment from an engine) in accordance with usual practice. In such a case, the housing of the servomotor must receive the force acting on the master cylinder. When the strength and rigidity of the housing of the servomotor are insufficient, there have been problems such that the housing of the booster is deformed, or that the effective stroke of the booster or the master cylinder is reduced, or the like.
It is possible to overcome these afore-mentioned problems by increasing the cross-sectional width of the shells which constitute the housing, however, this solution creates problems such that the weight of the booster increases and that the amount of the material needed for fabricating the housing also increases.
SUMMARY OF THE INVENTION
An object of the present invention is to provide a novel pneumatic force multiplying device solving the aforementioned problems. According to the invention, the pneumatic force multiplying or servo booster device further comprises at least one rigid connecting rod extending through the front and rear chambers, and the piston plate, and slidingly and sealingly through the diaphragm. The opposite ends of the connecting rod are connected to respective shells.
Preferably, two or more connecting rods are positioned in an equally spaced relationship both in the radial and circumferential directions with respect to the longitudinal axis of the device.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other objects and advantages of the invention will be clear from the foregoing and a reading of the ensuing specification in conjunction with the accompanying drawings which exemplify the preferred and several other embodiments of the present invention, in which:
FIG. 1 is a longitudinal sectional view of a pneumatic force multiplying device according to the invention;
FIG. 2 is a perspective view of a C-ring utilized in the device of FIG. 1;
FIG. 3 is a longitudinal sectional view of a second embodiment of the invention;
FIG. 4 is an enlarged partial view showing a portion of FIG. 2;
FIG. 5 is a view similar to FIG. 4 but showing a modified form of the present invention;
FIG. 6 is an enlarged partial view showing a portion of FIG. 3;
FIG. 7 is a view similar to FIG. 6 but showing a modified form of the present invention; and
FIG. 8 is a partial sectional view showing a seal member.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The pneumatic force multiplying or servo booster device illustrated in FIG. 1 comprises a housing defined by a front shell 2 and a rear shell 3, and a valve body 4 slidingly supported by the rear shell 3. The valve body 4 has a flange portion 4a on the front end thereof, and an annular groove 4b which is spaced from the flange portion 4a by a predetermined distance. A generally dish-like shaped piston plate 7 having a central opening therein is mounted on the valve body 4 with the inner circumferential portion of the opening thereof being clamped between the flange portion 4a and a C-shaped ring 8 (FIG. 2) which is fitted in the annular groove 4b. A flexible diaphragm 9 is bonded to the rear surface of the piston plate 7 with an inner circumferential portion 9a tightly fitting to the outer circumference of the valve body 4, and the an outer circumferential portion 9b is clamped between flange portions 2a and 3a of respective shells 2 and 3. The diaphragm 9 divides the interior of the housing into a front chamber A and a rear chamber B. The valve body 4 incorporates therein a valve mechanism 10 for effecting the force multiplying action of the device. For actuating the valve mechanism 10 there is provided an input rod 11 which is retained in the valve body 4, and the rear end which projects from the valve body, is adapted to be connected to a brake pedal (not shown) or the like. An output rod 12 projects through the front wall of the front shell 2 and is adapted to be connected to a piston or the like of a master cylinder (not shown) which is connected to the front shell 2 through a spacer 13. The rear end of the output rod 12 is slidably received in a disc holder 15 and receives therefrom the output force of the device through an elastic disc 14. The disc holder 15 is secured to the piston plate 7 by means of a plurality of circumferentially spaced pawls 7a which are formed on the piston plate 7 by a method such as a cutting and bending operation whereby the pawls 7a respectively engage the outer circumference of the disc holder 15. Thus, the valve body 4, the diaphragm 9, the piston plate 7 and the disc holder 15 constitute an integral sub-assembly.
According to the invention, there are provided three connecting rods 17 which are symmetrically spaced both in the radial and circumferential directions with respect to the longitudinal axis of the device (only one rod 17 is shown in FIG. 1). Each connecting rod 17 extends through the front shell 2, the piston plate 7, the diaphragm 9 and the rear shell 3. A reduced diameter portion 17a having a threaded portion on the outer end thereof is formed on each end of the connecting rods 17, and an outwardly facing shoulder 17b is positioned on the rod between a reduced diameter portion 17a and the main body portion of the connecting rod 17. The reduced diameter portion 17a outwardly extends from the front end of each of the connecting rods 17, through an opening formed in the front shell 2 and through the spacer 13. A nut 18 threadably engages the threaded portion of the connecting rod 17 thereby securing the spacer 13 to the front shell 2. In the embodiment, the master cyliner (not shown) is fixedly supported on the spacer 13. On the rear end of each connecting rod 17, the reduced diameter portion 17a extends through an opening formed in the rear shell 3 and through an opening formed in a toe-board (not shown) of a vehicle, and threadably engages a nut (not shown), thus, the rear shell 3 is rigidly connected to the toe-board, whereby the pneumatic force multiplying device and the master cylinder are rigidly mounted on a chasis member of the vehicle. The connecting rod 17 extends through respective openings formed in the piston plate 7 and the diaphragm 9 which partition the chambers A and B. A lip seal 9c is integrally formed on the diaphragm 9 to sealably and slidably engage the connecting rod 17. On the front end of the connecting rod 17 there is provided an annular seal member 21 which seals the outside the chamber A, which is shown as a vacuum chamber in the embodiment, from the ambient. On the rear end of the connecting rod there is provided a washer 19 which is welded on the inner wall of the rear shell 3 to tightly engage the shoulder 17b of the connecting rod to seal the chamber B. If desired, a suitable gasket or the like may be provided between the shoulder 17b and the washer 19.
In operation, the input rod 11 moves forward in response to the depression of a brake pedal (not shown), the valve mechanism 10 is actuated to, firstly, discontinue the communication between the chambers A and B and, to, secondly, communicate the chamber B with the atmosphere. Thus, a differential pressure is generated across the piston plate 7 and the diaphragm 9 and, the piston plate 7, the diaphragm 9, the valve body 4 and the disc holder 15 integrally move forward whereby a multiplied force is transmitted through the output rod 12 to the master cylinder. The reaction of the force in the output rod is transmitted to the input rod 11 through the elastic disc 14. The reaction of the force generated in the master cylinder is transmitted through the connecting rods 17 to the chasis member of the vehicle and not through the front and rear shells 2 and 3.
The embodiment shown in FIGS. 3 and 4 is generally similar to the first embodiment and, corresponding numerals have been applied to corresponding parts.
The connecting rods 17 are integrally connected to the front shell 2 as shown in FIG. 4. Specifically, the shoulder 17b on the forward end of each of the connecting rods 17 is tightly pressed against the inner wall of a portion 2b surrounding the opening of the front shell 2 by forming a projection 17c under a caulking process or the like. Alternatively, the caulking process may be substituted by a nut 20 threadably engaged with the connecting rod 17 as shown in FIG. 5. The connecting rods 17 of the embodiment of FIG. 3 further act to tightly connect the front and rear shells 2 and 3, specifically, the outer circumferential portion 9b of the diaphragm 9 is simply clamped between the end portions 2a and 3a of the front and rear shells 2 and 3. Thus it is possible to omit conventional connecting ring such as shown in FIG. 1, thereby reducing the outer diameter of the device.
Since the connecting rods 17 are integrally connected to the front shell 2, the assembling of the booster including the assembling of the shells can be performed very easily.
Alternatively, the connecting rods are integrally secured to the rear shell 3 and releasably connected to the front shell 2.
FIG. 6 shows detailed construction of the lip portion 9c of the diaphragm 9 in the embodiments of FIGS. 1 and 3.
An annular lip portion 9c integrally formed on the diaphragm 9 slidingly and sealingly engages the connecting rod 17. A bore 7b is formed in the piston plate 7 for allowing the connecting rod 17 to freely pass therethrough. The diaphragm 9 further has a sleeve-like portion 9d extending through the bore 7b which tightly engages with the inner circumference of the bore 7b, and a flange-like portion 9e extends radially outward from the sleeve-like portion 9d for engaging the surface portion of the piston plate 7 surrounding the bore 7b. The sleeve-like portion 9d and the flange-like portion 9e constitute a retaining portion for retaining the lip portion 9c in its proper position with respect to the piston plate 7, thus assuring aforementioned sealing characteristics of the lip portion 9c.
FIG. 7 shows a modified form, in which, the flange-like portion 9e of the diaphragm 9 is modified to define an annular recess 9f for receiving therein an annular resilient ring 22, whereby the retaining portion of the diaphragm 9 is reliably retained on the piston plate 7, and thus the relative position of the lip portion 9c and the piston plate 7 can be reliably maintained.
In the embodiments of FIGS. 6 and 7, the flange-like portion 9e of the diaphragm may not necessarily have an annular configuration.
FIG. 8 shows the details of the seal member 21 in the embodiment of FIG. 1. As shown in FIG. 8, a recessed portion 2c is formed in the front shell 2, and the seal member 21, received in the recessed portion 2c, has an axial length larger than the depth of the recessed portion 2c. Thus, when the reduced diameter portion 17a of the connecting rod 17 is inserted through the front shell 2, the seal member 21 and the spacer 13, and the nut 18 is tightly applied, the front shell 2 and the spacer 13 are tightly connected and the seal member 21 assures the seal.
As described heretofore in detail, the pneumatic force multiplying device according to the invention comprises a rigid connecting rod extending through the front and rear shells with the opposite ends thereof being connected to respective shells, thus, it is possible to prevent the deformation of the shells thereby maintaining desired characteristics during long periods of usage.
Further, since the force acting on the shells can substantially be reduced, the shells may be formed of a thinner material than that of the conventional shells and, further, the shells can be made of a synthetic resin or the like, thus further reducing the fabricating cost of the booster.
Further, the front and rear shells are connected by the connecting rod, thus, it is possible to omit the connecting means, such as the connecting ring shown in FIG. 1, or the like, and thus the assembling operation can be performed easily and economically. | A vacuum servo booster device includes a housing defined by a front shell and a rear shell, a valve body slidably supported by the rear shell and incorporating therein a valve mechanism, a flexible diaphragm connected to the circumference of the valve body and extending in the radial direction toward the outer circumference of the housing to divide the interior of the housing into a front chamber and a rear chamber, and a piston plate mounted around the valve body and extending contiguous to the diaphragm. The improvement is constituted by at least one rigid connecting rod extending through both chambers and the piston plate and slidingly and sealingly through the diaphragm with the opposite ends thereof being connected to respective shells. | 1 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This is a divisional application of U.S. patent application Ser. No. 11/178,054, filed Jul. 8, 2005, to which priority is claimed and which is incorporated herein by reference.
TECHNICAL FIELD
[0002] This disclosure relates to systems and methods for stimulating the cochlea, and more particularly to systems and methods for fitting a cochlear implant to a user.
BACKGROUND
[0003] Prior to the past several decades, scientists generally believed that it was impossible to restore hearing to the deaf. However, scientists have had increasing success in restoring normal hearing to the deaf through electrical stimulation of the auditory nerve. The initial attempts to restore hearing were not very successful, as patients were unable to understand speech. However, as scientists developed different techniques for delivering electrical stimuli to the auditory nerve, the auditory sensations elicited by electrical stimulation gradually came closer to sounding more like normal speech. The electrical stimulation is implemented through a prosthetic device, called a cochlear stimulation system, that interacts with the inner ear to restore partial hearing to profoundly deaf people.
[0004] A cochlear stimulation system generally includes an internal portion that includes an electrode array that is inserted in a cochlear duct, usually the scala tympani. One or more electrodes of the array selectively stimulate different auditory nerves at different places in the cochlea based on the pitch of a received sound signal. The internal portion interacts with an external portion that includes a speech processor that processes converted acoustic signals in accordance with a selected speech processing strategy to generate appropriate control signals for controlling the electrode array.
[0005] In order for the patient to properly perceive sounds with the cochlear stimulation system, the system must be “fitted” or “tuned” to accommodate the electrode array's particular placement in the patient's cochlea. Such a fitting method includes a pitch ranking and channel allocation process. Pursuant to this process, the electrodes of the electrode array are ranked based on their pitch. The speech processor then assigns certain frequency bands to each electrode of the array such that each electrode is associated with a particular channel that represents a frequency or range of frequencies.
[0006] The fitting process can be time consuming and tedious for both the patient and for the clinician that is performing the fitting process. In view of the foregoing, there is a need for a cochlear stimulation system that minimizes the need to repeat the fitting process for a patient.
SUMMARY
[0007] Disclosed is a cochlear stimulation system having patient parameters that reside in memory of an internal portion of the system. Different external systems define how the cochlear stimulation system processes a received acoustic signal and uses the patient information uploaded from the implant to parameterize system processing. The external system uses external and internal processing capability to convert acoustic signals to electrical stimulus most appropriate for the patient. Because the patient parameters reside internally, the external portion of the system can be replaced to provide an external replacement processor and potentially offer the patient a new type of program without having to re-program the cochlear stimulation system. Some programs may require that patient-specific data to change, other programs will allow the patient to just attach an unprogrammed external portion.
[0008] In one aspect, a cochlear stimulation system comprises an external portion and an internal portion. The external portion includes an acoustic transducer for sensing acoustic signals and converting them to electrical signals. The internal portion includes a multi-electrode array having a first plurality of electrodes configured for placement in first cochlear duct of a patient, programmable memory, and a cochlear stimulation program residing in the programmable memory. The cochlear stimulation program includes data that defines sound processing and corresponding cochlear stimulation for the system.
[0009] In another aspect, a method of implementing a program for a cochlear stimulation system, comprises implanting an internal portion of a cochlear stimulation system under the skin of a patient, the internal portion including at least one cochlear stimulation program; attaching an external portion of the cochlear stimulation system to the patient; and uploading a first cochlear stimulation program to the external portion from the internal portion.
[0010] In another aspect, a cochlear stimulation system comprises an internal portion implantable under the skin of a patient. The internal portion includes a multi-electrode array having a first plurality of electrodes configured for placement in first cochlear duct of a patient and a cochlear stimulation program including data that defines sound processing and corresponding cochlear stimulation for the system. The internal portion is configured to upload the cochlear stimulation program to an external portion of the cochlear stimulation system.
[0011] The details of one or more embodiments are set forth in the accompanying drawings and the description below. Other features and advantages will be apparent from the description and drawings, and from the claims.
DESCRIPTION OF DRAWINGS
[0012] The features and advantages will be more apparent from the following more particular description thereof, presented in conjunction with the following drawings, wherein:
[0013] FIG. 1 shows a cochlear implant system capable of providing high rate pulsatile electrical stimuli to the cochlea of a patient.
[0014] FIG. 2 shows a partial functional block diagram of the cochlear stimulation system.
[0015] FIG. 3 schematically shows an external portion and an internal portion of the cochlear stimulation system, the internal portion including one or more cochlear stimulation programs.
[0016] Like reference symbols in the various drawings indicate like elements.
DETAILED DESCRIPTION
[0017] Disclosed are devices and methods for matching information between cochlear implants in two ears of a patient. It will be helpful to first provide an overview of the structure and functionality of an exemplary cochlear implant system. This overview is provided below in connection with the description of FIG. 3 . It should be appreciated that the following description is exemplary and that the device and methods described herein can be used with other types and other configurations of cochlear implant systems.
[0018] FIG. 1 shows a cochlear stimulation system 5 that includes a speech processor portion 10 and a cochlear stimulation portion 12 . The speech processor portion 10 includes a speech processor (SP) 16 and a microphone 18 . The microphone 18 may be connected directly to the SP 16 or coupled to the SP 16 through an appropriate communication link 24 .
[0019] The cochlear stimulation portion 12 includes an implantable cochlear stimulator (ICS) 21 and an electrode array 48 . The electrode array 48 is adapted to be inserted within the cochlea of a patient. The array 48 includes a plurality of electrodes 50 , e.g., sixteen electrodes, spaced along the array length and which electrodes are selectively connected to the ICS 21 . The electrode array 48 may be substantially as shown and described in U.S. Pat. No. 4,819,647 or 6,129,753, both patents incorporated herein by reference.
[0020] The ICS 21 and the SP 16 are linked together electronically through a suitable data or communications link 14 . The data link 14 can be a transcutaneous (through the skin) data link that allows power and control signals to be sent from the SP 16 to the ICS 21 . In some embodiments, data and status signals may also be sent from the ICS 21 to the SP 16 .
[0021] At least certain portions of the cochlear stimulation system 5 can be included within an implantable portion that is implanted beneath the patient's skin, while other portions of the cochlear stimulation system 5 can remain in an external portion of the system. In general, at least the microphone 18 and associated analog front end (AFE) circuitry (described below) are part of the external portion of the system, and at least the ICS 21 and the electrode array 48 are part of the implantable portion of the system. Moreover, certain portions of the external portion of the cochlear stimulation system 5 can be contained in a behind the ear (BTE) unit that is positioned at or near the patient's ear. For example, the BTE unit can include the SP 16 and a battery module, which are coupled to a corresponding ICS 21 and an electrode array 48 .
[0022] As used herein, the term “external” means not implanted under the skin or residing within the inner ear. However, the term “external” can also mean residing within the outer ear, residing within the ear canal or being located within the middle ear.
[0023] As mentioned above, in order for the patient to properly perceive sounds with the cochlear stimulation system 5 , the system must be fitted or tuned to accommodate the electrode array's particular placement in the patient's cochlea. Such a fitting method generally requires a clinician to spend a period of time with the patient tuning the system to the patient's particular requirements. The result of the fitting process is at least one “program” (referred to herein as a cochlear stimulation program) that is particularly suited for the patient. The cochlear stimulation program includes various parameters that define how the cochlear stimulation system processes a received acoustic signal, including how the system converts the acoustic signal into a digital signal and maps components of the digital signal to the electrodes in the electrode array. It should be appreciated that a particular patient can have multiple cochlear stimulation programs that vary based upon a particular acoustic environment of the patient.
[0024] The cochlear stimulation program generally includes a mechanism for transforming acoustic signals to stimulus that executes on internal and external hardware. The program is parameterized through “strategy parameters” and “stimulation parameters” that are adjusted to each patient ear. The strategy parameters define how the speech processor transforms a received acoustic signal into to a stimulation waveform, while patient-specific stimulation parameters determine acoustic processing options of the external processor and define how the stimulation current is mapped to the electrodes in the array as a function of information contained within the sensed acoustic signal. Electronic circuitry within the ICS 21 allows a specified stimulation current to be applied to selected pairs or groups of the individual electrodes included within the electrode array 48 in accordance with a specified stimulation pattern defined by the SP 16 .
[0025] FIG. 2 shows a partial block diagram of one embodiment of a cochlear implant system capable of providing a high pulsatile stimulation pattern. FIG. 2 depicts the functions that are carried out by the SP 16 and the ICS 21 . The process generally begins when the microphone 18 is exposed to sound waves. The microphone 18 senses the sound waves and converts such sound waves to corresponding electrical signals and thus functions as an acoustic transducer. The electrical signals are sent to the SP 16 over a suitable electrical or other link 24 . The SP 16 processes these converted acoustic signals in accordance with a selected speech processing strategy to generate appropriate control signals for controlling the ICS 21 . Different speech processing strategies require different external software and sometimes different external hardware. It is conceivable that each different sound coding strategy will require a different external processor rather than downloading different code into a generic external processor. It is the task of the external processor to understand how to use the patient (ear) specific data stored in the implant in the context of the implemented program. The external software/hardware that performs this function is configured at the factory.
[0026] The speech processing strategy was developed during the fitting process described above. The control signals specify or define the polarity, magnitude, location (which electrode pair or electrode group receive the stimulation current), and timing (when the stimulation current is applied to the electrode pair) of the stimulation current that is generated by the ICS. Such control signals thus combine to produce a desired spatio-temporal pattern of electrical stimuli in accordance with a desired speech processing strategy.
[0027] A speech processing strategy is used, among other reasons, to condition the magnitude and polarity of the stimulation current applied to the implanted electrodes of the electrode array 48 . Such speech processing strategy involves defining a pattern of stimulation waveforms that are to be applied to the electrodes as controlled electrical currents.
[0028] It should be appreciated that the functions shown in FIG. 2 (dividing the incoming signal into frequency bands and independently processing each band) are representative of just one type of signal processing strategy that may be employed. Other signal processing strategies could just as easily be used to process the incoming acoustical signal. A description of the functional block diagram of the cochlear implant shown in FIG. 2 is found in U.S. Pat. No. 6,219,580, incorporated herein by reference. The system and method described herein may be used with other cochlear systems other than the system shown in FIG. 2 , which system is not intended to be limiting.
[0029] The cochlear implant functionally shown in FIG. 2 provides n analysis channels that may be mapped to one or more stimulus channels. That is, after the incoming sound signal is received through the microphone 18 and the analog front end circuitry (AFE) 22 , the signal can be digitized in an analog to digital (A/D) converter 28 and then subjected to appropriate gain control (which may include compression) in an automatic gain control (AGC) unit 29 . After appropriate gain control, the signal can be divided into n analysis channels 30 , each of which includes at least one bandpass filter, BPFn, centered at a selected frequency. The signal present in each analysis channel 30 is processed as described more fully in the U.S. Pat. No. 6,219,580, or as is appropriate, using other signal processing techniques. The signals from each analysis channel may then be mapped, using mapping function 41 , so that an appropriate stimulus current of a desired amplitude and timing may be applied through a selected stimulus channel to stimulate the auditory nerve.
[0030] The exemplary system of FIG. 2 provides a plurality of analysis channels, n, wherein the incoming signal is analyzed. The information contained in these n analysis channels is then appropriately processed, compressed and mapped in order to control the actual stimulus patterns that are applied to the user by the ICS 21 and its associated electrode array 48 .
[0031] The electrode array 48 includes a plurality of electrode contacts 50 , 50 ′, 50 ″ and labeled as, E 1 , E 2 , . . . Em, respectively, which are connected through appropriate conductors to respective current generators or pulse generators within the ICS. Through these plurality of electrode contacts, a plurality of stimulus channels 127 , e.g., m stimulus channels, may exist through which individual electrical stimuli can be applied at m different stimulation sites within the patient's cochlea or other tissue stimulation site.
[0032] The cochlear stimulation program is typically stored in volatile memory located in the external portion of the cochlear stimulation system. Storage of the cochlear stimulation program in the external portion presents drawbacks. For example, if the external portion of the system has to be replaced, such as if the patient loses or damages the external portion, the fitting process has to be re-performed for the new external portion. This can be undesirable, as it requires the patient to go through the time consuming fitting process all over again.
[0033] There is now described an embodiment of the cochlear stimulation system wherein the cochlear stimulation program is stored in the implantable portion of the system. FIG. 3 shows a schematic representation of the cochlear stimulation system 5 , which includes the components described previously with reference to FIG. 2 , including the speech processor 16 , which can reside in an external portion of the system. As mentioned, the cochlear stimulation system includes an external portion 305 and an internal portion 310 that are communicatively linked via a communications link 314 .
[0034] The internal portion 310 includes programmable memory 315 that can be used to store data, such as strategy parameters and the stimulation parameters of one or more cochlear stimulation programs. The data stored in the programmable memory 315 can be communicated to, or reprogrammed by, the external portion 305 through one-way or bi-directional communication. The programmable memory can be volatile or non-volatile memory. Non-volatile memory advantageously eliminates the need for re-loading of the cochlear stimulation programs upon loss of power to the system.
[0035] It should be appreciated that the programmable memory is not limited to storing a single cochlear stimulation program. Multiple cochlear stimulation programs can reside in the programmable memory 315 . In this regard, an external controller can be configured to permit the patient to select a desired the cochlear stimulation program on the fly. For example, the programmable memory 315 can include a first cochlear stimulation program that is particularly suited for relatively loud environments and a second cochlear stimulation program that is used for more quiet environments. Depending on the environment, the patient can upload the appropriate cochlear stimulation program from the internal portion to the external portion of the cochlear stimulation system.
[0036] The cochlear stimulation program(s) are preferably downloaded to the programmable memory 315 of the internal portion 310 via the communication link 314 shortly after the fitting process. With the cochlear stimulation program(s) residing in the programmable memory 315 , the speech processor 16 can extract the data from the cochlear stimulation program to the external portion 305 . This permits the external portion to be modified or replaced without losing the cochlear stimulation program(s) and without having to re-program the cochlear stimulation system.
[0037] In an exemplary method of establishing or implementing a program for the cochlear stimulation system, the cochlear stimulation system is first coupled to the patient. This includes implanting the internal portion of a cochlear stimulation system under the skin of a patient, such as by implanting the multi-electrode array in the cochlea. The external portion of the cochlear stimulation system is also coupled to the patient and a communication link is established between the internal portion and the external portion.
[0038] Pursuant to a fitting or tuning process (see, e.g., U.S. Pat. No. 6,289,247, incorporated herein by reference, for an example of one type of fitting or tuning process) one or more cochlear stimulation programs are created for the patient. As mentioned, the cochlear stimulation program includes various parameters that define how the cochlear stimulation system processes a received acoustic signal, including how the system converts the acoustic signal into a digital signal and maps components of the digital signal to the electrodes in the electrode array. The one or more cochlear stimulation programs are then loaded into the programmable memory of the internal portion.
[0039] This permits the patient or a clinician to upload the cochlear stimulation program (or a portion thereof) to the external portion of the cochlear stimulation system on an as-needed basis. For example, the cochlear stimulation program can be uploaded from the internal portion to the external portion when the external portion is replaced. A new cochlear stimulation program can be uploaded to the external portion from the internal portion where the user desires to use a different version of the program, such as where the audio environment changes. Advantageously, the external portion can be exchanged or replaced without having to re-tune the cochlear stimulation system.
[0040] A number of embodiments have been described. Nevertheless, it will be understood that various modifications may be made without departing from the spirit and scope of the claims. Accordingly, other embodiments are within the scope of the following claims. | Disclosed is a cochlear stimulation system having patient parameters that reside in memory of an internal portion of the system. Different external systems define how the cochlear stimulation system processes a received acoustic signal and uses patient information uploaded from an implant to parameterize system processing. The external system uses external and internal processing capability to convert acoustic signals to electrical stimulus most appropriate for the patient. Because the patient parameters reside internally, the external portion of the system can be replaced to provide an external replacement processor and potentially offer the patient an new type of program without having to re-program the cochlear stimulation system. | 0 |
RELATED APPLICATION
The present application is a continuation-in-part of application Ser. No. 07/672,879, filed Mar. 18, 1991, in the names of Roger G. Little and Edward A. Burke, for High Energy Density Nuclide-Emitter, Voltaic-Junction Battery, now U.S. Pat. No. 5,260,621.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to radionuclide-emitter, voltaic-junction batteries, and, more particularly, to compact electric batteries that are powered by the combination of a nuclear radiation emitting source and a responsive semiconductor voltaic-junction for service in many applications where chemical batteries are unsatisfactory or inferior.
2. The Prior Art
Compact long-life energy sources have wide applications in such fields as aerospace systems, cardiac pacemakers, computer memory maintenance, remote instrumentation, etc. Chemical batteries suffer generally from theoretical limits in the energy density that they can accommodate. Radionuclide-emmiter, voltaic-junction cells have much higher theoretical limits in energy density, in some cases more than a factor of 1,000 greater, but, in the past, have not achieved desirable high energy density and long life in practice. Major problems have been encountered in adapting such prior art cells for practical use at relatively low temperature.
Silicon p-n junction cells for directly converting radiation, either visible or ionizing, to electricity were developed in the early 1950's. Specific use of radio-isotopes to power silicon p-n cells, known as betavoltaic cells, were extensively studied in the 1970's for applications where low power but high energy density were important, for example, in cardiac pacemakers. A primary motivation for these studies was that the theoretical energy density is much higher in betavoltaic cells than in the best chemical batteries, 24.3 W-h/cm 3 versus 0.55 W-h/cm 3 for mercury-zinc batteries. Unfortunately, isotopes that could be employed with silicon had to be limited to low energy beta emitters because of radiation damage. For example, a typical threshold energy for electron damage is about 0.180 MeV assuming an atomic displacement damage threshold of 12.9 eV. Alpha particles were known to cause so much damage that they were not seriously considered at any energy. This constraint excluded the most potent nuclide sources, and thus restricted maximum power of such devices because of limits to the specific activity achievable at maximum concentration with reasonable half-lives.
In the aforementioned co-pending patent application of the inventors hereof, the invention is directed to a relatively powerful battery that operates at a temperature above the point at which damage is rectified by annealing in the voltaic-junction. In some applications, particularly some applications involving prosthetic inserts for the human body, batteries that operate at relatively low temperatures are required.
BRIEF DESCRIPTION OF THE INVENTION
The primary object of the present invention is to provide a novel high energy density electric cell comprising a nuclear source of relatively high energy radiation fluence, a semiconductor voltaic-junction characterized by a logarithmic curve for this fluence relating minority carrier diffusion length and a damage constant, and an enclosure having a sufficiently low thermal impedance for dissipation of sufficient heat from the nuclear source to permit predetermined degradation of the minority carrier diffusion length initially and predetermined maintenance of the minority carrier diffusion length thereafter. The nuclear radiation includes energetic radiation such as alpha, beta and gamma emissions or combinations thereof. Preferred inorganic crystalline materials characteristically incorporated in the semiconductor junction are selected from the class consisting of cadmium telluride, indium phosphide, silicon carbide and synthetic diamond. The semiconductor junction, for example, is differentially treated with n or p dopants. The thermal impedance is composed of a thermal insulator such as a ceramic electrical non-conductor. The arrangement is such that damage to the semiconductor junction, resulting from the highly energetic emissions of the nuclear source, at first occurs rapidly and thereafter substantially stabilizes at an operative electrical output for an operative predetermined period.
Other objects of the present invention will in part be obvious and will in part appear hereinafter.
For a fuller understanding of the nature and objects of the present invention, reference is made to the following specification, which is to be taken in connection with the accompanying drawings, wherein:
FIG. 1 is an exaggerated cut-away view of a nuclear battery embodying the present invention;
FIG. 2 is an exploded view of a single power cell of the nuclear battery of FIG. 1;
FIG. 3 is an assembled view of the power cell of FIG. 2;
FIG. 4 illustrates curves of Activity Density versus Power Density for a system of the present invention;
FIG. 5 illustrates a curve of Efficiency versus Fluence for a system of the present invention; and
FIG. 6 illustrates a curve of Carrier Concentration versus Damage Constant for a system of present invention
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The illustrated electric cell is particularly adapted for biomedical applications where low temperature operation, i.e. at temperatures approximating the temperature of the human body, are desirable. At these temperatures, the nuclide-emmiter, voltaic-junction and thermal impedance housing are interrelated so as to be thermally neutral for an operational period that begins after an initial seasoning period during which cell efficiency stabilizes, and that is designed to continue at predeterminedly acceptable efficiency until the end of the operational period. In contrast to chemical batteries which suffer a precipitous loss of power at end of life, the cell of the present invention suffers precipitous energy loss during the initial seasoning period prior to use and degrades slowly but acceptably thereafter.
The basic reason that high energy cells will provide useful power after significant radiation damage is that the energy density of radio-isotopes is so high relative to chemical systems. The energy density in radio-isotope powered systems can range from 1,000 to 10,000 times that in the best chemical batteries. This means that efficiency can drop to relatively low levels and yet exhibit a lifetime and a power density far exceeding those of ordinary batteries. From a mathematical standpoint, the damage accumulates as the logarithm of the fluence, which means that damage accumulates at an ever decreasing rate as time progresses.
The Embodiment of FIGS. 1 to 3
A preferred embodiment of the present invention is shown in FIG. 1 as comprising a stack 22 of alternate nuclide-emitter and semiconductor-junction strata, an inner heavy metal shield 24 that absorbs nuclear radiation escaping from stack 22, an intermediate low thermal impedance housing 26 that facilitates heat transfer from within stack 22, and an external metal casing 28 that snugly receives housing 26. The electrical output of stack 22 is established across a positive terminal 30 and a negative terminal 32. Negative terminal 32 connects electrically to metal casing 28. Positive terminal 30 projects through an opening in an electrically insulating cap 33 at the top of casing 28.
As shown in FIG. 2, stack 22 is characterized by a sequence of say ten power cells of the type shown in FIGS. 2 and 3. Each power cell includes a pair of semiconductor-junction strata 34 between which is sandwiched a radio-nuclide emitter stratum 36. Each voltaic-junction stratum typically ranges in thickness from 1 to 250 microns. At the lower end of this range, the voltaic-junction stratum, in one form, is deposited on a substrate composed, for example, of silicon. Each nuclide-emitter stratum typically ranges in thickness from 0.1 to 5 microns. The upper thickness limit is determined by undue self-absorption of emitted particles. Each voltaic-junction stratum has an electrically positive face region 38 and an electrically negative face region 40. Positive face region 38 is established by subjection to a p-dopant selected, for example, from the class consisting of zinc and cadmium. Negative face region 40 is established by subjection to an n-dopant selected, for example, from the class consisting of silicon and sulfur. A lead 42 from positive face region 38 and a lead 44 from negative face region 40 connect into the remainder of the electrical system.
The Radionuclide-Emitter
In one form, emitter strata 36 produce alpha particles characterized by a monoenergetic level in excess of 4.5 MeV and ranging upwardly to about 6.5 MeV and ordinarily 5 to 6.1 MeV. In another form, emitter strata 36 produce beta particles having a maximum energy level in excess of 0.01 MeV and ranging upwardly to about 3.0 MeV. Typical compositions of emitter strata 36 are selected from the class consisting of the isotopes listed in the following table, in which E max refers to maximum energy, E avg to average energy, and T 1/2 to half life:
TABLE I______________________________________ Type of Maximum Half Emitter Energy LifeIsotope (Mev) (Mev) Years______________________________________H.sup.3 β 0.018 12.3Ni-63 β 0.067 92.0Sr-30/Y-90 β 0.545/2.26 27.7Pm-147 β 0.230 2.62Tl-204 β 0.765 3.75Kr-5 β 0.670 10.9Cd-113 β 0.58 14.0Pu-238 α 5.50 66.4Cm-242 α 6.10 0.45Cm-244 α 5.80 18.0Po-210 α 5.30 .38Am-241 α______________________________________
The Voltaic-Junction
Critical factors in the selection of voltaic-junction materials for a given nuclear radiation source, in accordance with the present invention, are: carrier generation as a function of radiation damage; and cell performance as a function of radiation exposure.
The semiconductor parameter most sensitive to radiation damage is the diffusion length of minority carriers in the base region of a voltaic-junction cell. The sensitivity is quantitatively indicated by a damage constant usually designated K L . The relationship between the diffusion length, L, and this damage constant is given by
1/L.sub.2 -1L.sub.o.sup.2 =K.sub.L.φ
Here L is the diffusing length after an exposure to a radiation fluence, φ, L o is the diffusion length prior to exposure, and K L is the damage constant.
For reasons that will become apparent below, preferred voltaic-junction materials according to the present invention are selected from the class consisting of cadmium telluride, indium phosphide, silicon carbide and synthetic diamond.
EXAMPLE I
The present invention is specifically illustrated by a configuration of the cell of FIGS. 1, 2 and 3 in which voltaic-junction 34 is an indium phosphide stratum, opposite face regions of which are implanted with (1) zinc ions to establish a p-region and (2) silicon ions to establish an n-region. Each voltaic-junction stratum is approximately 150 microns thick. In one version of this example, emitter stratum is composed of Pu-238. In another version of this example, the emitter stratum is composed of Sr-90. Each emitter stratum is approximately 1.5 microns in thickness. Radiation shielding enclosure 24 is composed of tantalum. Thermal insulating enclosure 26 is composed of ceramic. The thickness and composition of insulating enclosure 26 is selected to maintain the temperature of stack 22 at the temperature of its environment, i.e. about 30° to 40° C. for terrestrial applications in which the cell operates at room or body temperature. The indium phosphide thereby is seasoned by radiation damage initially and maintains a predetermined efficiency for a predetermined operational period thereafter.
A compilation of damage constants for different semiconductors is given in FIG. 6. This figure was taken from a paper by M. Yamaguchi and K. Ando entitled "Mechanism for Radiation Resistance of InP Solar Cells", J. Appl. Phys. 63, 555 (1988). It is to be noted that at high carrier concentrations, N-type InP has a damage constant about 1,000 times smaller than GaAs.
EXAMPLE II
In this example, cadmium telluride is substituted for indium phosphide as the voltaic-junction semiconductor. Here, according to an article by Woodyard and Landis, entitled, "Radiation of Thin Film Solar Cells for Space Photvoltaic Power," Solar cells, 31, 297 (1991), for electron fluence of 3×10 16 cm -2 , short circuit current, which is a good indicator of cell damage, indicates a favorable curve of diffusion length versus damage constant.
EXAMPLE III
The significance of fluence is indicated in FIG. 5, which shows a radiation result for an InP cell exposed to an alpha fluence equivalent to 10 17 1 MeV electrons per cm 2 . It can be seen that the cell has lost about 30% of it initial efficiency at a fluence of 10 16 electrons/cm 2 . The data points in this figure are experimental and the solid line is a theoretical prediction. This comparison confirms the following calculations for forecasting battery performance.
EXAMPLE IV
These calculations of battery performance employed three basic tools: (1) a Monte Carlo computer program known as TRIM to calculate the carrier generation and radiation damage in a solar cell exposed to alpha radiation, (2) damage correlation theory to transform experimental results on electron damage coefficients to alpha damage coefficients, and (3) a computer device program known well known in the field as PC-1D, which predicts the cell performance as a function of radiation exposure when given diffusion lengths derived from the radiation, e.g. alpha damage coefficients. All of these components of the calculations have been well tested against experimental results over the past few years but have not before been used together in the present manner to forecast radiation damage and radio-isotope powered battery performance.
EXAMPLE V
Projected performance for a given battery design is a function of power density at the end of a given period of time and the amount of radioactive material needed to achieve it. FIG. 4 is a summary of the computations previously described. Curves are given for the activity density versus power density for 5, 10, 20 and 30 year batteries. The points indicate the relative amount of damage at the end of the design life period. For example, for the battery with a 10 year life, the highest data point occurs at a power density of 100 μW/cm 3 and an active density of 700 mCi/cm 3 . This highest point means that the battery at the 10 year point is at 5% of its beginning of life power. Each of the points represent a 5% in the fraction of-initial power left. For example the fourth point from the top occurs at about 45 μW/cm 3 . A battery designed for this level has 20% of its initial power.
COMPARISON WITH PRIOR ART BATTERIES
Since most previously developed silicon-based beta voltaic cells have used Pm-147, this nuclide serves as a good basis for comparison of prior art batteries with batteries of the present invention. Pm-147 emits beta particles with a peak energy of 0.23 MeV, average energy of 0.063 MeV, and half-life of 2.62 years. Promethium cells generally provide a maximum power of 1000 μW/cm 3 which drops to 266 μW/cm 3 after 5 years. At least 1.5 Ci/cm 2 has been required to produce 50 μW/cm 2 .
To illustrate the advantage provided by InP, for example, the Pm-147 silicon cell is compared below in Table 2 with other beta isotopes and an alpha emitter. In Table 2, T refers to half-life, E max refers to maximum energy, Ci/cm 2 refers to curies per square centimeter, BOL refers to "Beginning Of Life" EOL refers to "End Of Life" W refers to watts and h refers to hours.
TABLE 2______________________________________ Output (5 years) T.sub.1/2 E.sub.max Activity BOL EOL TotalIsotope Years MeV Ci/cm.sup.2 μW/cm.sup.3 μW/cm.sup.3 W-h/cm.sup.3______________________________________Pm-147 2.62 0.230 1.50 1000 266 24.3T1-204 3.75 0.765 1.05 672 266 19.2Sr-90 27.7 0.545 0.19 301 266 13.3Pu-238 86.4 5.5 0.004 276 266 11.9______________________________________
The activity level for each of the above isotopes was adjusted to give the same End Of Life power density as Pm-147. This means that the longer lived isotopes require a much smaller activity level to achieve the same End Of Life power level. We note that total energy output of the Pu-238 powered cell at the end of twenty years is calculated to be 44.7 W-h/cm 3 and its power density 235 W-h/cm 3 . After 20 years, the Pm-147 cell is calculated to generate just 33.0 W-h/cm 2 and its power density is calculated to be 5.04 μWcm 3 . Another method of comparison is by lifetimes, assuming that the same average power is produced. Table 3 below compares the power output half-life for different cases, all starting at 1 mW/cm 3 and generating an average power of 722 μW/cm 3 .
TABLE 3______________________________________Best Chemical BatteriesHg--Zn (chemical battery) 0.55 W-h/cm.sup.3 1 MonthBest Betavoltaic - SiPm.sup.147 -Si 16.6 W-h/cm.sup.3 2.6 YearsInP at Room TempSr.sup.90 /Y.sup.90 -InP 182 W-h/cm.sup.3 28 Years______________________________________
LOGARITHMIC CURVE CONSIDERATIONS
It is to be noted that, even following the initial drop in efficiency during seasoning, the higher energy output of Sr-90 is far superior to previous configurations based on Si junctions, even ignoring emissions of the daughter nuclide, Y-90, which would also contribute. The number of curies required to provide a given power level is directly related to lifetime and inversely related to average energy of the emitted particles.
Thus:
for Pm-147, the activity is 1.5 Ci/cm 2 ;
for Sr-90, the activity is 0.63 Ci/cm 2 ; and
for Pu-238, the activity is 0.017 Ci/cm 2 .
It is found that damage effectiveness of electrons drops rapidly with energy below 1 MeV and, for a pure Sr-90 beta spectrum, is estimated to be 1.2% of that for 1 MeV electrons. Tests have established that 10 16 /cm 2 of 1 MeV electrons reduce InP cell efficiency to 80% of its initial value at room temperature. Considering the spread of energies in a Sr-90 beta spectrum, there is a requirement for an exposure of 10 18 Sr-90 beta particles to produce the same effect as a 1 MeV electron beam.
For 0.667 curies/cm 2 of Sr-90 and again neglecting the daughter emissions, approximately 2.47×10 10 electrons/cm 2 /sec penetrate one face of the InP stratum. Since activity is sandwiched between two cells, actual curies/cm 2 is 1.33 Ci, from which 2.47×10 10 /sec follows. Exposure time required to reach a fluence of 10 18 is estimated at 4.05×10 7 seconds, 1.125×10 4 hours, or 1.28 years. An electron beam of 10 μA/cm2 delivers a fluence of 10 16 /cm 2 in 2.67 minutes so that test irradiation takes no longer than an hour.
Efficiency of isotope powered cells is the fraction of particle energy converted to electrical energy. For Pm-147 powered silicon cells, it has been found that 5.55×10 10 beta particles per square centimeter per second yields a power output of 25 W/cm 2 . For Pm-147 beta particles with an average energy of 0.0625 MeV, the input power is 555 μW/cm 2 . The total efficiency achieved in this case is 4.5%. The theoretical efficiency achievable has been calculated as greater than 10%.
High energy particles, such as alpha particles from Pu-238, will displace atoms from their normal bound positions in a crystalline semiconductor such as indium phosphide. The number of atoms displaced depends upon the energy and mass of the incident particle, the mass of the target atoms, and the minimum energy required to remove it from its bound lattice position. A displaced atom can have considerable recoil energy immediately after being struck by the incident particles. The excess energy is dissipated by ionizing and displacing adjacent atoms in the crystal lattice until the primary recoil energy has dropped to thermal energies (0.025 eV at room temperature). The end result is a number of vacant lattice sites (vacancies) and displaced atoms in interstitual positions in the lattice (interstitials).
At room temperature (300° K.) the vacancies and interstitials are mobile, and diffuse through the crystal lattice until they interact with other defects or lattice impurities, or reach the surface, or annihilate. Many of the complex defects that result from these interactions are stable at room temperature and introduce energy levels throughout the forbidden gap of the semiconductor. The defect energy levels can reduce the lifetime of minority carriers, the majority carrier concentration, and the mobility of the majority carriers. All of these properties have a major impact on the operation of a device.
OPERATION
The nuclide-emitter, voltaic-junction and thermal impedance housing are interrelated so as to be thermally neutral for an operational period. This operational period begins after an initial seasoning period during which cell efficiency stabilizes. Throughout this operational period the cell efficiency continues at predeterminedly acceptable levels. The energy density of the selected radio-isotopes is so high that overall efficiency can drop to relatively low levels and still exhibit a lifetime and a power density far exceeding those of ordinary batteries. From a mathematical standpoint, the damage accumulates as the logarithm of the fluence, which means that damage accumulates at an ever decreasing rate as time progresses. | An electric battery comprises: a nuclear source of relatively high energy radiation fluence; a semiconductor junction characterized by a curve for this fluence relating minority carrier diffusion length and a damage constant and; an enclosure having a sufficiently low thermal impedance for dissipation of sufficient heat from the nuclear source to permit predetermined degradation of the minority carrier diffusion length initially and predetermined maintenance of the minority carrier diffusion length thereafter; the nuclear source being a radionuclide selected from the class consisting of alpha, gamma and beta emitters; and the curve being substantially logarithmic. | 6 |
BACKGROUND TO THE INVENTION
The invention relates to a framed glazing unit, and in particular to such a unit which is openable such as a door, especially a door that is commonly referred to as an all-glass door, or a window, or to such a unit which is fixed and mounted in a glazing assembly adjacent to or in the vicinity of a door or a window and may incorporate hinge, lock, closer, stay or stop fittings, such as a transom panel (otherwise referred to as a fanlight), a door side panel (otherwise referred to as a door side section or a door side light), or similar.
Such an all-glass door of known construction normally consists, apart from its fittings, solely of a glass sheet. Known doors of this type have compact glass sheets. In many cases, the thermal conductivity of such doors is unacceptably high. The same applies to door side sections, fanlights, windows or similar.
SUMMARY OF THE INVENTION
An aim of the invention is to provide a framed glazing unit, such as a door of this kind or a correspondingly designed fanlight, transom panel, door side section , door side panel, door side light, window or similar (hereinafter referred to as a "door etc") whose thermal conductivity is comparatively low relative to known framed glazing units and which can thus be used in an energy-saving manner.
The present invention provides a framed glazing unit for forming a door, window, transom panel or door side panel, the unit comprising two sheets of glazing material arranged in spaced relation beside one another, a peripheral frame holding the sheets at a distance from one another and enclosing a space between the sheets, sealing means for hermetically sealing the space and a dessicant communicating with the space, said frame being covered by the sheets and being adapted to support fittings for mounting the unit so as to comprise an openable door or window or a fixed transom panel or door side panel of a glazing assembly.
The framed glazing unit preferably has mounted on the frame thereof fittings such as hinges, locks, closers, stays or stops or components thereof.
In one preferred embodiment of the invention there is provided a door etc. which is characterised by two glass sheets arranged at a distance from one another, by the frame that holds the sheets at a distance from one another, preferably incorporating fittings for the door, said frame being covered essentially by the sheets, by sealing means for hermetically sealing the space enclosed by the frame between the sheets and by a dessicant communicating with this space. Preferably, the dessicant is provided in chambers along the inner side of the frame communicating with the space, preferably by perforations in the walls facing the space.
Toughened glass, tempered glass, safety glass and synthetic glass are particularly preferred as the glass. Alternatively, plastics sheets may be used as the glazing sheets.
One advantage of the invention is that the frame between the two sheets, unlike a normal frame, does not have to be bearing element for the door panel etc. Instead as is common with all-glass doors, all the sheets are self-supporting, whilst the frame is preferably non-supporting.
In order to accommodate a relative thermal expansion between the frame and the sheets, the door etc. is preferably characterised by the fact that the sheets and the frame have holes lying in a line outside the space sealed by the frame, through which screw elements pass which are segregated from the sheets and the frame and which press the sheets against the frame.
However, in order to be able to press the sheets firmly against the frame, the door etc. is preferably characterised by the fact that, for the purpose of segregation, the screw elements are separated by a distance from the internal peripheral faces of the holes in the sheets and in the frame and that seals made of fibres and/or plastic are positioned between the sheets and the areas of the screw elements exerting pressure on the sheets.
A particularly good seal between the side faces of the frame and the faces of the sheets facing opposite them is achieved if the side faces of the frame are glued to the faces of the sheets facing opposite them, preferably by means of sealing double-sided adhesive strips.
The seal is further enhanced if the frame has sides with a cross-section in the shape of a T whose transverse webs lie adjacent, via seals, to the peripheral faces of the sheets.
Tests have shown that the thickness of the sheets should preferably be between 4 mm and 12 mm, and more preferably between 6 mm and 8 mm, that the distance between the sheets should amount to between 13 mm and 19 mm, preferably between 15 mm and 17 mm, especially 16 mm, and that the frame should have a box section of width between 75 mm and 85 mm, preferably between 77 mm and 83 mm, and a wall thickness of between 2 mm and 4 mm, preferably between 2.5 mm and 3.5 mm.
In order to attach fittings, the door etc. is preferably characterised by the fact that there are holes in the frame and in the sheets for the purpose of attaching fittings. The fittings may comprise hinges, locks, closers, stays or stops, or components of such devices.
Thus, the fittings are then essentially arranged between the sheets, which does not present any major difficulties with the dimensions stated for the box section.
In order to make the frame particularly rigid at its corners, especially for accommodating fittings, the door etc. is preferably characterised by the fact that the frame has corner pieces preferably made from cast metal which are fitted in a sealed fashion into its sides and which accommodate fittings.
A particularly simple form of embodiment of the door etc., based on the traditional structure, is characterised by the fact that the frame is formed by one or more elongated spacers containing a dessicant and that the corners of the sheets and correspondingly the corners of the frame are cut away to accommodate fitting shoulders.
BRIEF DESCRIPTION OF THE DRAWINGS
Embodiments of the present invention, relating to doors, are described hereinafter with reference to the accompanying drawings. (Fanlights, transom panels, door side sections, door side panels, door side lights, windows or similar in accordance with further embodiments of the invention may be designed in a corresponding manner).
FIG. 1 shows a view of a door;
FIG. 2 shows an exploded view of the lower part of a first form of embodiment of a door;
FIG. 3 shows a second form of embodiment corresponding to FIG. 2;
FIG. 4 shows a section IV--IV in FIG. 1 in a third form of embodiment;
FIG. 5 shows a section IV--IV in FIG. 1 in a fourth form of embodiment;
FIG. 6 shows a section VI--VI in FIG. 1 in a fifth form of embodiment;
FIG. 7 shows a section VI--VI in FIG. 1 in a sixth form of embodiment;
FIG. 8 shows an exploded view of a seventh form of embodiment of a door;
FIG. 9 shows an enlarged view of part of the door of FIG. 8; and
FIG. 10 shows a glazing assembly incorporating a door, a transom panel and a door side panel, all constructed of framed glazing units in accordance with the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The same reference numbers refer to the same or essentially the same parts.
Referring to FIGS. 1 and 2, a door in accordance with a first embodiment of the invention has two glass sheets 2,4 (glass sheets 6,8 in the embodiments of FIGS. 5 and 6) arranged beside one another spaced at a distance and an internal non-supporting frame 10 holds the sheets 2,4 at the prescribed distance from one another. In addition, the frame 10 seals off the space 12 encompassed by it between the sheets. The frame 10 contains chambers 14 communicating with the space 12 through perforations 13, a dessicant 17 being provided in said chambers. The sheets 2,4 and the frame 10 have holes 18,19,20 and 21,22,23 lying in a line outside the chambers 14, through which are passed screw elements 26 respectively which press sheets 2,4 against frame 10. For clarity of illustration, only one screw element is shown in FIG. 2 on each side of the door. These screw elements 26 are segregated from the sheets 2,4 and the frame 10. To achieve this, the screw elements 26 stand at a distance from the internal peripheral circumferential faces of the holes 18,19,20 and 21,22,23 in the sheets 2,4 and the frame 10.
Seals 29,30 are arranged between the sheets 2,4 and the faces of screw elements 26 exerting pressure on sheets 2,4. Seals 29 are made from plastic and seals 30 from fibrous material. Further holes 24,25 lying in a line outside the chambers 14 are provided mid-way up the sheets 2,4 and the frame 10, the holes 24 being shown in FIG. 1. As shown in FIG. 4, screw elements 27 pass through the holes 24,25 and are separated therefrom by seals 29 and 30. The screw elements 27 according to FIG. 4 comprise a screw 36 with a countersunk head 38 (hole 24 is suitably conical) and a nut 40 supported from the outside on sheet 4 and having blind holes 42 into which a tool can fit.
In the case of the door according to FIG. 1, a floor closer 100 is shown diagrammatically at the bottom left and a swivelling pivot bearing 104 is shown top left. Cylindrical holes 104 are shown at the bottom right and the top right through which keyholes 106 of safety locks 108 (FIG. 2) are accessible.
FIG. 2 shows that the frame 10 comprises solid end pieces 62,63 which are substantially L-shaped corner pieces with male parts in the form of lugs 110 pointing to side pieces 52 of the frame 10, which lugs can be inserted via sealing plates 112 into cooperating female parts in the form of insertion sockets 114 which are provided in the side pieces 52.
The side faces of frame 10 are glued to the side faces of sheets 2,4 facing towards them by means of sealing double-sided adhesive strip 50 (such as Scotch tape, "Scotch" being a Registered Trade Mark).
The side pieces 52 of the frame 10 have a cross-section in the shape of a T whose transverse web 54 lies adjacent, via seals 56, to the peripheral faces of sheets 2,4. The transverse web includes a channel, preferably a dovetailed channel, 126 for receiving a peripheral seal.
The screw elements 26 according to FIG. 2 consists of three pairs of two countersunk screws 116 in each, which are to be screwed from both sides of the door through a metal bush 118 or a metal washer 120 and a seal 29 comprising a plastic packing ring or a seal 30 comprising a fibre material packing ring into holes 21,22 and 23 in the frame end pieces 62,36, for which purpose these holes are provided with internal threads. To the outer faces of end pieces 62 and 63 are screwed, by means of countersunk screws 124, rail pieces 122 in whose outer face there is a dovetailed section 126 to accommodate an all-round seal. The outer faces of the transverse webs 54 of the side pieces 52 are provided with corresponding dovetailed sections 128 which lie flush to the dovetailed sections 126.
At the bottom in corner piece 62 there is a blind hole 130, rectangular in cross-section, into which a correspondingly shaped pivot of the floor closer 100 can be inserted via a recess 132 in the rail piece 122. Correspondingly, a safety lock 108 is inserted into the corner piece 63.
In the form of embodiment according to FIG. 2, chambers 14 are integral with the side pieces 52.
In the form of embodiment according to FIG. 3, which is a modification of that of FIG. 2, chambers 15 are provided instead of chambers 14 and chambers 15 are formed into a separate frame which runs all round the frame 10 at a small distance from the side pieces 52.
As shown in FIG. 4, sheet 2 may have a greater thickness than that of sheet 4. FIG. 5 is a modification of FIG. 4 wherein, instead of screw elements 27, there are provided screw elements 28 comprising a bolt 44 with terminal threads onto which nuts 40 are screwed, such as those described in connection with FIG. 4. In addition, in the FIG. 5 embodiment sheets 6,8 are provided instead of sheets 2,4, sheets 6,8 having the same thickness.
FIG. 6 shows in detail the screw assemblies of FIG. 3 in which screws 116 are screwed through the glass sheets 6,8 into the end pieces 62 and pass through metal washers 120 and seals 30 on both sides of the frame 10. In the FIG. 6 embodiment, sheets 6,8 are provided which have the same thickness.
FIG. 7 shows in detail the screw assemblies of FIG. 2 in which on one side of the frame 10 screws 16 are screwed though the glass sheet 2 into the end piece 62 via metal bush 118 and seal 29 and on the other side of the frame 10 screws 116 are screwed through the glass sheet 4, metal washers 120 and seal 30 into the end piece 62. In the FIG. 7 embodiment, sheets 2,4 are provided in which sheet 2 is thicker than sheet 4.
In the form of embodiment according to FIGS. 4 and 7, the thickness of sheet 2 is 10 mm and the thickness of sheet 4 is 6 mm. In the form of embodiment according to FIGS. 5 and 6, the thickness of both sheets 6,8 is 6 mm. The distance between sheets 2,4 and 6,8 is preferably 16 mm. After many tests, this has proved to be particularly advantageous, also bearing in mind the heat circulation of the air in space 12.
Frame 10 has a box section preferably with a width of 80 mm and a wall thickness of 3 mm. This is particularly advantageous with regard to the accommodation of door fittings in the box section of frame 10.
With reference to the embodiment of FIGS. 8 and 9, a door 10 has two sheets 2,4 which are held at a distance from one another via seals 153 by a frame 10 formed by an elongated spacer 149 containing dessicant 17, the walls of said frame facing space 12 being perforated with perforations 151.
The corners of sheets 2,4 and the frame 10 are cut away in order to accommodate fittings. In the area of the cut-aways, the sheets 2,4 and the frame 10 have holes 134 through which countersunk screws 136 are inserted for the purpose of attaching fittings 138,140. The fitting 140 is provided with a projecting area 142 which is accommodated in a recess 144 left free by the cut-away and in a recess 146 left free by the other fitting 138.
The screws 136 penetrate holes 148 in the fitting 138, before they penetrate the holes 134, and they are screwed into the internally threaded parts 150 of fitting 140.
A peripheral seal (not shown) that encompasses sheets 2,4 and the frame 10, is carried by seal-mounting side sections 152, top and bottom sections 156 and side corner sections 154, each section being dovetailed.
The sections 154,156 are screwed down to fitting part 140 by means of countersunk screws 158,160. The fittings 138,140 are covered on the outside by caps 162 which can be fitted onto projections 166 on fittings 138,140 by means of edge perforations 164 provided in them.
FIG. 10 shows a glazing assembly 200 formed from glazing units in accordance with the present invention. The glazing assembly 200 comprises a door 202, a door side panel 204 mounted horizontally adjacent thereto and a transom panel 206 mounted above the door 202 and door side panel 204.
The door 202 may have the construction shown in the preceding FIGS. 1 to 9. The door side panel 204 and the transom panel 206 have the general glass sheet/frame construction illustrated in FIGS. 1 to 9. The door side panel 204 may have mounted thereon fittings for a door, such as lock, closer or stop fittings and the transom panel 206 may have hinge, lock, closer or stop fittings mounted thereon. Such fittings are, as described with reference to FIGS. 1 to 9, mounted on the frame of the glazing unit.
In alternative glazing assemblies in accordance with the present invention, the transom panel may extend only over the width of the door and the side panel may extend upwardly so as to be horizontally adjacent to the transom panel. Alternatively, the transom panel may be split so as to have two panels, one above the door and one above the door side panel. In further alternatively arrangements, two adjacent doors may be provided, featuring either a full-height or door-height side panel and there being either a transom panel either extending over the full width of the opening of the doors or split transom panels extending over either the width of a respective door or the width of a respective door and the adjacent side panel. | The invention relates to a door, a fanlight, door side section (door side light), window or similar, characterised by two glass sheets arranged beside one another at a distance, by a frame holding the sheets at a distance from one another--preferably incorporating fittings for the door etc., said frame essentially being covered by the sheets, by sealing means for the hermetic sealing of the space enclosed by frame between sheets and by a dessicant communicating with this space. | 4 |
BACKGROUND
The statements made herein merely provide information related to the present disclosure and may not constitute prior art, and may describe some embodiments illustrating the invention.
It is known that in drilling some wells, sections of casing are run down a borehole, often with a float shoe at the lower end which is equipped with a double valve enabling the casing to fill with drilling mud both while the casing is moving down and also while it is stationary. Within the casing is a baffle collar which defines a socket for a latching dart carried by a plug. The plug and dart are driven down to the collar, when the pumping of cement into the casing has been completed, by a launching dart which also closes the passageway through the plug. U.S. Pat. No. 4,664,192.
Also known are well liner running shoes which include ports for discharging cement into the well annulus between the liner and the wellbore wall, a check valve to prevent reverse flow of fluid up through the interior of the liner and the workstring, receiver means for receiving a cement plug or “dart” and receiver means for receiving a running tool which may be disconnected from the shoe after the liner has been set in its predetermined position. U.S. Pat. No. 5,277,255.
SUMMARY
In some first embodiments, an apparatus includes a tubular subject to a first pressure value at a distal end and a second pressure value at a proximal region within the tubular, a shoe disposed within the distal end of the tubular, a sealable valve disposed within the proximal region within the tubular, and a cement composition contained within a medial region of the tubular formed between the distal end and the proximal region. In some cases the tubular is a casing disposed in a wellbore penetrating a subterranean formation.
The surface of the subterranean formation may be located undersea, or on land. Also, the first pressure value may be greater than or equal to the second pressure value, and vice versa. The sealable valve may be a ball valve, a sleeve valve, flapper valve, butterfly valve, multiple flapper valves, multiple checks valves, or any other suitable valve arrangement known to those with skill in the art. Alternatively, in some cases the apparatus does not include a check valve in the shoe.
In some other embodiments, methods are provided which include introducing a casing into a wellbore penetrating a subterranean formation, the casing forming an annulus with the wellbore surface, where the casing is subject to a first pressure value at a distal end and a second pressure value at a proximal region within the casing, and where a shoe is positioned at the distal end of the casing. Then, placing a sealable valve within the proximal region of the casing, injecting a first cement composition into the casing, through the sealable valve and shoe, and into the annulus, and the placing a second cement composition in a medial region of the tubular formed between the distal end and the proximal region. Afterward, the sealable valve is closed.
For these embodiments, in some cases the tubular is a casing disposed in a wellbore penetrating a subterranean formation. The surface of the subterranean formation may be located undersea, or on land. Also, the first pressure value may be greater than or equal to the second pressure value, and vice versa. The sealable valve may be a ball valve, a sleeve valve, flapper valve, butterfly valve, multiple flapper valves, multiple checks valves, or any other suitable valve arrangement known to those with skill in the art. Alternatively, in some cases the apparatus does not include a check valve in the shoe.
In yet some other embodiments, methods are provided which include introducing a tubular into an open hole wellbore penetrating a subterranean formation, the tubular forming an annulus with the open hole wellbore surface, where the tubular is subject to a first pressure value at a distal end and a second pressure value at a proximal region within the tubular, and where a shoe is positioned at the distal end of the tubular; placing a sealable valve within the proximal region of the tubular; injecting a cement composition into the casing, through the sealable valve and shoe, and into the annulus; and, closing the sealable valve.
Again, in some cases the tubular is a casing disposed in a wellbore penetrating a subterranean formation. The surface of the subterranean formation may be located undersea, or on land. Also, the first pressure value may be greater than or equal to the second pressure value, and vice versa. The sealable valve may be a ball valve, a sleeve valve, flapper valve, butterfly valve, multiple flapper valves, multiple checks valves, or any other suitable valve arrangement known to those with skill in the art. Alternatively, in some cases the apparatus does not include a check valve in the shoe.
BRIEF DESCRIPTION OF THE DRAWINGS
The manner in which the objectives of some embodiments and other desirable characteristics may be obtained is explained in the following description and attached drawings in which:
FIG. 1 illustrates an apparatus having a shoe with a check valve at the very bottom of the string, a casing joint, and a float collar with a check valve.
FIG. 2 illustrates an apparatus having a shoe with a check valve at the very bottom of the string, a casing joint with cement composed therein, a sealable valve thereabove, and a float collar with a check valve.
DESCRIPTION
At the outset, it should be noted that in the development of any such actual embodiment, numerous implementation—specific decisions must be made to achieve the developer's specific goals, such as compliance with system related and business related constraints, which will vary from one implementation to another. Moreover, it will be appreciated that such a development effort might be complex and time consuming but would nevertheless be a routine undertaking for those of ordinary skill in the art having the benefit of this disclosure. In addition, the composition used/disclosed herein can also comprise some components other than those cited. In the summary of the invention and this detailed description, each numerical value should be read once as modified by the term “about” (unless already expressly so modified), and then read again as not so modified unless otherwise indicated in context.
Some embodiments relate to methods of cementing, prior to perforation, a wellbore with casing disposed therein. Some embodiments of the invention incorporate the concept of a “hard bottom” into the production casing string. The term “hard bottom” means a sealing component with high pressure integrity, and not necessarily easy to drill out. The pressure integrity is obtained by adding valves to the bottom of the production casing or production liner. These valves allow the casing to be cemented in the well but after cementing, seal the bottom of the production casing mechanically and with high pressure integrity. The valves (not cement) keeps the formation fluids from coming into the well bore through the shoe. The cement trapped between shoe and ball valve in the illustration above can now be a redundant seal.
In some instances, the concept is to add a reliable barrier. In current practice, if all proceeds as planned, the cement between shoe and float collar provides a good barrier. However, in some embodiments, a technique to incorporate an additional barrier is used as a contingency in case all does not proceed as planned in the operation, such as the instance where cement is over displaced. This can be a critical well control issue and adding a sealable valve, such as a ball valve, further ensures a reliable barrier.
Some embodiments disclosed are casing or liner cementing methods including positioning lower and upper wiper plugs having elastomer cups that are inwardly compressed in an open-bottomed tubular basket near the top of the liner, the basket having an outer diameter that is less than the inner diameter of the liner to permit cement to flow therebetween, the basket having a tubular body extending upwardly therefrom; providing a push rod in the body that can move longitudinally thereof and which has a lower end engaging the upper plug, pumping a first piston or dart down into engagement with the upper end of the rod and then applying pressure to the dart to force the rod downward a selected distance to expel the lower plug from the basket and out into the liner where said cups expand to engage the liner walls and provide a separation between the lower end of a column of cement and the drilling fluids, pumping a certain volume of cement slurry into the liner with said lower plug moving downward at the lower end of the cement, pumping a second piston or dart down into engagement with the first dart, and then applying pressure to force both of the darts and the rod further downward another selected distance to expel the upper plug from the basket and out into the liner where its cups expand to provide a separation between the upper end of the column of cement and the displacing fluids. The cement and plugs then are pumped on down the liner, and when the lower plug seats against a float collar or float shoe, a passage is opened through the plug to enable the cement to flow into the annulus. When the upper wiper plug engages the lower one, the displacement is complete. The basket and body assembly then is retrieved to the surface so that the inside of the liner is unobstructed. Apparatus in accordance with this includes a tubular body having a cylindrical, open-bottomed basket mounted on its lower end. Lower and upper elastomeric wiper plugs are force-fitted into the basket, which temporarily reduces their respective outer diameters. A push rod is mounted for longitudinal movement in the body with its lower end in engagement with the upper plug. The upper end of such rod is adapted to be engaged by a first dart or piston that is pumped down the running string and into the body in order to drive the rod and both wiper plugs downward until the lower plug is expelled from the basket. Upon expulsion, the plug expands radially outward to its relaxed diameter where the outer edges of its cups engage the inner walls of the liner. This plug then moves ahead of a column of cement which is being pumped down the running string and out of lateral ports in the body above the rod. From there the cement flows through the annular space between the basket and the inner wall of the liner. At the appropriate time a second dart or piston is pumped down into the body and engages the first dart. Fluid pressure then is applied to drive the two darts and the rod further downward until the upper wiper plug also is expelled from the basket and launched into the liner at the upper end of the column of cement. This plug expands like the first one to provide a moving seal that prevents contamination of the upper end of the cement column. When the cementing is complete, means are provided to enable the body, the basket, the drive rod and the darts to be retrieved to the surface. U.S. Pat. No. 5,890,537.
In general, there are three possible locations where formation fluid can enter the well bore in a cemented casing prior to perforating; at the shoe, at the top of the liner or casing and through a ruptured casing. The leak at the shoe is thought to be the most likely and some embodiments address improvements to the pressure integrity of the completion in the shoe area.
As discussed, at least in part above, typical hardware at the end of a casing string or liner allows cement to be pumped down the casing inner diameter and back up the wellbore through the annulus formed between the casing and the wellbore. This hardware arrangement typically has check valves which keeps the cement from re-entering (u-tubing) back into the casing at the end of the cementing operation, when pump pressure is removed or reduced. This equipment is typically designed and built to be easily drillable with plastic and aluminum interior parts that are often cemented or held with epoxy. Components of this type arrangement are illustrated in FIG. 1 .
As shown in FIG. 1 , the casing shoe 110 has a check valve and is at the very bottom of the string. Next, a casing joint is commonly used followed by the float collar 100 . The float collar may also have a check valve 120 . Also, as shown in FIG. 1 , a check valve in the shoe and a check valve in a float collar re spaced typically 20-40 ft apart. After the cementing operation, the 20-40 ft of cement can become the barrier and is pressure testable when the cement is cured.
In one embodiment, during the cementing operation, a casing wiper dart is pumped on top of the last cement going in the well and a pressure spike indicates the wiper has hit bottom or “bumps”. Below the wiper is expected to be a good column of cement between the shoe and float collar. This cement column is expected to be the long term barrier to keep formation fluids from entering the well bore from the bottom. A primary purpose for these check valves is to keep cement from u-tubing, but these check valves can also provide a barrier to formation fluid entering the well bore at the shoe.
Cementing a liner or a casing string back to the wellhead is typically done the same way in any onshore, or offshore formation, notwithstanding water depth. A casing hanger or liner hanger is on top of the casing string and attaches to a workstring (in most cases, the available drill pipe). The workstring inner diameter (ID) is smaller than the casing so there are actually two cement wiper darts used. The casing wiper is commonly pre-assembled below the liner hanger and has a hollow ID. The smaller workstring wiper dart is launched from the surface at the end of the cement. This smaller dart wipes the workstring ID and lands inside the casing wiper dart and seals. Pressuring up, shears some screws and releases the casing wiper dart. Systems have wiper darts before and after the cement column.
If the operation is performed and results according to plan, the wipers are effective and bump at the end on cement column, and subsequently, a non contaminated volume of cement cures in the casing joint between shoe and float collar. But there are several things that can compromise the long term cement seal at the bottom of the casing. Some of the things that can go wrong are:
1. Wipers plugs do not “bump” 2. Wipers are damage and allow contamination 3. Contaminates on ID of drill string or casing are swept off the surface by wiper dart and contaminates last feet of cement 4. Wiper is damaged and allows over displacement and a wet shoe 5. Cement does not cure sufficiently before a pressure test 6. Weak cement 7. Check valves leak and contaminated cement u-tubes back into bottom of casing 8. Contaminated cement does not cure, does not develop sufficient strength or has channels
In some embodiments of the invention, a ball valve is incorporated where the float collar is installed. The ball is closed when all the cement or nearly all of the cement is pumped past ball valve. The ball valve will allow an immediate pressure test (both positive and negative) up to full casing rating regardless of the condition of the cement. Additionally, reliance on cement to provide a long term seal at the bottom of the production casing string is avoided.
Additionally, if the ball valve or valves are used without check valves, the casing will “auto fill” while running in the hole. This eliminates the need to top fill. If top filling is not done frequently, well control issues could arise.
Referring now to FIG. 2 , which shows a casing show and float collar 200 , in some embodiments, when the ball valve 220 is closed, it can create a “hard bottom” which may be more difficult to drill. There are two common cases when drilling out the bottom is desired. The first case is if the production casing did not get close to the proper depth and is cemented high in the hole. The bottom would then be drilled out and a smaller liner would be run through this casing. The second case is a planned temporary bottom where the well would be produced for a period of time and then the well bore lengthened to produce from a deeper zone. However, a drillable shoe on the production casing string is not perceived as bringing much value in some instances. The drillable shoe on the intermediate casing and everything larger is optimum and is just repeated on the production casing. If a well with a hard shoe does need to be deepened, the well can be drilled by side tracking. The arrangement in FIG. 2 also includes a sealable valve 230 , such as a flapper valve, and the cement 240 located in a medial region of the tubular formed between the distal end and the proximal region.
Some methods which may be used to close the ball valve proximate the shoe include, but are not limited to, bumping of the wiper dart, a ball dropped before the cement wiper dart, a temperature profile based on the cooling effect of pumping cement and then warming back to or near reservoir temperature, RF tags in cement passing through ball valve, RF signal in wiper dart or other device pumped or drop in well at end of the cement column but does not pass through valve, pressure pulse signal, electromagnetic signal, acoustic signal, seismic signal, or the like.
Alternative to the ball valves described above, the functionality of the ball valve could be duplicated with other sealable valves such as a sleeve valve, multiple flapper valves (facing opposite directions) held open during cementing, multiple checks (facing opposite directions) held open during cementing, and the like.
The foregoing disclosure and description of the invention is illustrative and explanatory thereof and it can be readily appreciated by those skilled in the art that various changes in the size, shape and materials, as well as in the details of the illustrated construction or combinations of the elements described herein can be made without departing from the spirit of the invention. None of the description in the present application should be read as implying that any particular element, step, or function is an essential element which must be included in the claim scope: THE SCOPE OF PATENTED SUBJECT MATTER DEFINED ONLY BY THE ALLOWED CLAIMS. Moreover, none of these claims are intended to invoke paragraph six of 35 USC section 112 unless the exact words “means for” are followed by a participle. The claims as filed are intended to be as comprehensive as possible, and NO subject matter is intentionally relinquished, dedicated, or abandoned. | Methods include introducing a casing into a wellbore penetrating a subterranean formation, the casing forming an annulus with the wellbore surface, where the casing is subject to a first pressure value at a distal end and a second pressure value at a proximal region within the casing, and where a shoe is positioned at the distal end of the casing. Then, placing a sealable valve within the proximal region of the casing, injecting a first cement composition into the casing, through the sealable valve and shoe, and into the annulus, and the placing a second cement composition in a medial region of the tubular formed between the distal end and the proximal region. Afterward, the sealable valve is closed. | 4 |
RELATED APPLICATIONS
This application is a continuation of U.S. application Ser. No. 09/675,628 filed Sep. 29, 2000 entitled, now U.S. Pat. No. 6,981,228 “Interactive Topology Graphs for Visualization and Characterization of Sonet Consumption Patterns.”
BACKGROUND
The present invention relates generally to telecommunications and more particularly, to a system and method for monitoring telecommunication network activities.
It is often desired to monitor specific activities of various aspects of a telecommunication network. Traditionally, the monitoring has been hardware specific. For example, a monitoring system can show if a node or link in a network is up or down, and can set off alarms accordingly. Such monitoring works well with a realtime analysis of the hardware in the network.
However, it is often desired to monitor other aspects of the network. Consider for example a synchronized optical network (a “SONET”) ring or chain. SONET was proposed by Bellcore in the middle 1980s as a standard for connecting fiber-optic transmission systems. SONET defines interface standards at the physical layer, including a hierarchy of interface rates that allow data streams at different rates to be multiplexed. SONET establishes Optical Carrier (“OC”) levels, or speeds. Typical OC levels include OC-1 for 51.85 Mbps, OC-3 for 155.52 Mbps, OC-12 for 622.08 Mbps, OC-24 for 1.244 Gbps, OC-48 for 2.488 Gbps, and OC-192 for 9.9532 Gbps.
One way to track facility assignments and equipment inventory in a SONET ring or chain is to use a system called the Trunks Integrated Record Keeping System (“TIRKS”). TIRKS is commonly used to help a regional bell operating company (“RBOC”) determine if facilities exist to provide service, track order completion, fulfill circuit orders, and perform inventory planning.
Although TIRKS provides a great detail of information, the method of acquiring the information is very long and tedious. For example, in order to retrieve information such as consumption patterns of a SONET ring or chain, many steps must be performed on TIRKS. The information provided by TIRKS is in a raw-data format, and must be manually complied into a tabular form to represent the desired information. For a typical SONET ring, this process takes between two to six hours.
What is desired is a system and method that allows a user to quickly determine the status of the SONET ring. This status can be related to such things as available bandwidth and other consumption-related items.
Furthermore, what is desired is an interactive system and method for monitoring a network's status.
Further still, what is desired is a system and method that can provide a great deal of information about a network to a user. The information should be provided in a usable fashion, and should be responsive to user specific information for desired components of the network.
Furthermore, what is desired is a system and method for monitoring a network's status in a very fast manner, as compared to conventional techniques such as running a TIRKS online report facility.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a simplified description of several typical SONET rings and a monitor system according to one or more embodiments of the present invention.
FIG. 2 illustrates a computer system for use with the monitoring system of FIG. 1 .
FIGS. 3-5 provide screen shots, such as from the computer system of FIG. 2 , that illustrate different embodiments of the present invention.
FIG. 6 is one embodiment of a simplified flow chart that illustrates one embodiment of a software program for implementing features of the present invention.
FIG. 7 is a simplified flow chart that illustrates another embodiment of a software program for implementing features of the present invention, including creating the screen shots of FIGS. 3-5 .
DETAILED DESCRIPTION
The present disclosure relates to monitoring systems, such as can be used in a synchronized optical network (“SONET”) ring. It is understood, however, that the following disclosure provides many different embodiments, or examples, for implementing different features of the invention. Specific examples of components and arrangements are described below to simplify the present disclosure. These are, of course, merely examples and are not intended to limit the invention from that described in the claims.
The following disclosure is divided into three different sections. First of all, an exemplary network and system is provided. The exemplary network identifies two telecommunication networks that may benefit from the present invention, and the exemplary system provides an example of a system for providing a graphical user interface for monitoring either or both of the networks. Secondly, a plurality of screen shots are provided for illustrating the graphical user interface. Thirdly, an exemplary software routine is discussed for implementing one embodiment of the graphical user interface.
Exemplary Network and System
Referring to FIG. 1 , the reference numerals 10 and 12 designate, in general, two simplified SONET rings. The SONET rings 10 , 12 include a plurality of nodes 14 and a plurality of available bandwidth (generically described as links) 16 . Some of the nodes exist in both rings 10 , 12 , and are therefore considered hubs. It is understood that there are various types of nodes, and that the present description is not limited to any particular type. Any node 14 may be representative of a single component, a single facility, or a larger group of components and links. In the present example, each node includes a plurality of terminations where a service enters or exits the SONET ring 10 , 12 . In continuance of the example, the nodes 14 are designated OC-48, and therefore each node has a potential of 48 “drop ports.” Also, it is understood that there are many types of links, with each link having various potentially available bandwidths.
Referring also to FIG. 2 , a monitoring system 20 may be connected to one or more nodes of the networks 10 , 12 . In one embodiment, the monitoring system 20 includes a personal computer 21 with a graphics display 22 , a control unit 24 , and user inputs 26 such as a keyboard and pointer device. The computer 21 is connected through a log-on connection 30 to a file server 32 , which also includes hardware components found in a typical server computer. The file server 32 is further connected to an inventory system 34 , such as the TIRKS system discussed above. It is well known by those of ordinary skill in the art that various implementations can exist for the monitoring system 20 . For example, in some implementations, the monitoring system 20 may include a larger, mainframe-type computer that is either locally or remotely accessible by a terminal or personal computer. In other implementations, the monitoring system 20 may include a series of computers. In still other implementations, the monitoring system may include or utilize a series of adjunct processors to one or more of the nodes 14 .
The monitoring system 20 can perform various software routines that can produce a series of graphical output images. The images are arranged in a unique way to illustrate the status of the SONET ring 10 . For example, the images can locate a spare node from among the various nodes of the SONET ring 10 . The images can identify usage patterns between two or more nodes. Furthermore, the images can help identify spare bandwidths available. The images are discussed and illustrated below by providing several screen shots, such as may appear on the graphics display 22 .
Exemplary Screen Shots
The following discussion is directed to a graphical user interface comprising several different images. Since the images are dynamic and interactive, screen shots of the images will be further discussed. The screen shots relate to exemplary situations of a SONET ring, such as the network 10 or 12 of FIG. 1 , at a single moment in time. It is understood that different portions of the screen shots can be combined in various manners to produce even more examples of the graphical user interface.
Referring also to FIG. 3 , a screen shot 100 can be used to illustrate a current condition of a SONET ring on the display of a monitoring system. The screen 100 is divided into three main areas: a SONET ring area 102 , a link area 104 , and a node area 106 . The main areas can be further divided, as necessary. For example, in the screen 100 , the node area 106 includes a node detail area 106 a.
Referring to the SONET ring area 102 , a pictorial description of a SONET ring being monitored is displayed in a circular configuration 110 . One benefit of the present embodiment is that many nodes and links can be simultaneously displayed. To illustrate this benefit, the SONET ring to be displayed will be larger than those illustrated in FIG. 1 , with many more nodes and links.
The ring configuration 110 includes eleven nodes N 1 -N 8 and N 10 -N 12 and a plurality of links L 1 -L 24 between the nodes for the SONET ring. (Note that node N 8 is connected to node N 10 . A node N 9 is skipped for future expansion). The specific links L 1 -L 24 are chosen and highlighted by pull down menus 112 . In the present example, the configuration 110 illustrates the links L 1 -L 24 between each of the nodes N 1 -N 12 .
Several of the nodes N 1 -N 8 and N 10 -N 12 serve as hubs. In the present example, a legend 114 identifies that nodes N 2 , N 3 , N 4 , N 6 , N 7 , N 8 , N 11 , and N 12 are hubs. The legend 114 also assigns specific colors to the various nodes and links to indicate a status for each. In FIGS. 3-5 , different colors are illustrated with different line styles or hatchings. A first color 114 a indicates that a specific link or node is consumed. A second color 114 b indicates that a specific link or node is available. The nodes can have additional states, such as restricted 114 c , pending 114 d , and other 114 e . In addition, a mismatch between two nodes can be quickly identified. For example, if one of the links between nodes N 2 and N 3 is inventoried differently in the two nodes, a mismatch would occur. As such, a status of each node and link can be immediately determined by a user's quick perusal of the ring configuration 110 .
On several links there is an indicator 120 . The indicator signifies that service on the corresponding link is dropping at that node. The link is therefore consuming one of the drop ports at the corresponding node. For example, there are 13 links dropping at node N 2 and 32 links dropping at node N 3 . The links without the indicator 120 illustrate service that is passing through that node to another node. For example, at node N 3 , link L 4 passes straight through. Instead, link L 4 goes between (and consumes drop ports at) node N 2 and node N 4 .
In addition to the information provided in the SONET ring area 102 , more detailed information can be provided for a specific node. In the example illustrated in FIG. 3 , the node N 1 has been “selected” for additional information. The selection process can be performed by using the input devices 26 described above, with reference to FIG. 2 , or may be selected by the monitor system 20 .
Referring to the link area 104 , link information for the selected node is provided in a series of columns: SYS Num, Direction, Usage, Detail, and Riding OC. The column SYS Num provides a list of all the selected links from the pull-down menu 112 . The columns Direction, Usage, and Detail provide directions east (E) or west (W) that identify the link and describe the service provided by the corresponding link. The column Riding OC describes other systems riding on the corresponding drop ports. For example, the links L 1 -L 3 east and west are T 3 's. T 3 's are synchronous digital carriers used to transmit a formatted digital signal at 45 Mb/s.
Referring to the node area 106 , information for the selected node is provided in a series of columns: Mapped, HECI, Relay, Total, Spare, and Restricted. The Mapped, Relay, Total Spare, and Restricted columns describe the various drop ports associated with the node. The HECI column identifies a human equipment common interface (HECI) value. The HECI value provides a summary of specific usage of a particular unit. The HECI value can be provided in greater detail in the node detail area 106 a , when such information is available.
As discussed above, in the present example, node N 1 is the selected node, but additional information may be desired for one of the non-selected nodes. To find the additional information, the pointer device 26 ( FIG. 2 ) is positioned over a node. In the present example, the pointer device 26 is positioned over node N 11 . As a result, a window 122 appears with additional information for node N 11 . In the example shown in FIG. 3 , the window 122 indicates that node N 11 is a central office identified as DLMRCA12, with a Relay value of 010131.14. The relay has 19 working (W) drop ports, 1 restricted (X) drop port, and 4 spare (S) drop ports. Node N 11 is also a hub node (reference number NSH61A), and may therefore connect to one or more additional networks.
Referring now to FIG. 4 , a screen shot 130 illustrates bandwidth usage patterns in an interactive manner. A pull-down menu 132 is used to select two nodes in a specific sequence, and a pull-down menu 134 is used to identify bandwidth usage. For the sake of example, the bandwidth usage patterns from node N 3 to node N 10 is illustrated.
In this example, links L 3 , L 5 , L 15 , and L 16 are highlighted as the available links between node N 3 and node N 10 . The links are available because the drop ports 120 exist on the west side (W) of node N 3 and the east side (E) of node N 10 . To find additional information about a particular link, the pointer device 26 ( FIG. 2 ) can be positioned over the link. In the present example, the pointer device 26 is positioned over link L 3 . As a result, a window 136 appears with additional information for link L 3 . In the example shown in FIG. 4 , the window 136 indicates that link L 3 is a working T 3 connection between nodes N 3 and N 1 . It is noted that as illustrated in FIG. 4 , L 3 is a spare link between nodes N 6 and N 5 .
Referring now to FIG. 5 , a screen shot 140 identifies spare links in an interactive manner. A pull-down menu 142 is used to select all the links, and a pull-down menu 144 is used to identify a specific status of the links. For the sake of example, all of the spare links are to be identified.
In this example, many links between various nodes are identified. The identified links are spares because there are no drop ports on either side. To find additional information about a particular link, the pointer device 26 ( FIG. 2 ) can be positioned over the link. In the present example, the pointer device 26 is positioned over link L 13 . As a result, a window 146 appears with additional information for link L 13 . In the example shown in FIG. 4 , the window 146 indicates that link L 13 is a spare.
The screen shot 140 also illustrates how a user can select a specific link. Pull-down menus 148 , 150 are used to identify the link, accordingly. For the sake of example, link L 13 is identified.
In this example, the link is in use between the node N 5 to N 3 , N 3 to N 10 , N 10 to N 8 , and N 8 to N 6 . The link L 13 is available (spare) between nodes N 6 and N 5 . In addition to the color scheme provided, the pointer device 26 can be positioned to identify more information about that link. In the present example, the pointer device 26 is positioned over link L 3 between nodes N 7 and N 6 . As a result, a window 152 appears with additional information for link L 13 . In the example shown in FIG. 4 , the window 152 indicates that link L 3 is a working T 3 link.
Software Description
Referring now to FIG. 6 , a computer program 180 can be used for visualizing and characterizing at least a portion of a SONET ring, such as the rings 10 , 12 of FIG. 1 . The computer program 180 may be encoded on a computer readable medium. Execution begins at step 182 , where one or more menus are provided from which a user may specify specific components of the SONET ring. At step 184 , a graphical representation of the SONET ring illustrating each node and link of the SONET ring specified by the user is calculated and drawn. At step 186 , a user selection for identifying one node of the SONET ring is received. At step 188 , an inventory system such as TIRKS is accessed for data related to the user selection. At step 190 , detailed information about the selected node is displayed.
Referring now to FIG. 7 , another software routine 200 can be implemented to visualize and characterize a portion of a SONET ring, such as the rings 10 , 12 of FIG. 1 . The software routine 200 may be encoded on a computer readable medium and can provide the above described screen shots 100 , 130 , 140 of FIGS. 3-5 on the monitor system 20 . Execution begins at step 202 where a first stage of user input is provided, such as the pull-down menus 112 , 132 - 134 , 142 - 144 , and 148 - 150 of FIG. 3-5 . In this way, a user can select specific nodes for a specific size of display. It is understood that as more nodes and links are selected, the granularity of the information provided will also increase. It is further understood that generic aspects of a graphical user interface (GUI), such as pull-down menus, are well understood by those of ordinary skill in the art.
At step 203 , the user can choose between two different operations of the routine 200 . A visualization process (discussed in steps 204 - 214 , below) is a look-up and read process. This allows the user to quickly and easily determine the status of a SONET ring using one or more of the screen shots 100 , 130 , 140 discussed above. A review process (discussed in steps 220 - 230 , below) is an automatically updated, periodic monitor of one or more SONET rings.
The visualization process begins at step 204 , where a user selection is received. The user selection at this step of the process 200 is for determining the configuration for the SONET ring to be displayed.
At step 206 , a series of calculations and/or data queries are performed. Since the data queries often take a relatively long time (as compared to the calculations), these queries may be initiated first. For example, one or more queries can be implemented using TIRKS. The various nodes and links that have been specified are then queried and the information is returned.
Several calculations may be performed concurrently with the data queries. For example, the size and shape of the configuration for the SONET ring may be determined (e.g., ring configuration 110 of FIG. 3 ). In the embodiments of FIGS. 3-5 , it is desired that the SONET ring be configured in a circle, with evenly spaced nodes and links. Once the nodes and links are drawn, their color (or other aspect) is drawn according to the query results and a predetermined legend, such as the legend 114 of FIG. 3 , is provided.
At step 208 , a response is made to a selected link or node. In the examples of FIGS. 3-5 , node N 1 is a default selection, but the user can select another node using the pointer device 26 . Once selected, execution proceeds to step 210 where additional information is provided for the selected node and corresponding links. In the examples of FIGS. 3-5 , this information is provided in the link area 104 and the node area 106 .
Upon completion of steps 208 - 210 (or prior to their completion), execution proceeds to step 212 where a response is made to a link or node identified using the pointer device 26 . In the present embodiment, the identification of a link or node made at step 208 is different than that made at step 212 . For example, in step 208 , the link or node can be selected by “clicking” the pointer device or pressing an appropriated key on a keyboard. In step 212 , the link or node is identified by merely positioning the pointer device over the corresponding component. Once identified, execution proceeds to step 214 where additional information is provided for the selected component. In the examples of FIGS. 3-5 , this information is provided in pop-up windows 122 , 136 , 146 , and 152 . Execution then returns to step 202 for additional user selection.
The review process begins at step 220 , where a series of calculations and/or data queries are performed. Since the data queries often take a relatively long time (as compared to the calculations), these queries may be initiated first. For example, one or more queries can be implemented using TIRKS. The various nodes and links that have been specified are then queried and the information is returned. Several calculations may be performed concurrently with the data queries.
At step 222 , a link exhaust calculation is made. The link exhaust calculation is made by examining a usage trend (e.g., from the previous 12 months) and the amount of spare bandwidth (from the spare links), to predict when the network will be exhausted.
At step 224 , each link and node is reviewed. The review may consider the different technologies (e.g., OC-3, OC-12, TS3) of the components, as identified by a stored reference value (e.g., in the server 32 of the monitor system 20 ). Each technology can be detected and tracked, and exhaust conditions can be thereby determined. The information may then be presented to the user, such as through a demand and capacity (D&C) chart on the display 22 .
At step 226 , a determination is made as to whether the user has modified any preset values. For example, the user may modify a technology type for a component, may change a predefined exhaust condition (e.g., from 20% to 10% spare), and so forth. If the user does make modifications, execution returns to step 220 .
At step 228 , the user can be notified in other manners. For example, the file server 32 can send an e-mail to the user notifying any upcoming exhaust conditions.
At step 230 , the review process may be performed on an automatic, cyclic basis. For example, the review process may be performed every week. To illustrate this process, the flow chart of FIG. 7 illustrates execution returns to step 220 . If an automatic process is not desired, execution returns to step 202 .
It is understood that the process 200 is illustrated in a top-down flow chart to provide a simple and clear description. In actuality, many steps may be performed simultaneously, and may actually be performed by different nodes and/or different components of the monitor system 20 and the SONET ring 10 . Such processing distribution is well known to those of ordinary skill in the art.
CONCLUSION
Thus, there is disclosed a system and method for providing interactive topology graphs for visualization and characterization of SONET consumption patterns. In some embodiments, the system and method allow a user to quickly determine the status of the SONET ring. This status can be related to such things as available bandwidth and other consumption-related items. The system may be interactive, and can quickly provide specific information without providing superfluous or unnecessary information to the user. In addition, implementations of the various embodiments described above can be performed very quickly, as compared to conventional techniques, such as running a TIRKS online report facility.
While the invention has been particularly shown and described with reference to the preferred embodiment thereof, it will be understood by those skilled in the art that various changes in form and detail may be made therein without departing form the spirit and scope of the invention. | A computer-based monitoring system provides interactive topology information about a synchronized optical network (SONET). The monitoring system utilizes a trunks integrated record keeping system (TIRKS) connected to the SONET for collecting status data in a raw format. A computer system retrieves the raw format status data from TIRKS and provides the data in a simple graphical user interface to a user. The interface includes several menus from which the user may specify specific components of the SONET, and a graphical output for providing a graphical representation of the SONET. The graphical output illustrates each node and link and interactively provides more detailed information about any user selected link or node. | 7 |
FIELD OF THE INVENTION
[0001] The present disclosure relates to the field of oncology, biomarkers, biology and drug discovery. Particularly, the disclosure relates to compositions useful for studying the cell cycle, RNA-editing enzymes, monitoring of disease progression, and pharmacological screening. The disclosure also includes methods for expanding stem cells. The disclosure also relates to compositions and methods for inhibiting the action of double-stranded RNA-specific adenosine deaminases, or ADAR enzymes. The disclosure includes methods and compositions for treating, ameliorating or preventing diseases and conditions, such as cancer, including cancers associated with stem cells such as, without limitation, a myeloproliferative neoplasm like chronic myeloid leukemia (CML) or acute myeloid leukemia (AML).
BACKGROUND OF THE DISCLOSURE
[0002] RNA editing is a post-transcriptional processing mechanism that results in an RNA sequence that is different from that encoded by the genomic DNA and thereby diversifies the gene product and function. The type of RNA editing that is most prevalent in higher eukaryotes converts adenosine residues into inosine (A-to-I editing) in double-stranded RNA (dsRNA) through the action of double-stranded RNA-specific adenosine deaminases (Bass B L, Weintraub H, Cell, 1988; 55(6):1089-98). RNA-specific adenosine deaminases include ADAR1 (also known as ADAR), ADAR2 (ADARB1), and ADAR3 (ADARB2). ADAR1 and ADAR2 are active in embryonic cell types, and ADAR3 may play a nonenzymatic regulatory role in RNA-editing activity (Osenberg S, et al., GPLoS One, 2010, 5(6):e11173; Chen C X et al., RNA, 2000, 6(5):755-767.
[0003] The ADAR1 enzyme destabilizes double-stranded RNA through conversion of adenosine to inosine. The ADAR1 enzyme modifies cellular and viral RNAs, including coding and noncoding RNAs. ADAR1 targets double-stranded RNA hairpin-containing loop structures, such as microRNAs (miRNAs) by operating through base-pairing with complementary sequences within an mRNA molecule leading to mRNA degradation and gene silencing. ADAR activity is suggested in various tumor types (Galeano F. et al., Semin Cell Dev Biol, 2012 23(3):244-250; Cenci et al., J Biol Chem, 2008, 283(11):7251-7260).
[0004] Traditional treatments for myeloproliferative neoplasm are a great financial burden on patients. Moreover, they are not efficient at eradicating cancer stem cells (CSC), such as leukemia cancer stem cells (LCS). Studies suggest that LCS promote therapeutic resistance, relapse and disease progression, the leading causes of leukemia mortality, as a result of enhanced survival and self-renewal combined with a propensity to become dormant in supportive microenvironments. Therapies capable of breaking LSC quiescence while sparing normal hematopoietic stem cell (HSC) function have remained elusive. New drugs that target cancer stem cells are urgently needed for patient care as well as research tools that aid in the studies of the role cancer stem cells play in cancer. The disclosure herein provides drugs and research tools useful in prognostication, pharmacological screening, treating and studying cancer.
SUMMARY OF THE INVENTION
[0005] Disclosed herein are methods of expanding cells, such as stem cells and hematopoietic cells, comprising increasing ADAR1 activity in such cells, such as by overexpression of ADAR1 on a plasmid. In some aspects of this embodiment, the cells are cord blood cells (CB), such as cord blood cells that are CD34 + . Included in this embodiment are the cell or cells that overexpress ADARI.
[0006] Another embodiment disclosed herein are methods for transplanting hematopoietic-reconstituting cells into a subject in need thereof, the method comprising administering to the subject CD34 + cells having enhanced expression of ADAR1. In an aspect of this embodiment, the subject has a disorder treatable by hematopoietic stem cell transplantation, such as a hematopoietic deficiency or malignancy.
[0007] In a related embodiment are methods for reconstituting hematopoietic cells into subjects in need thereof comprising: a) collecting cord blood cells from a donor or donors; b) transducing into the cells from step (a) a vector that overexpresses ADARI; c) expanding the transduced cells for about 3-5 days; d) collecting the cells from step (c); and e) transplanting the expanded cells from step (D) into the subject in need of treatment. In some aspects of this method the cord blood cells are CD34 + . In some embodiments of this method the subject is being treated for leukemia, lymphoma or other blood-related diseases. In some aspects of this method the subjects blood supply has been damaged by chemotherapy, radiation, or toxic agent and/or the patient needs a bone marrow transplant. In some aspects of this method the cells to be expanded are transduced with a vector that overexpresses ADAR1 such as a lentiviral vector. In some embodiments of the method successful expansion is measured by an elevation in CD45 + as compared to the CD45 + levels in cord blood cells without overexpression of ADAR1 or a normal control. In some embodiments the expanded cells are CD34 + CD38 − and Lin − human stem cells.
[0008] Also disclosed herein are vectors that overexpress ADAR1 and vectors that express a mutant version of ADAR1 protein wherein the mutation results in an ADAR1 protein that retains dsDNA and dsRNA binding capacity but has reduced ability to convert A-to-I activity. In aspects of this embodiment, the mutant ADAR1 protein has a mutation in the active RNA-editing sites, such as a point mutation, for example, a point mutation at nt5293 which results in an A to C mutation resulting in glutamic acid to alanine change. In some aspects the vector is a human-specifc lentivaral vector. Also included in this embodiment are cells containing the disclosed ADAR1 vectors. In some embodiments the cells are K562 cells.
[0009] Another embodiment disclosed herein is a reporter vector for measuring A-to-I editing comprising dual-luciferase, or enhanced green fluorescence protein (EGFP) or enhanced yellow fluorescence protein (EYFP) and a stop codon (TAG) in a hairpin structure which is part of the promoter sequence, wherein the stop codon is removed due to RNA editing resulting in a reporter gene signal being generated as a readout of RNA-editing level. In some aspects this vector contains an opposite oriented Alu-sequence to detect RNA editing in non-coding regions. Included in this embodiment are cells containing the vectors, such as stem cells and cancer stem cells. In an aspect of this embodiment are methods for measuring and tracing the A-to-I RNA-editing changes in a cancer stem cell comprising introducing the vectors into cancer stem cells and correlating changes in A-to-I RNA editing after exposure to agents. In some aspects the cancer stem cells are in in vitro stromal co-culture system or in vivo xenograft mouse models.
[0010] In another embodiment are vectors comprising wild-type GLI2 cloned into pcDH-EF1-T2A-cop and ligated in frame with the FLAG epitope. In a related embodiment are vectors comprising mutant GLI2 wherein the transcription activation domain has been deleted, In some embodiments the mutant GLI2 is cloned into pcDH-EF1-T2A in frame with the FLAG epitope. Included in these embodiments are cells containing the GLI2 wild-type and mutant GLI2 vectors. The cells can be stem cells, such as cancer stem cells.
[0011] Also disclosed herein are vectors comprising a bi-cistronic fluorescent ubiquitination-based cell-cycle indicator (FUCCI) reporter in a vector that is suitable for use in mammalian cell populations and which are useful for studying the cell cycle. In some embodiments the vector contains a bi-cistronic FUCCI reporter that was generated by cloning mCherryhCdt1 and Venus-hGeminin into vector pcDH-EF1-T2A. Included in this embodiment are cells that contain the bi-cistronic FUCCI reporter vectors. The cells can be stem cells, such as cancer stem cells.
[0012] In another embodiment are methods for treating, ameliorating or preventing diseases and conditions associated with the down regulation of one or more microRNA identified in FIGS. 8-11 comprising: administering to a subject in need of treatment a composition that upregulates one or more of the downregulated microRNA, wherein the composition is one or more of antisense DNA, RNAi, ribozyme, short hairpin RNA, a small molecule, an antibody or antibody fragment, a small HA oligosaccharide, or soluble HA-binding proteins. In some aspects the downregulation of the microRNA is associated with a stem cell, such as a cancer stem cell, for example a leukemia stem cell. In some aspects of this embodiment the condition or disease to be treated is cancer or an inflammatory disease, such as a myeloproliferative neoplasm, for example, chronic myeloid leukemia or acute myeloid leukemia. In some aspects of this embodiment, the chronic myeloid leukemia is in the blast phase. In still other aspects of this embodiment the composition administered upregulates Let7a. In some embodiments the upregulator of Let7a is a vitamin D3 derivative. In other embodiments, the patient is treated with an inhibitor or ADAR1, such as 8-azaadenosine or an 8-azaadenosine derivative.
[0013] As used herein, the term “subject” refers to an animal, typically a human (i.e., a male or female of any age group, e.g., a pediatric patient (e.g., infant, child, adolescent) or adult patient (e.g., young adult, middle-aged adult or senior adult) or other mammal, such as a primate (e.g., cynomolgus monkey, rhesus monkey); other mammals such as rodents (mice, rats), cattle, pigs, horses, sheep, goats, cats, dogs; and/or birds, that will be or has been the object of treatment, observation, and/or experiment. When the term is used in conjunction with administration of an, agent, composition, compound or drug, then the subject/patient has been the object of treatment, observation, and/or administration of the composition, compound or drug.
[0014] In an embodiment disclosed herein are methods for monitoring if a subject with cancer or an inflammatory disease should be treated or enrolled in a clinical trial comprising: (a) isolating blood cells from the subject during or after treatment; (b) processing the isolated stems cells to detect and/or quantitate one or more microRNA identified in FIGS. 8-11 ; (c) determining if the level of expression of the microRNA has decreased or increased from the levels of expression of the microRNA seen before treatment or as compared to normal controls; wherein if the level of expression of one or more microRNA has decreased and is a microRNA associated with a disease state, such as mir26a-sp, mir26b-5p, mir155-5p, mir21-5p, mir125a-5p, mir23b-3p, let7c, let7e, mir150-5p, and let7d the subject should be treated or enrolled in a clinical trial. In some aspects of this embodiment, the subject has been diagnosed with CML. In a related embodiment, the subject is treated with an agent/compound and the subject is then monitored to determine if the level of expression of a microRNA shown herein to be decreased in a disease state has increased from the levels of expression of the microRNA seen before treatment, wherein if the level of expression of one or more microRNA identified in FIGS. 8-11 , such as mir26a-sp, mir26b-5p, mir155-5p, mir21-5p, mir125a-5p, mir23b-3p, let7c, let7e, mir150-5p is upregulated after treatment, such upregulation can be used as an indicator that the treatment is working.
[0015] In another embodiment disclosed herein are primers comprising, consisting of, or consisting essentially of the primers identified in FIG. 16 and Table 1.
[0016] Disclosed herein are methods for screening for agonists and inhibitors of RNA editing comprising: (a) contacting a CD34 + cell which overexpresses ADAR1 with a test compound; and (b) determining whether the test compound acts as an agonist or inhibitor. In some aspects the determination is measured using the fluorescent A-to-I editing reporter described in FIG. 3A which is transduced into the CD34 + cell. In other aspects the determination is done through use of RESSq-PCR or qPCR using direct sequencing of CSC-specific RNA-editing biomarkers or microRNAs as described in FIGS. 8-11, 14 and FIG. 16 .
[0017] An embodiment disclosed here is a method of treating, ameliorating or preventing diseases and conditions responsive to the inhibition or slowing of cell differentiation and/or self-renewal (or self-renewal capacity) of dysfunctional cells, cancer cells, leukemia cells, hematopoietic stem cells or cancer stem cells, comprising, administering 8-azaadenosine or an 8-azaadenosine derivative. In some aspects the 8-azaadenosine derivative is a compound as shown in FIG. 25 . In other aspects of this embodiment, the disease or condition is cancer or inflammatory disease, such as a myeloproliferative neoplasm, for example chronic myeloid leukemia (CML) or acute myeloid leukemia (AML).
[0018] In still other embodiments are methods for detecting leukemic progression into blast phase comprising the steps of: (a) collecting a blood sample from a subject with leukemia; (b) isolating mononuclear cells from the blood sample; (c) isolating CD34 + cells; (d) isolating RNA from the CD34 + cells; (e) generating cDNA from the isolated RNA; (f) performing quantitative PCR using one or more primer sets for the genes listed in Table 1—MDM2, APOBEC3D, GLI1, AZIN1, SRPN, GSK3B, PTPN14, SF3B3, ABI1, LYST; and (g) quantifying the data to determine the relative A-to-G(I) editing ratios in one or more of MDM2, APOBEC3D, GLI1, AZIN1, SRPN, GSK3B, PTPN14, SF3B3, ABI1, LYST and MDM4, wherein if the ratio of edited is higher than a normal standard or a previous determination from the same patient obtained in chronic phase such increased editing activity indicates the patient may be in blast phase or entering blast phase and should be treated or entered into a clinical trial. In some embodiments of this method, the one or more primer sets are represented by SEQ ID Nos. 1-4 for MDM2 position 69237534; SEQ ID NOS. 5-8 for APOBEC3D position 39415872; SEQ ID NOS:9-12 for APOBEC3D position 39415911; SEQ ID NOS:13-16 for SRP9 position 225976198; SEQ ID NOS: 17-20 for Gli1 position 57864624; SEQ ID NOS:21-24 for Gli1 position 57864911(negative control); SEQ ID NOS:25-28 for GSK3B position 119545199; SEQ ID NOS:29-32 for AZIN position 103841636; SEQ ID NOS:33-36 for PTPN14 position 214529774; SEQ ID NOS:37-40 for SF3B3 position 70610885; SEQ ID NOS:41-44 for ABI1 position 27049636; SEQ ID NOS:45-48 for LYST position 235990569; and SEQ ID NOS:49-52 for MDM4 position 204521159. In some embodiments of this method, the cDNA preparation utilizes gene transcription with reverse transcription and gene-specific primers and/or random hexamer primers only and/or a supermix containing both random hexamer and oligo-dT primers.
[0019] Disclosed herein are methods for testing whether an agent is effective for reducing the editing activity of ADAR1 comprising: (a) adding the agent to cells that have ADAR1 activity; (b) isolating RNA from the cells of step (a); (c) generating cDNA from the isolated RNA; (d) performing quantitative PCR using one or more primer sets for the genes listed in Table 1—MDM2, APOBEC3D, GLI1, AZIN1, SRPN, GSK3B, PTPN14, SF3B3, ABI1, LYST; and (e) quantifying the data to determine the relative A-to-G(I) editing ratios in one or more of MDM2, APOBEC3D, GLI1, AZIN1, SRPN, GSK3B, PTPN14, SF3B3, ABI1, LYST and MDM4, wherein if the ratio of edited/wild-type is lower than cells not treated with the tested agent indicates that the agent lowers the editing activity of ADAR1 and may be useful for treating conditions associated with increased levels of ADAR1 activity, such as leukemia and inflammatory diseases. In some embodiments of this method the one or more primer sets are represented by SEQ ID Nos. 1-4 for MDM2 position 69237534; SEQ ID NOS. 5-8 for APOBEC3D position 39415872; SEQ ID NOS:9-12 for APOBEC3D position 39415911; SEQ ID NOS:13-16 for SRP9 position 225976198; SEQ ID NOS: 17-20 for Gli1 position 57864624; SEQ ID NOS:21-24 for Gli1 position 57864911(negative control); SEQ ID NOS:25-28 for GSK3B position 119545199; SEQ ID NOS:29-32 for AZIN position 103841636; SEQ ID NOS:33-36 for PTPN14 position 214529774; SEQ ID NOS:37-40 for SF3B3 position 70610885; SEQ ID NOS:41-44 for ABI1 position 27049636; SEQ ID NOS:45-48 for LYST position 235990569; and SEQ ID NOS:49-52 for MDM4 position 204521159. In some aspects of this embodiment, the cells that have ADAR1 activity are cells containing a wild-type ADAR1 expression vector. In other aspects of the methods the cells are K562 cell. In some embodiments, the K562 cells are stably-transduced with lentiviral-ADAR1. In other aspects of this method the cells treated with an agent are CD34 + cells obtained from primary CML patients; or cells obtained from an immunocompromised non-human animal transplanted with primary blast crisis cells, such as, without limitation, a mouse.
[0020] In another embodiment are methods for detecting leukemic progression into blast phase comprising the steps of: (a) collecting a blood sample from a subject with leukemia; (b) isolating mononuclear cells from the blood sample; (c) isolating CD34 + cells; (d) isolating RNA from the CD34 + cells; (e) converting the RNA from step (d) into cDNA; (f) evaluating miRNA expression using MiScript qPCR array; and (g) determining if one or more of mir26a-5p, mir26b-5p, mir155-5P, mir21-5P, mir125a-5P, mir23b-3P, let7c, let7e, mir150-5p, or let7d are downregulated as compared to a normal control or a previous sample from the subject while in chronic phase, wherein if one or more of mir26a-5p, mir26b-5p, mir155-5P, mir21-5P, mir125a-5P, mir23b-3P, let7c, let7e, mir150-5p, or let7d are downregulated indicates that the patient is in or entering blast phase and should be treated or enrolled in a clinical trial.
[0021] Also disclosed herein are methods for testing whether an agent is effective for reducing the editing activity of ADAR1 comprising: (a) adding the agent to cells that have ADAR1 activity; (b) isolating RNA from the cells of step (a); (c) generating cDNA from the isolated RNA; (d) evaluating miRNA expression using MiScript qPCR array; (e) determining if one or more of mir26a-5p, mir26b-5p, mir155-5P, mir21-5P, mir125a-5P, mir23b-3P, let7c, let7e, mir150-5p, or let7d are upregulated as compared to cells not treated with the tested agent, wherein if one or more of mir26a-5p, mir26b-5p, mir155-5P, mir21-5P, mir125a-5P, mir23b-3P, let7c, let7e, mir150-5p, or let7d are upregulated this may indicate that the tested agent inhibits ADAR1 activity and may be useful to treat conditions associated with high ADAR1 editing activity, such as leukemia or inflammatory diseases. In some embodiments of this method, the cells that have ADAR1 activity are cells containing a wild-type ADAR1 expression vector. In other embodiments of this method, the cells are K562 cells. In other embodiments of this method the cells are K562 cells stably-transduced with lentiviral-ADAR1.
[0022] As used herein, the terms “compositions,” “drug,” “agent,” “compound,” and “therapeutic agent” are used interchangeably, and may include, without limitation, small molecule compounds, biologics (e.g., antibodies, proteins, protein fragments, fusion proteins, glycoproteins, etc.), nucleic acid agents (e.g., antisense, RNAi/siRNA, shRNA, and microRNA molecules, etc.), vaccines, etc., which may be used for therapeutic and/or preventive treatment of a disease (e.g., malignancy).
[0023] “Therapeutically effective amount,” or “therapeutic effect,” as used herein, refers to a minimal amount or concentration of an agent, composition, compound and/or drug that, when administered alone or in combination, is sufficient to provide a therapeutic benefit in the treatment of the condition, or to delay or minimize one or more symptoms associated with the condition. The term “therapeutically effective amount” can encompass an amount that improves overall therapy, reduces or avoids symptoms or causes of the condition, or enhances the therapeutic efficacy of another therapeutic agent. The therapeutic amount need not result in a complete cure of the condition; partial inhibition or reduction of the malignancy being treated is encompassed by this term.
[0024] The details of one or more embodiments of the invention are set forth in the accompanying drawings and the description below. Other features, objects, and advantages of the invention will be apparent from the description and drawings, and from the claims.
[0025] All publications, patents, patent applications cited herein are hereby expressly incorporated by reference for all purposes except to the extent they are inconsistent with the disclosures herein.
DESCRIPTION OF THE DRAWINGS
[0026] FIG. 1 —shows that ADAR1 induces cell cycle transit. Cord blood (CB) CD34 + cells were transduced with ADAR1 or ORF lentivirus. After 5-days, the cells were collected for FACS cell cycle analysis. An expansion of cells in S phase and decrease in G 0 were observed.
[0027] FIG. 2 —shows that ADAR1 knock-down increases quiescence. CD34 + cells from CML BC patient were transduced with lentivirus expressing shADAR1 or shControl backbone for 3-days. FACS analysis indicates both the primary and serial engrafted samples have an increased G 0 population.
[0028] FIG. 3 —(A) Plasmid map of fluorescent A-to-I editing reporter in pCDH lentivirus backbone; (B) Validation of A-to-I editing reporter in K562 using luciferase signal as readout. (C) Inactive ADAR1 mutant plasmid map. The RNA editing site of ADAR1 is mutated from A 5293 →C 5293 , which leads to glutamic acid (E) to alanine (A).
[0029] FIG. 4 —shows that overexpression of ADAR1 in human stem cells leads to expansion in stem cell population in vitro (A) and (B) and in vivo (C).
[0030] FIG. 5 —(A) shows the cloning scheme for generation of GLI2 lenti-viral constructs using pCDH-EF1-T2A-copGFP; (B) shows fold expression of GLI2 in SKNO-1 cells transduced with GLI2 lenti-viral construct; (C) shows Western blot analysis of cell extracts containing GLI2 lenti-viral constructs.
[0031] FIG. 6 —shows generation of bi-cistronic FUCCI lenti-viral constructs using pCDH-EF1-T2A-copGFP. (A) FUCCI plasmids were used as templates to PCR subclone both Venus_hGeminin and mCherry_Cdt1 into pCDH-EF1-T2A lentiviral vector. (B) depiction showing the different fluorescent expression patterns of mCherry and mVenus in the cell cycle-with mCherry expressed primarily in G1 and mVenus in s and G2. (C) Fluorescence of the mCherry and mVenus FUCCI construct in cells.
[0032] FIG. 7 —shows that ADAR1 drives leukemic progression by downregulating microRNA that target stem cell regulatory gene products.
[0033] FIG. 8 —shows that microRNA are downregulated in CD34 + positive cells during CML progression from chronic phase to blast crisis.
[0034] FIG. 9 —shows that lentiviral overexpression of ADAR1 leads to statistically significant downregulation of miRNA in primary CD34 + CML CP cells.
[0035] FIG. 10 —lentiviral overexpression of ADAR1 in cord blood leads to significant downregulation of 16 microRNA.
[0036] FIG. 11 —blast crisis CD34 + cells show downregulation of microRNA in common with cord blood cells overexpressing ADAR1. (A) downregulation of microRNA by overexpression of ADAR1 in cord blood; (B) comparison of microRNA expression in chronic phase versus blast crises phase showing downregulation of microRNA is similar to cord blood overexpressing ADAR1; (C) shows the ratio of p150 to p110 mRNA level in cord blood cells, CML chronic phase cells and CML blast crisis phase cells.
[0037] FIG. 12 —shows that ADAR1 downregulation of LET7 family member increases self-renewal, and lenti-viral overexpression of LET7A induces a reduction in colony formation and replating. (A) shows overexpression of LET7A reduces colony number (B) shows percentage of colony (GM, G, BFU-E, MIX, and M) in cells transduce with a vector control or vector overexpressing LET7A. (C) shows number of replating colonies in cells with vector control or vector overexpressing LET7A.
[0038] FIG. 13 —(A) shows relative mRNA expression of K562 cells WT, K562 lenti-ORF, or Lenti-ADAR1. (B) shows relative levels of ADAR1 isoforms (p150, p110), ADAR2 and RNA editing target gene MDM2 in wild-type (wt) K562, undifferentiated hESC (hues16 undiff), 293 cells and mouse bone marrow stromal cells (SL/M2).
[0039] FIG. 14 —shows the selection of CSC-specific RNA editing biomarkers used for RESSq-PCR assay primer design.
[0040] FIG. 15 —shows RNA editing site-specific qPCR (RESSqPCR) primer design strategy.
[0041] FIG. 16 —shows RESSq-PCR primer sets. RNA editing site specific primer sets (non-genomic sequences) and control (positive) gene specific primers. Sites with primers listed as “n/a” failed the design parameters using the ARMS-based primer design.
[0042] FIG. 17 —shows data for the validation of primer specificity of primers from FIG. 16 and Table 1 in cDNA and gDNA at RNA editing sites in MDM2, APOBEC3D, Gli1, GSK3b, and AZIN1 All primer sets generated single bands in cDNA by gel analysis.
[0043] FIG. 18 —data showing RESSq-PCR detects robust RNA editing at ADAR target sites in K562-ADAR1 cDNA.
[0044] FIG. 19 —shows validation by direct sequencing (ABOBEC3D-1). RESSq-PCR detects RNA editing at highly-edited sites in K562-ADAR1 RNA at similar ratios to direct sequencing.
[0045] FIG. 20 —Gli1 direct Sequencing demonstrating a 10.81 fold increase by RESSq-PCR and 12.75 fold increase by direct sequencing (peak height ratio)
[0046] FIG. 21 —shows inhibition of RNA editing in cord blood, ABM, and blast crisis cells with 8-azaadenosine. (A) 8-azaadenosine treatment results in reduced total ADAR1 levels by qRT-PCR, and (B) decreased RNA editing in APOBEC3D (Sites 1 & 2) by direct sequencing.
[0047] FIG. 22 —shows let7 regulation by BCR-ABL and ADAR editing of miRs is niche dependent. Lentiviral over-expression of BCR-ABL in CD34+ CB n=3 do not affect expression of members of let7 family
[0048] FIG. 23 —shows that all members of let7 family were downregulated in CB+BCR-ABL on stroma, while BCR-ABL effect was not consistent among the different members of let7 family in CB+ BCR-ABL without stroma. BCR-ABL overexpression affected CDKN1a expression when not on SLM2, while it affected CDKN 2A when in co-culture with SLM2
[0049] FIG. 24 —shows let7 is regulated by JAK2 overexpression. (A) Let7-d was significantly downregulated after JAK2 overexpression, while V617F induced the upregulation of both let7e and let7f compared to JAK2 WT; (B) Fold change vs PCDH-JAK2 significantly downregulated 4 members of let-7 family and miR-155. Notably, no significant differences were observed between V617F transduced cells and PCDH; (C) Fold change vs lenti-JAK2 V617F mutation induced the upregulation of 3 members of let7 family.
[0050] FIG. 25 shows 8-azaadenosine derivatives.
[0051] FIG. 26 —RNA editing inhibition with 8-azaadenosine in K562 cells stably expressing human ADAR1 p150. (A) qRT-PCR analysis of ADAR1 expression levels in K562 cells stably transduced with backbone control lentivirus, ADAR1 wild-type vector or ADAR1 mutant (catalytically deficient) vector. Cells were grown in the presence (+) of absence (−) of SLM2 humanized bone marrow stromal cells. (B, C) RNA editing analysis of 8-azaadenosine-treated (10-100 nM) cells (ADAR1 wt, B or ADAR1 mutant, C) using RESSq-PCR for a leukemia stem cell specific site in APOBEC3D.
[0052] FIG. 27 —A) Correlation analysis between ADAR1 expression level and RNA editing of APOBEC3D by RESSqPCR in 293 cells transduced with ADAR1 WT and Mutant. Graph despicts best-fit line by Pearson correlation analysis. B) RESSqPCR analysis of APOBEC3D in normal CD34+ cord blood cells transduced with lenti-ADAR1 wild-type, lenti-ADAR1 mutant (editing inactive ADAR1) or backbone vector, and treated with 8-Aza for 22 hrs (n=3). C) mRNA expression levels of ADAR1 in normal CD34+ cord blood cells transduced with lenti-ADAR1 WT, lenti-ADAR1 mutant or backbone vector, after 22 hrs of treatment with 8-Aza (25 nM) (n=3).
DETAILED DESCRIPTION OF THE EMBODIMENTS
[0053] Disclosed herein are compositions and methods useful for studying the cell cycle, RNA-editing enzymes, monitoring of disease progression, and pharmacological screening based on RNA editing detection. Also disclosed herein are research tools and methods useful to study stem cells and diseases associated with stem cells, including cancer stem cells. Specifically these tools involve ADAR1 constructs, GLI2 reporters, and cell-cycle fluorescent indicators.
[0054] Data disclosed herein indicates that ADAR1 accelerates G0 to G1 phase transition in normal hematopoietic stem cells (cord blood CD34 + population), coupled with increased cell size and elevated expression of Ki67. The expanded population maintains stemness without any significant increase in differentiation. ADAR1 shows a preference of localization to the cell nucleus, suggesting the A-to-I editing events happen in the nucleus. qRT-PCR microarray of cell-cycle genes indicates that p21 expression level is reduced by >70% when ADAR1 is overexpressed. Therefore, ADAR1 is a useful tool for in vitro expansion of normal hematopoietic stem cells ( FIG. 1 ). The data in FIG. 1 was obtained by transducing cord blood CD34 + cells with ADAR1 or ORF lentivirus. After 5-days, the cells were collected for FACS cell cycle analysis.
[0055] Moreover, shRNA knockdown of ADAR1 in CML BC sample shows a reduction of engraftment in bone marrow and spleen, and an enrichment of G0 population in the remaining cells. A decrease of self-renewal capacity as demonstrated by serial engraftment suggests the residual LSC failed to propagate ( FIG. 2 ). The data in FIG. 2 was generated as follows: CD34 + cells from CML BC patient were transduced with lentivirus expressing shADAR1 or shControl backbone for 3-days. The cells were then transplanted into immunocompromised mice. After 20 weeks, the mice were sacrificed and the bone marrow (BM) and spleen (SP) were collected. CD34 + cells from bone marrow were serial transplanted to examine the self-renewal capacity. FACS analysis indicated both the primary and serial engrafted samples have an increased G0 population.
[0056] Also disclosed herein are vectors such as lentiviral vectors that overexpress a mutant version of ADAR1 protein. The point mutation locates in the active RNA-editing sites, and when mutated, the ADAR1 protein will retain dsDNA and dsRNA binding capacity, but lacks the ability to convert A-to-I. These constructs are useful for understanding the functionality of ADAR1 ( FIG. 3 )
[0057] In another embodiment, disclosed herein is a human-specific quantitative fluorescence dsRNA lentiviral reporter that can accurately measure aberrant A-to-I editing activity using luciferase activity or EGFP/YGFP as readout (see reference, Gommans et al, 2010). This reporter was cloned into a pCDH lentiviral plasmids ( FIG. 3 ). The reporter contains a stop codon (TAG) in a hairpin structure as part of the promoter sequence. When RNA editing occurs, the stop codon is removed (TGG) and luciferase or fluorescent signal will serve as a readout of RNA editing level. In an aspect of this embodiment, an opposite orientated Alu-sequence is introduced into the hairpin structure to detect RNA editing in non-coding regions. The reporter's efficiency was confirmed in K562 leukemia cell line that stably overexpresses ADAR1 (approximate ˜10 fold by western blot). The results indicate a 5-fold increase in luciferase signal compared to K562 cells transduced with backbone lentivirus ( FIG. 3B ). In an aspect of this embodiment, the dsRNA reporter hairpin is introduced into a lentiviral backbone using luciferase activity or EGFP/EYFP as readout so that efficient transduction can be produced in quiescent myelodysplastic syndrome (MDS) and AML LSCs.
[0058] Such lentiviral A-to-I editing reporters can be used to measure and trace the A-to-I RNA editing changes in LCS and other CSC with in vitro stromal co-culture system and in vivo xenograft mouse models, and correlate these changes with exposure to agents such as toxins and other chemicals, including effects on therapeutic outcome.
[0059] We have also observed an expansion cord blood cells ex vivo. This could serve as a new blood supply for patients who have had theirs destroyed by chemotherapy or radiation to treat leukemia, lymphoma and other blood-related diseases ( FIG. 4 ). It has been difficult to successfully expand normal blood stem cells in vitro since the cells are likely to differentiate into mature blood cells. Our finding of ADAR1 indicates it is able to expand hematopoietic stem cells by 10-20 fold without significant increase in differentiation. It provides a safe and efficient method to produce large quantity of blood stem cell for bone marrow transplant and other medical needs, such for subjects who have had their blood cells destroyed by chemotherapy or radiation to treat, without limitation, leukemia, lymphoma and other blood-related diseases.
[0060] In one embodiment, the procedure can start with collection of cord blood cells from a donor or donors which is then transduced with lentivirus that overexpresses ADARI RNA editing enzyme. After about 3-5 days, the cells are collected and transplanted back into patients who received therapy to enable a healthy blood system to reestablish quickly. In some aspects the transplanted cells are CD34 + . Successful expansion can be determined, without limitation, by measuring the elevation in CD45 + ( FIG. 4 ). This method enables quick transplantation of donor blood cells immediately after patients receive chemotherapy or radiation. The increase in number of healthy donor blood also helps to provide a faster and better recovery. Since the culture condition is very simple and the turn-over-time is short, this method provides a more efficient alternative to existing technologies.
[0061] The data in FIG. 4 was obtained as follows: FACS-purified CD34 + CD38 − Lin − HSC (n=3) were transduced with ADAR1 or ORF backbone. The pictures were taken 3-days post transduction ( FIG. 4A ), when the cells were collected for qRT-PCR analysis. Genes involved in cell cycle arrest (CDKN1a and CDKN2a) were both down-regulated by ADAR1 ( FIG. 4B ). Cord blood CD34 + cells were transduced with ADAR1 or ORF and transplanted into immunodeficient mice. After 12 weeks, bone marrow were collected and analyzed by FACS ( FIG. 4C ).
Cell-Cycle Reporters
[0062] Currently, there are few methods to visualize cell cycle progression in LSC. Human LSC are characterized as quiescent self-renewing cells that drive leukemic transformation of myeloproliferative neoplasms and myelodysplastic syndromes. Additionally, current methods require sequential transduction and clonal selection. These methods and conditions are not feasible to study primary patient samples and LSC, which are generally limited in sample size. To alleviate this challenge, we generated a lentiviral biscistronic vector encoding FUCCI (fluorescent ubiquitination-based cell-cycle indicator) probes. The development of this new reporter offers a new and more effective method to track cell cycle progression in limited mammalian cell populations, including cell cycle changes in CSC. These constructs can identify changes in the cell cycle leading to new strategies to combat chemoresistance, and for screening new candidate therapeutics.
[0063] Bi-cistronic FUCCI reporter was generated by subcloning mCherry-hCdt1 into BspE1/SalI digested pcDH-EF1-T2A-copGFP and ligated in frame. Venus-hGeminin was subcloned into XbaI/BamHI digested pcDH-EF1-T2A-mCherry-hCdt1 and ligating in frame ( FIG. 6 ).
[0064] GLI2 Wild Type and mutant GLI2 Vectors: Wild type and mutant versions of GLI2 were generated by either subcloning full length human GLI2 or transcriptionally inactive GLI2 into XbaI/NotI digested pcDH-EF1-T2A-copGFP and ligated in frame with the FLAG epitope. Mutant GLI2 was generated by deletion of transcriptional activation domain of GLI2 denoted as pcDH-EF1-ΔTAD GLI2-T2A-copGFP ( FIG. 5 ). FIG. 5B shows the fold expression of GLI2 in GLI2 transduced SKNO-1 cells using the GLI2 vector. FIG. 5C show Western blots of cells transduced with the GLI2 vector.
Micro RNA:
[0065] While miRNA alterations have been associated with CML in the context of bulk tumor, no published studies have focused on CML LSC population that behaves remarkably different from bulk tumor and is responsible for disease progression and relapse. Disclosed herein is the finding that in Chronic Myeloid Leukemia (CML) progression is driven by ADAR1-dependent regulation of microRNA. Without wishing to be bound by any particular theory, it is postulated that in blast crisis, when ADAR1 p150 is upregulated, ADAR1 affects microRNA regulation by editing of pri-microRNA and pre-microRNA ( FIG. 7 ). This discovery is unique since it allows one to predict leukemia progression by identifying edited miRNA generated by malignant-specific A-to-I RNA editase ADAR1. This will also allow one to use edited miRNA signature, instead of a general miRNA profile as disease biomarkers. Moreover, the identification of disease progression markers can help identify and develop new targeted therapies. In an aspect of this embodiment, this discovery allows for the development of a detection platform of edited microRNA in LSC population from primary patients and to validate their role as diagnostic and prognostic biomarkers with primary leukemia patient at different disease stages and following different treatments.
[0066] Also, disclosed herein is finding that blast crisis CD34 + cells show downregulation of 13 microRNA compared to CD34 + Chronic Phase. This can be related to overexpression of ADAR1 in Blast Crisis. ADAR1, by editing microRNA precursors negatively affect complete maturation of microRNA mediated by RNAse Drosha and DICER, thus leading to degradation of the edited product and a consequent downregulation of the edited microRNA ( FIG. 8 ). The data in FIG. 8 was generated as follows: Primary CML patient samples and normal blood were CD34 selected for RNA extraction. cDNA was prepared in a reverse-transcription reaction using miScript RTII kit (QIAGEN) and used as a template to profile the expression of the 84 most abundantly expressed and best characterized miRNAs by using miScript miRNA PCR Array (QIAGEN), which contains miRNA specific miScript primer assays. qRT-PCR was performed with SYBR Green Kit (QIAGEN). qRT-PCR for the validation of array results was performed by using miRNA specific primer assays and SYBR Green Kit (QIAGEN). Normalization was performed by using miSCRIPT primer control (RNU6-2).
[0067] Another embodiment disclosed herein is the finding that Lenti-viral overexpression of ADAR1 in chronic phase primary samples leads to a statistically significant downregulation of 10 microRNA, thus, showing a microRNA expression profile more similar to that seen in blast crisis ( FIG. 9 ). The data generated in FIG. 9 was obtained as follows: CP CD34 + cells were transduced with lentiviral vectors overexpressing human ADAR1 or GFP-expressing lentiviral backbone. Cells were collected for RNA extraction and MiRNA expression was evaluated by MiScript qPCR array, and differentially expressed miRNAs was validated by qRT-PCR with specific primers.
[0068] Lenti-viral overexpression of ADAR1 in CD34 + Cord blood cells leads to the significant downregulation of 16 microRNA ( FIG. 10 ). The data shown in FIG. 10 was generated as follows CP CD34 + cells were transduced with lentiviral vectors overexpressing human ADAR1 or GFP-expressing lentiviral backbone. Cells were collected for RNA extraction and MiRNA expression was evaluated by MiScript qPCR array, and differentially expressed miRNAs was validated by qRT-PCR with specific primers.
[0069] In Blast Crisis, where ADAR1 is upregulated and induces malignant progenitor reprogramming, 10 out the 13 microRNA that are downregulated in comparison with chronic phase, are in common with the downregulated microRNA in ADAR1 overexpressing Cord blood ( FIG. 11 ).
[0070] Since in both ADAR1 transduced cord blood and blast crisis, we observed a downregulation of the family of reprogramming microRNA let7, we overexpressed let7a in cord blood and evaluated the expression of the target LIN28, as well as its effect on self-renewal. Let7a overexpression leads to a statistical significant decrease of the efficiency of colony formation. This reduction is driven by the reduction in GM colonies. Moreover, overexpression of let7a decreases self-renewal as shown by the reduction of number of replating colonies. Further, Lin28 is statistically downregulated after let7-a overexpression. ADAR1, by downregulating let7 family increases self-renewal ( FIG. 12 ). The data shown in FIG. 12 was obtained as follows: CD34 + cord blood n=3 cells were transduced with lentivirus overexpressing let-7a or GFP expressing lentiviral backbone. After 48 hours Hematopoietic progenitor assays was performed by plating cells into MethoCult Medium. After 2 weeks, total colony number FIG. 12A and change in individual colony types Fig. B between miRNA-overexpressing and the control conditions was analyzed. Individual colonies were replated into fresh Methocult medium and replating efficiency after 2 weeks of culture was evaluated as a measure of self-renewal capacity (n=2) FIG. 12C .
RESSq-PCR and RNA Editing Inhibitors:
[0071] Whole transcriptome RNA sequencing (RNA-Seq) revealed increased adenosine to inosine (A-to-I) RNA editing during CML progression concentrated within primate specific Alu-containing transcripts. However, detection of RNA editing by RNA-Seq in rare cell populations can be technically challenging, costly and requires PCR validation by direct sequencing which cannot reliably detect low levels of RNA editing, or cloning which is labor-intensive and low-throughput. RNA Editing Site-Specific qPCR (RESSq-PCR) provides a rapid, clinically amenable method to detect aberrant primate-specific RNA editing at CSC-associated loci.
[0072] To develop a model system for development of the RESSq-PCR diagnostic assay, we established an in vitro model of stable ADAR1 expression in leukemia cells, wherein the BCR-ABL + human leukemia cell line K562 was stably transduced with lentiviral human ADAR1-IRES-GFP (K562-ADAR1) or vector ORF (K562-ORF). Positively-transduced cells were identified on the basis of high GFP expression, FACS-purified to establish stable cell lines, and expanded under routine culture conditions. High levels of ADAR1 lentivirus and total human ADAR1 mRNA in K562-ADAR1 cells were confirmed by qRT-PCR using lentiviral-specific and human-specific primers, respectively ( FIG. 13 ). Cell types with high levels of endogenous ADAR1 expression (undifferentiated human embryonic stem cells) were used as a positive control for comparison to enforced ADAR1 overexpression in K562 cells ( FIG. 13 ). For the data shown in FIG. 13A , K562 cells were transduced with lentiviruses expressing human ADAR1-GFP (Lenti-ADAR1) or backbone-GFP (Lenti-ORF) control. Cells were FACS-purified for GFP-positive cells and expanded in culture. 106 cells were harvested and RNA was extracted and reverse transcribed using a cDNA supermix containing random hexamers and oligodT. ADAR1 lentivirus and total ADAR1 levels were measured by qPCR. In FIG. 13B relative levels of ADAR1 isoforms (p150, p110), ADAR2 and RNA editing target gene MDM2 were evaluated in wild-type (wt) K562, undifferentiated hESC (hues16 undiff), 293 cells and mouse bone marrow stromal cells (SL/M2).
[0073] We previously identified 274 differentially edited sites in CML blast crisis versus chronic phase, and selected top candidates from this dataset to develop site-specific primers and validate RNA editing sites as potential biomarkers of disease progression in primary patient samples. Candidate sites for validation and qRT-PCR assay development were selected from our previous RNA-sequencing data on the basis of greatest average change in RNA editing, with a focus on selecting sites within functionally relevant target genes involved in stem cell survival and self-renewal pathways, along with 3 known RNA editing sites within stem cell regulatory genes and cancer-associated pathways ( FIG. 14 ).
[0074] In order to implement rapid, inexpensive and clinically-amenable detection of RNA-edited transcripts that predict leukemic progression, we utilized a novel RNA editing site-specific quantitative RT-PCR (RESS-qPCR) primer design strategy. Since RNA-edited transcripts are predicted to differ at only one nucleotide position, developing highly specific primers for traditional qRT-PCR assays requires sensitive and selective primer design strategies. We have previously developed qRT-PCR primers that specifically recognize a gene product with one point mutation (JAK2 V617F11), and here we employed a similar strategy in designing RESSq-PCR primers ( FIG. 15 and FIG. 16 ). For each ADAR target site, two sets of primers containing non-genomic sequences were designed: one pair detecting the wild-type transcript (an “A” base), and one pair detecting the edited transcript (a “G” base representing inosine substitution) ( FIG. 16 and Table 1). An additional mismatch was incorporated upstream of the 3′ primer end to enhance allelic discrimination.
[0000]
TABLE 1
RESSq-PCR primer sets
Gene
1-FW Outer
2-Rev inner
3-FW inner
4-Rev Outer
MDM2
ATAGGACTGAGGT
ATAATGCTTGGAG
TAAATGGCCAAAG
AAGAGATTCTGCT
AATTCTGCACAGC
GACCTCCACATGT
GGATTAGTAGTGT
TGGTTGTAGCTGA
A
SEQ ID NO: 2
G
AG
SEQ ID NO: 1
SEQ ID NO: 3
SEQ ID NO: 4
MDM2
n/a
n/a
n/a
n/a
APOB
CTCTGGGATCTCT
GAGGTTGCAGTGA
GTCCAGGCTGGAA
GAGGCTGAAGCAG
EC3D
CTGCCTCCAAATA
GTCCAGATGGC
TGCAATGTCA
AAGAATCGCTTAA
TC
SEQ ID NO: 6
SEQ ID NO: 7
AC
SEQ ID NO: 5
SEQ ID NO: 8
APOB
TTTGAGACAGAGT
CGGGAGGCTGAAG
AACCTCCGCCTCC
CAAAATTAACCAG
EC3D
GTTGCTCCTCTTG
CAGAAGAATCTCT
CGAGTTGAG
GTGTGGTGATGCA
TCC
SEQ ID NO: 10
SEQ ID NO: 11
TG
SEQ ID NO: 9
SEQ ID NO: 12
SRP9
CACTGTCTCAAAA
CTTGAACCCAGGA
GGCATGATCTTGG
CTAAAAATACAAA
ATACATACCTTCA
GTGAGGTCC
CTCACTTCA
AATTAGCTGGGCG
GCA
SEQ ID NO: 14
SEQ ID NO: 15
TG
SEQ ID NO: 13
SEQ ID NO: 16
Gli1
GGGGAGGACAGAA
CTGGCTCTTCCTG
ACTGAGAATGCTG
AAGTCCATATAGG
CTTTGATCCTTAC
TAGCCCGCT
CCATGGATGATG
GGTTCAGACCACT
CT
SEQ ID NO: 18
SEQ ID NO: 19
GC
SEQ ID NO: 17
SEQ ID NO: 20
Gli1
ATATCCTGACCCC
AGGACACTGGCTG
TGTACCCAGGCCC
GGCTTGACTTGCA
(neg
ACCCAAGAAACAT
TAGGTTCCAACC
CAAGGCTATA
CTTGTCCATAATG
ctrl)
SEQ ID NO: 21
SEQ ID NO: 22
SEQ ID NO: 23
TT
SEQ ID NO: 24
GSK3B
CAAAGGCAAGTCT
TCTTTTAAAGTCT
AACCAATTTCAAG
AAGAAGAAAACCT
ATAAATACCCGAA
AGTGTGAGACTTT
CTGTGCCCT
TTTTCTGTGCTGA
GA
GGTCTG
SEQ ID NO: 27
TG
SEQ ID NO: 25
SEQ ID NO: 26
SEQ ID NO: 28
AZIN1
ACTGAATGACATC
GAGCTTGATCAAA
CATTCAGCTCAGG
AATACAAGGAAGA
ATGTAATAAATGG
TTGTGGCAG
AAGAAGACATCT
TGAGCCTCTGTTT
CT
SEQ ID NO: 30
SEQ ID NO: 31
AC
SEQ ID NO: 29
SEQ ID NO: 32
PTPN14
TTTCCCAAGCTGA
CCTTTTCTTGAGT
CACCACGTAACAA
TTTTGTACTTTTT
AAAGACAAG
ACAGCTTTGCTA
CAGGTGAAC
TCCTCTTACTGCA
SEQ ID NO: 33
SEQ ID NO: 34
SEQ ID NO: 35
TT
SEQ ID NO: 36
MBD3
n/a
n/a
n/a
n/a
SF3B3
TCACACCTGTAAT
GTGTGCACCACCA
AACCCCATCTCTC
ATAGGCTGAAGTG
CCCAGCACTTTGA
TGCCTGTCT
CAAAAATACAAAA
ATCCTCCTGTCTC
SEQ ID NO: 37
SEQ ID NO: 38
AGTG
AG
SEQ ID NO: 39
SEQ ID NO: 40
ABI1
AGAGAGCCAAGAA
TATTTTTAGTAGA
TTTGAGACCAGCC
GTTCAAGTGATTC
ATAAGCCTTTAAG
CACGGGTTTTCGA
TGGCCATAAT
TCCTGTCTCAACC
GG
CG
SEQ ID NO: 43
TC
SEQ ID NO: 41
SEQ ID NO: 42
SEQ ID NO: 44
WTAP
n/a
n/a
n/a
n/a
LYST
TGGCAAAACCCTG
GTTCTAGAGGTTG
CTGTAATCCCAGC
TTTGAGACAGAGT
TTTCTACTAAAAA
TCATGTCGCG
TACTCAGGTGTCT
CTCACTTTTTCAC
TAT
SEQ ID NO: 46
SEQ ID NO: 47
C
SEQ ID NO: 45
SEQ ID NO: 48
LYST
n/a
n/a
n/a
n/a
MDM4
TGGAAGAAGAATT
CTAGGTGATCTCC
GGCGTAGTGGCTC
GTAAAAATGGGGT
GTCTTGGACCACA
CAAAGTGTTGGGC
ACGCCTTTG
TTCTCCATGTCGG
CA
TT
SEQ ID NO: 51
TC
SEQ ID NO: 49
SEQ ID NO: 50
SEQ ID NO: 52
[0075] In FIG. 17 , cDNA and genomic DNA (gDNA) from K562-ADAR1 cells were analyzed by RESSq-PCR with primers specific for wild-type (WT, A), edit (G) or positive (outer flanking) gene sequences at RNA editing sites in MDM2, APOBEC3D, Gli1, GSK3b, and AZIN1 Site-specific primers distinguished G(I) bases at RNA editing sites in cDNA and as predicted gave no signal in gDNA ( FIG. 17 ).
[0076] All primer sets generated single bands in cDNA by gel analysis. In independent experiments, RESSq-PCR accurately detected robust RNA editing in K562-ADAR1 cells ( FIG. 18 ). Relative A-to-I RNA editing ratios were increased by 2 to 3 fold in ADAR1-expressing cells compared to vector controls (ORF) at sites in MDM2, APOBEC3D, Gli1 and AZIN1 transcripts ( FIG. 18 ). Increased A-to-I changes in RNA editing sites were confirmed by targeted sequencing ( FIGS. 19, 20 ).
Small Molecule Inhibitors:
[0077] As proof-of-concept that small molecule inhibitors could block RNA editing activity, CD34 + cells from a CML blast crisis patient were treated with vehicle or 1 μM 8-azaadenosine (Veliz et al., JACS 2003) for 24 hours and co-cultured on humanized bone marrow stromal cells (SL/M2) for 5 days. Direct sequencing of two CSC-specific RNA editing biomarkers in APOBEC3D showed a reduction in edit/wild-type sequence ratios following 24 hrs of 8-azaadenosine treatment ( FIGS. 21, 26, 27 ). These data show that RESSq-PCR for these and other RNA editing biomarkers can form the basis of screening methods to test activity of RNA editing inhibitor compounds derived from 8-azaadenosine and related small molecules ( FIG. 25 and EP0066918) to identify novel agonists and inhibitors of RNA editing in high-throughput RESSq-PCR and RNA editing reporter screens. Thus, RESSq-PCR and RNA editing inhibitors is an allele-specific diagnostic assay that can be used for detection of primate-specific RNA editing events in cancer stem cells.
[0078] We have also demonstrated that let7 regulation by BCR-ABL and ADAR editing of miRs is niche dependent ( FIGS. 22-23 ) and that JAK2 overexpression regulated let7 family members ( FIG. 24 ). The data shown in FIG. 22 was obtained by transducing CD34 + CB n=3 with lenti-BCR-ABL and expression of let7 family was evaluated by RT-qPCR. Lentiviral over-expression of BCR-ABL in CB n=3 do not affect expression of members of let7 family.
Generating and Manipulating Nucleic Acids:
[0079] In alternative embodiments, nucleic acids of the invention are made, isolated and/or manipulated by, e.g., cloning and expression of cDNA libraries, amplification of message or genomic DNA by PCR, and the like.
[0080] The nucleic acids used to practice this invention, whether RNA, iRNA, shRNA, antisense nucleic acid, cDNA, genomic DNA, vectors, viruses or hybrids thereof, can be isolated from a variety of sources, genetically engineered, amplified, and/or expressed/generated recombinantly. Recombinant polypeptides generated from these nucleic acids can be individually isolated or cloned and tested for a desired activity. Any recombinant expression system can be used, including e.g. bacterial, fungal, mammalian, yeast, insect or plant cell expression systems.
[0081] Alternatively, nucleic acids used to practice this invention can be synthesized in vitro by well-known chemical synthesis techniques, as described in, e.g., Adams (1983) J. Am. Chem. Soc. 105:661; Belousov (1997) Nucleic Acids Res. 25:3440-3444; Frenkel (1995) Free Radic. Biol. Med. 19:373-380; Blommers (1994) Biochemistry 33:7886-7896; Narang (1979) Meth. Enzymol. 68:90; Brown (1979) Meth. Enzymol. 68: 109; Beaucage (1981) Tetra. Lett. 22: 1859; U.S. Pat. No. 4,458,066.
[0082] Techniques for the manipulation of nucleic acids used to practice this invention, such as, e.g., subcloning, labeling probes (e.g., random-primer labeling using Klenow polymerase, nick translation, amplification), sequencing, hybridization and the like are well described in the scientific and patent literature, see, e.g., Sambrook, ed., MOLECULAR CLONING: A LABORATORY MANUAL (2ND ED.), Vols. 1-3, Cold Spring Harbor Laboratory, (1989); CURRENT PROTOCOLS IN MOLECULAR BIOLOGY, Ausubel, ed. John Wiley & Sons, Inc., New York (1997); LABORATORY TECHNIQUES IN BIOCHEMISTRY AND MOLECULAR BIOLOGY: HYBRIDIZATION WITH NUCLEIC ACID PROBES, Part I. Theory and Nucleic Acid Preparation, Tijssen, ed. Elsevier, N.Y. (1993).
[0083] Another useful means of obtaining and manipulating nucleic acids used to practice the methods of the invention is to clone from genomic samples, and, if desired, screen and re-clone inserts isolated or amplified from, e.g., genomic clones or cDNA clones.
[0084] Sources of nucleic acid used in the methods of the invention include genomic or cDNA libraries contained in, e.g., mammalian artificial chromosomes (MACs), see, e.g., U.S. Pat. Nos. 5,721,118; 6,025,155; human artificial chromosomes, see, e.g., Rosenfeld (1997) Nat. Genet. 15:333-335; yeast artificial chromosomes (YAC); bacterial artificial chromosomes (BAC); P I artificial chromosomes, see, e.g., Woon (1998) Genomics 50:306-316; P 1-derived vectors (PACs), see, e.g., Kern (1997) Biotechniques 23: 120-124; cosmids, recombinant viruses, phages or plasmids.
[0085] Nucleic acids or nucleic acid sequences used to practice this invention can be an oligonucleotide, nucleotide, polynucleotide, or to a fragment of any of these, to DNA or RNA of genomic or synthetic origin which may be single-stranded or double-stranded and may represent a sense or antisense strand, to peptide nucleic acid (PNA), or to any DNA-like or RNA-like material, natural or synthetic in origin. Compounds use to practice this invention include “nucleic acids” or “nucleic acid sequences” including oligonucleotide, nucleotide, polynucleotide, or any fragment of any of these; and include DNA or RNA (e.g., mRNA, rRNA, tRNA, iRNA, shRNA) of genomic or synthetic origin which may be single-stranded or double-stranded; and can be a sense or antisense strand, or a peptide nucleic acid (PNA), or any DNA-like or RNA-like material, natural or synthetic in origin, including, e.g., iRNA, ribonucleoproteins (e.g., e.g., double stranded iRNAs, e.g., iRNPs). Compounds use to practice this invention include nucleic acids, i.e., oligonucleotides, containing known analogues of natural nucleotides. Compounds use to practice this invention include nucleic-acid-like structures with synthetic backbones, see e.g., Mata (1997) Toxicol. Appl. Pharmacol. 144: 189-197; Strauss-Soukup (1997) Biochemistry 36:8692-8698; Samstag (1996) Antisense Nucleic Acid Drug Dev 6: 153-156. Compounds use to practice this invention include “oligonucleotides” including a single stranded polydeoxynucleotide or two complementary polydeoxynucleotide strands that may be chemically synthesized. Compounds use to practice this invention include synthetic oligonucleotides having no 5′ phosphate, and thus will not ligate to another oligonucleotide without adding a phosphate with an ATP in the presence of a kinase. A synthetic oligonucleotide can ligate to a fragment that has not been dephosphorylated.
[0086] In alternative aspects, compounds used to practice this invention include genes or any segment of DNA or RNA involved in producing a polypeptide chain; it can include regions preceding and following the coding region (leader and trailer) as well as, where applicable, intervening sequences (introns) between individual coding segments (exons). “Operably linked” can refer to a functional relationship between two or more nucleic acid (e.g., DNA or RNA) segments. In alternative aspects, it can refer to the functional relationship of transcriptional regulatory sequence to a transcribed sequence. For example, a promoter can be operably linked to a coding sequence, such as a nucleic acid used to practice this invention, if it stimulates or modulates the transcription of the coding sequence in an appropriate host cell or other expression system. In alternative aspects, promoter transcriptional regulatory sequences can be operably linked to a transcribed sequence where they can be physically contiguous to the transcribed sequence, i.e., they can be cis-acting. In alternative aspects, transcriptional regulatory sequences, such as enhancers, need not be physically contiguous or located in close proximity to the coding sequences whose transcription they enhance.
[0087] In alternative aspects, the invention comprises use of “expression cassettes” comprising a nucleotide sequence used to practice this invention, which can be capable of affecting expression of the nucleic acid, e.g., a structural gene or a transcript (e.g., encoding a DRP or antibody) in a host compatible with such sequences. Expression cassettes can include at least a promoter operably linked with the polypeptide coding sequence or inhibitory sequence; and, in one aspect, with other sequences, e.g., transcription termination signals. Additional factors necessary or helpful in effecting expression may also be used, e.g., enhancers.
[0088] In alternative aspects, expression cassettes used to practice this invention also include plasmids, expression vectors, recombinant viruses, any form of recombinant “naked DNA” vector, and the like. In alternative aspects, a “vector” used to practice this invention can comprise a nucleic acid that can infect, transfect, transiently or permanently transduce a cell. In alternative aspects, a vector used to practice this invention can be a naked nucleic acid, or a nucleic acid complexed with protein or lipid. In alternative aspects, vectors used to practice this invention can comprise viral or bacterial nucleic acids and/or proteins, and/or membranes (e.g., a cell membrane, a viral lipid envelope, etc.). In alternative aspects, vectors used to practice this invention can include, but are not limited to replicons (e.g., RNA replicons, bacteriophages) to which fragments of DNA may be attached and become replicated. Vectors thus include, but are not limited to RNA, autonomous self-replicating circular or linear DNA or RNA (e.g., plasmids, viruses, and the like, see, e.g., U.S. Pat. No. 5,217,879), and can include both the expression and non-expression plasmids. In alternative aspects, the vector used to practice this invention can be stably replicated by the cells during mitosis as an autonomous structure, or can be incorporated within the host's genome.
[0089] In alternative aspects, “promoters” used to practice this invention include all sequences capable of driving transcription of a coding sequence in a cell, e.g., a mammalian cell such as a brain cell. Thus, promoters used in the constructs of the invention include cis-acting transcriptional control elements and regulatory sequences that are involved in regulating or modulating the timing and/or rate of transcription of a gene. For example, a promoter used to practice this invention can be a cis-acting transcriptional control element, including an enhancer, a promoter, a transcription terminator, an origin of replication, a chromosomal integration sequence, 5′ and 3′ untranslated regions, or an intronic sequence, which are involved in transcriptional regulation. These cis-acting sequences typically interact with proteins or other biomolecules to carry out (turn on/off, regulate, modulate, etc.) transcription.
[0090] “Constitutive” promoters used to practice this invention can be those that drive expression continuously under most environmental conditions and states of development or cell differentiation. “Inducible” or “regulatable” promoters used to practice this invention can direct expression of the nucleic acid of the invention under the influence of environmental conditions or developmental conditions.
[0091] Cloning and transduction of pCDH vectors is described in the user manual for pCDH cDNA Cloning and Expression Lentivectors from System Biosystems, and which is incorporated herein by reference.
[0092] Methods related to ADAR1 as it relates to cancer stem cells, including full transcriptome RNA sequencing, assays and the like are disclosed in WO 2013/036867 and Jiang et al., Proc. Natl Acad Sci USA 2013, 110(3):1041-1046, which are incorporated herein by reference.
[0093] RNA Editing Site-Specific qPCR is described in Ye S, Dhillon S, Ke X, Collins A R & Day I N (2001) An efficient procedure for genotyping single nucleotide polymorphisms. Nucleic Acids Res 29, E88, and Chen et al., Anal Biochem, 2008, 375(1):46-52. Other methods for determining RNA editing sites are disclosed in, for example, Chateigner-Bouting and Small, Nucl Acids Res, 2007, 35(17), e114 and Paz et al., Genome Res., 2007, 17(11):1586-1595.
Kits and Instructions:
[0094] The invention provides kits comprising compositions and/or instructions for practicing methods of the invention. As such, kits, cells, vectors, primers, and the like can also be provided. In alternative embodiments, the invention provides kits comprising: a composition used to practice a method of any of the invention, or a composition, a pharmaceutical composition or a formulation of the invention, and optionally comprising instructions for use thereof.
Detailed Methods
Primary Samples and Tissue Processing:
[0095] A large collection of leukemia patient samples and normal age-matched control bone marrow samples were obtained from consenting patients. Peripheral blood or bone marrow samples were processed by Ficoll density centrifugation and viable cells stored in liquid nitrogen. Normal peripheral blood mononuclear cells (MNC) were obtained from AllCells (Alameda, Calif.). Mononuclear cells from normal or CML patients were then further purified by magnetic bead separation of CD34 + cells (MACS; Miltenyi, Bergisch Gladbach, Germany) for subsequent FACS-purification of hematopoietic progenitor cells (CD34 + CD38 + Lin − ) that represent the LSC fraction in BC CML (Jamieson et al.). Datasets from previous RNA-seq analyses of purified CML LSC are available through the NIH Sequence Read Archive (SRA), accession ID SRP028528.
Primary CSC Purification:
[0096] For primary patient-derived LSC purification, CD34-selected cells were stained with fluorescent antibodies against human CD34, CD38, lineage markers (cocktail, all antibodies from BD Biosciences, San Diego, Calif.) and propidium iodide as previously described (Jiang et al., Jamieson et al, and Abrahamsson et al.). Following staining, cells were analyzed and sorted using a FACS Aria II, and hematopoietic progenitor (CD34 + CD38 + Lin − ) populations were isolated. Freshly-sorted cells were collected in lysis buffer (Qiagen, Germantown, Md.) for RNA extraction followed by RNA-seq or qRT-PCR analyses as previously described (Jiang et al.).
High-Fidelity PCR and Sanger Sequencing Analysis:
[0097] For PCR and targeted Sanger sequencing analysis, 1-2 μL of first-strand cDNA templates were prepared for PCR in 25-50 μL reaction volumes using the high-fidelity KOD Hot Start DNA Polymerase kit according to the manufacturer's instructions (EMD Millipore, Temecula, Calif.). “Outer” primers (Additional file 2: Table S2) used for sequencing produce predicted amplicons of approximately 150-250 nucleotides in length, and flank each editing site with approximately 50-100 bp on either side of the editing site to facilitate successful sequencing analysis. PCR cycling conditions were as follows: 95° C. for 2 minutes, followed by 35 cycles of 95° C. for 20 seconds, 62° C. for 10 seconds and 70° C. for 10 seconds, with a final extension step of 70° C. for 30 seconds. Production of amplicons of the predicted size was verified for each outer primer set by DNA gel electrophoresis using 10-20 μL of the completed reaction mixture separated on 2% agarose gels containing ethidium bromide and visualized under UV light. Then, 15 μL of each reaction was processed within 24 hrs for PCR purification and sequencing was performed on ABI 3730xl DNA Sequencers (Eton Bioscience, San Diego, Calif.). Sanger sequencing was carried out using the reverse outer primer used for PCR amplification, so edited loci are identified in the reverse complementary sequence as T/C nucleotides, except in cases where the gene products are transcribed from the reverse strand. Sequence chromatograms were analyzed using 4Peaks (by A. Griekspoor and Tom Groothuis) and peak heights calculated using ImageJ (NIH). For RNA editing analysis of sequencing chromatograms, ratios of edited/WT peaks were calculated using the raw peak amplitude of each sequence trace.
Cell Lines and Culture Conditions:
[0098] K562 cells (ATCC, Manassas, Va.) were maintained in complete medium containing DMEM (Life Technologies, Carlsbad, Calif.), 10% fetal bovine serum (FBS), 1% Glutamax (Life Technologies), and 1% penicillin-streptomycin (Life Technologies). Parental cell lines and stably-transduced lines were authenticated as K562 by routine qRT-PCR analysis of BCR-ABL transcript levels (Jiang et al.). Mouse bone marrow stromal cell lines (SL and M2) expressing human interleukin-3 (IL-3), stem cell factor (SCF) and granulocyte-colony stimulating factor (G-CSF), which support erythroid and myeloid cell expansion and differentiation, were maintained under standard culture conditions, as previously described (Hogge et al.). Briefly, SL cells were grown in complete medium containing DMEM, 10% FBS, 1% Glutamax, and 1% penicillin-streptomycin, while M2 cells were grown in complete medium containing RPMI, 10% FBS, 1% Glutamax, and 1% penicillin-streptomycin (all from Life Technologies). Every four passages, cells were selected by addition of G418 and hygromycin to the culture media for one passage (3-4 days), to maintain human cytokine expression (Hogge et al.). All cell lines were maintained in T-25 or T-75 culture flasks and were passaged at dilutions of 1:5-1:10 every 2-4 days. Low passage aliquots of cells were thawed every two months to ensure consistency of experiments.
Lentiviral Vector Preparation and ADAR1 Site-Directed Mutagenesis:
[0099] We have previously characterized lentiviral vectors (Thermo Scientific) for overexpression of human ADAR1 p150-IRES-GFP (Jiang et al.). For production of the catalytically-inactive ADAR1 mutated (ADAR1m) lentivirus, site-directed mutagenesis was carried out using the QuikChange II Site-Directed Mutagenesis Kit (Agilent) according to manufacturer's instruction. Mutagenic primers were designed to produce a nucleotide substitution of A5293C, which generates an E912A amino acid change and abolishes RNA editase activity (Lai et al.). Primers contained the desired mutation and anneal to the same sequence on opposite strands of the plasmid [(FW 5′-GTCAATGACTGCCATGCAGCAATAATCTCCCGG-3′ (SEQ ID NO:53), REV 5′-CCGGGAGATTATTGCTGCATGGCAGTCATTGAC-3′ (SEQ ID NO:54)]. XLI super competent cells were transformed with amplification products, after digestion with DpnI. Colonies were screened to identify mutated clones by DNA sequencing (Sanger sequencing, Eton Bioscience). Lentiviruses including control vectors (ORF) were produced according to established methods (Goff et al.) with some batches of lentivirus being produced by the GT3 Viral Vector Core Facility (UCSD). We have previously validated lentivirus transduction efficiency in normal cord blood, 293T cells and K562 cells, with an increase of approximately five-fold overexpression of ADAR1 transcripts confirmed by qRT-PCR analysis (Jiang et al).
[0000] Transduction of Human Cell Lines and Primary Cells with Lentiviral-ADAR1:
[0100] For preparation of stably-transduced K562 cell lines, 50,000 wild-type (wt) K562 cells were plated into 96-well U-bottom plates in complete culture medium and transduced with lentiviral vectors expressing GFP (ORF), ADAR1-GFP, or ADAR1m-GFP at multiplicities of infection (MOI) from 50-200. After transduction, cultures were expanded for at least 5 passages and then processed for FACS purification of GFP-positive cells to establish pure stably-transduced lines. Stable expression of lentivirus-enforced ADAR1 conferring increased transcript levels of human ADAR1 in K562-ADAR1 cells was confirmed at every 5 passages by qRT-PCR.
[0101] For transduction of human normal HSC and CML progenitors, 50,000 CD34-selected (MACS, Miltenyi, Auburn, Calif.) cells were plated in 96-well U-bottom plates in StemPro media (Life Technologies) supplemented with human cytokines (IL-6 10 ng/mL, FLT3 50 ng/mL, SCF 50 ng/mL, and Tpo 10 ng/mL) as previously described Jiang et. al and Abrahamsson et al. Twenty-four hours later, cells were transduced with lentiviral vectors (ADAR1 or ORF control, MOI=50-100) for up to five days. For co-culture experiments, CD34-selected CP CML cells were transferred three days after transduction (MOI=75) to monolayers of mouse bone marrow stromal cell cultures containing a 1:1 mixture of irradiated SL and M2 cells (50,000 total stromal cells per well in 24-well plates) (Goff et al.). Primary transduced cells were maintained in co-culture for 5-days in Myelocult (Stem Cell Technologies, Vancouver, Canada) and then the total culture was harvested in lysis buffer for RNA extraction and qRT-PCR and RESSq-PCR analyses.
Generation of a Stable ADAR1 RNA Editing Detection Model System:
[0102] For purification of stably-transduced K562 cell lines, K562 cells transduced with lentiviral-ADAR1 or ORF controls (MOI=50-200) were collected (minimum 1×10 6 cells), washed in HBSS containing 2% FBS (staining media), and sorted using a FACS Aria II for high GFP signal to purify the highly-transduced cell population. Purified cells were collected in complete media and maintained under routine culture conditions for K562 cells. The lentiviral-ORF and ADAR1 vectors include a blasticidin-resistance gene, but we observed no significant change in ADAR1 expression in our stably-transduced cell lines following selection with blasticidin, and therefore no subsequent selection method was used after FACS purification.
Nucleic Acid Isolation, Reverse Transcription and Quantitative RT-PCR:
[0103] Cell lines, lentivirus-transduced primary hematopoietic cells, or FACS-purified primary cells were harvested in lysis buffer (Qiagen). RNA was purified using RNeasy extraction kits with a DNase (Qiagen) incubation step to digest any trace genomic DNA present. For RNA extraction from cell line lysates, 1-2×10 6 cells were extracted using RNeasy mini columns, and for primary cells, 5-10×10 4 cells were lysed and extracted using RNeasy micro columns. Genomic DNA was purified from equal numbers of cells lysed separately using the QIAamp DNA Blood Mini Kit (Qiagen) including an RNase A incubation step to digest any RNA present (Qiagen). RNA was stored at −80° C. and gDNA stored at −20° C. Immediately prior to reverse transcription of RNA samples, nucleic acid concentrations were quantified on a NanoDrop 2000 spectrophotometer (Thermo Scientific), and purity was considered acceptable if A260/A280 values were >1.8. For standard qRT-PCR analysis of relative mRNA expression levels, DNA was synthesized using 50 ng-1 μg of template RNA in 20 μL reaction volumes using the First-Strand SuperScript III Reverse Transcriptase Supermix (Life Technologies) followed by incubation with RNase H according to the manufacturer's protocol and as described previously (Abrahamsson et al.). All cDNA products were stored at −20° C.
[0104] Because RNA editing events often occur in pre-processed RNA species, for cDNA preparation, we tested three different conditions, including (1) reverse transcription with gene-specific primers, (2) random hexamer primers only, or (3) a supermix containing both random hexamers and oligo-dT primers. Using cDNA prepared with all three methods was suitable for detection of intronic regions in cDNA prepared from DNase-digested RNA extracts, and detected increased RNA editing in K562-ADAR1 cells. We therefore proceeded with the standard supermix reverse transcription method for RESSq-PCR, as this would provide the most versatility for use of valuable human tissue samples and would allow analysis of total mRNA expression of other genes in the same samples.
[0105] Primers were synthesized by ValueGene (San Diego, Calif.) and diluted to 10 μM working dilutions in DNase/RNase-free water. qRT-PCR was performed in duplicate using cDNA (1 μL reverse transcription product per reaction) on an iCycler (Bio-Rad, Hercules, Calif.) using SYBR GreenER Super Mix (Life Technologies) in 25-μL volume reactions containing 0.2 μM of each forward and reverse primer. Cycling conditions were as follows: 50° C. for 2 minutes, then 95° C. for 8 minutes and 30 seconds, followed by 40 cycles of 95° C. for 15 seconds and 60° C. for 60 seconds. Melting curve analysis was performed on each plate according to the manufacturer's instructions. For standard qRT-PCR, HPRT mRNA transcript levels were used to normalize Ct values obtained for each gene, and relative expression levels were calculated using the 2 −ddCt method. To ensure validity of results, only Ct values <35 were used in gene expression analyses. All primer sets were tested in a no-template control (NTC) reaction containing only water instead of cDNA, and all gave Ct values >35 in NTC reactions. Production of a single amplicon of the expected size was verified for each primer set by DNA gel electrophoresis on 2% agarose gels containing ethidium bromide. For all cell line experiments, assays were repeated at least three times using separate RNA extracts and cDNA preparations.
RNA Editing Fingerprint Assay:
[0106] In order to implement a rapid, cost-effective and clinically amenable method to detect a CSC-specific RNA editing fingerprint of cancer progression, we devised an RNA editing site-specific primer design strategy that is compatible with SYBR green qRT-PCR protocols (RESSq-PCR). Since RNA-edited transcripts are predicted to differ from wild-type (WT) sequences at only one nucleotide position, detection of RNA editing by qRT-PCR requires highly sensitive and selective primer design strategies. We have previously developed qRT-PCR primers that specifically recognize a gene product with a single point mutation (JAK2 V617F (Geron et al.), and here we employed a similar approach in designing RESSq-PCR primers. Allele-specific PCR strategies, based on positioning the 3′ base of a PCR primer to match one variant allele, have been used for the detection of SNPs and mutations in human genomic DNA or cDNA Ye et al., however are not routinely used in quantitative detection of RNA single nucleotide modifications.
[0107] The RESSq-PCR assay primer design was applied to specific cancer and stem cell-associated loci ( FIG. 14 ). Efficiency of all primer sets ( FIG. 16 and Table was tested using serial dilutions of K562-ADAR1 cDNA. Primer sets were tested experimentally for human specificity and were considered to be human-specific if they returned Ct values >35 in cDNA prepared from mouse bone marrow stromal cell controls. Editing site-specific primers for some loci ( FIG. 14 ) either failed to discriminate between cDNA and gDNA, or K562-ADAR1 cells did not display increased editing by Sanger sequencing, and therefore were not continued for assay development. RESSq-PCR was performed in duplicate using cDNA (1-5 μL reverse transcription product per reaction) or gDNA (10-200 ng input gDNA) on an iCycler (Bio-Rad) using SYBR GreenER Super Mix (Life Technologies) in 25-μL volume reactions containing 0.2 μM of each forward and reverse primer. Cycling conditions were the same as for standard qRT-PCR. Relative RNA editing rates (Relative edit/WT RNA) were calculated using the following calculation: 2 −(Ct Edit-Ct WT) .
Statistical Methods:
[0108] qRT-PCR data were measured as a continuous outcome and each group was assessed for distribution. For normally distributed data, the Student's t-test was applied to compare differences in RNA expression and editing ratios calculated by Sanger sequencing and RESSq-PCR, and values are expressed as means±SEM. Experiments were performed in triplicate on blind-coded samples, and all statistical analyses were performed using GraphPad Prism (San Diego, Calif.).
REFERENCES
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Jamieson C H, Ailles L E, Dylla S J, Muijtjens M, Jones C, Zehnder J L, Gotlib J, Li K, Manz M G, Keating A, et al: Granulocyte-macrophage progenitors as candidate leukemic stem cells in blast-crisis CML. N Engl J Med 2004, 351:657-667.
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[0124] A number of embodiments of the invention have been described. Nevertheless, it will be understood that various modifications may be made without departing from the spirit and scope of the invention. Accordingly, other embodiments are within the scope of the following claims. | Compositions and methods for expanding CD34+ cells, performing research related to cancer stem cells, RNA-editing enzymes and for monitoring, diagnosing and treating, ameliorating and preventing diseases such as cancers or inflammatory diseases. | 2 |
CROSS-REFERENCE TO RELATED APPLICATION
This application is a continuation application of U.S. Ser. No. 08/171,726, filed on Dec. 22, 1993, now U.S. Pat. No. 5,461,839.
FIELD OF THE INVENTION
This invention relates to sheathing materials used on the exterior surfaces of buildings, and particularly to exterior thermoplastic siding and procedures for making such siding more rigid.
BACKGROUND OF THE INVENTION
For decades, the exterior of many residential and commercial buildings has been protected by "finishing" or "sheathing" materials including wood, metal, and polymer resins. Metal sheathing, such as aluminum siding, was at one point very popular, since it was more insect- and weather-resistant than wood siding, and could be anodized, painted, or laminated to provide a plurality of colors and styles. Metal sheathing also proved to be long lasting and energy efficient, but because it could not be easily sawed, clipped, or drilled with hand tools, it was relatively labor intensive to install. Additionally, metal sheathing materials had to be extremely thin to be cost efficient, and, because of their inherent lack of ductility, were susceptible to dents by minor impact loads.
In more recent times, "vinyl siding", (which is actually a resinous composition containing polyvinyl chloride), has provided a cheaper and more impact-resistant material for exterior siding panels. This material can also be provided in a wide variety of colors and patterns, but is more flexible and forgiving, and hence, will not deform plastically under minor impact loads. Thermoplastics, like polyvinyl chloride, are also easy to machine and cut and can be worked with almost any hand tool at the construction site.
It has been found, however, that vinyl siding has not always been satisfactory as an exterior sheathing material for irregular exterior wall surfaces. Due to earlier poor construction techniques, material inconsistency, or foundation settling, exterior walls in both new and old constructions are not always flat. Since vinyl siding, as opposed to metal siding, is very flexible, it usually conforms to the irregularities of the wall surface, resulting in a crooked, bowed, or unpleasing finish.
In order to compensate for this deficiency in vinyl siding, installers frequently must resort to using wooden shims which must be separately nailed to the support surface before the siding can be installed. Attempts have also been made to loosely nail the siding to the support surface so that the siding will "float" over the uneven portions of the exterior wall. In order to float the siding over the irregularities, but still provide a relatively straight and orderly appearance, the panel must be fairly rigid so as to span high and low points along the wall. Unfortunately, polyvinyl chloride, even in its most rigid state, only has a flexural modulus of about 0.5×10 6 psi, and a tensile strength of about 1/7 of that of wrought aluminum.
Accordingly, there is a need for a thermoplastic-based siding panel that is more resistant to bending, or conforming to irregularities in exterior wall surfaces, but which retains its low cost and ability to be worked with ordinary hand tools at the construction site.
SUMMARY OF THE INVENTION
This invention provides exterior finishing panels having an anesthetically pleasing outwardly-facing surface. The panels include a rigid support member disposed along a portion of their length. This support member includes a flexural modulus, a measure of the materials "stiffness", which is greater than the flexural modulus of the thermoplastic sheet.
Accordingly, this invention provides vinyl siding which is stiffer and more resistant to bending along cracked, pitted, or bowed exterior wall surfaces than standard vinyl siding. The siding panels of this invention are reinforced, much like reinforced concrete is supported against tensile loads by steel rebar, to obtain a better "floating" effect along irregular surfaces. The panels are easier to handle, since they are not as susceptible to bending, and they are easier to install, since a rigid straight panel will lock into another rigid straight panel with less effort on a more consistent and predictable basis.
The exterior siding of this invention is able to ride uneven walls straighter, and presents a finished appearance which is flatter looking. The rigid panels will also provide the homeowner with a stronger and more rigid feel when the owner presses up against these newly-installed panels. Since the panels are stiffer, they can be provided in longer lengths over the current 12 foot standard length, with little chance of kinking. Since the preferred support members of this invention are also engineering thermoplastics themselves, they can be sawed with conventional hand tools, which will avoid unnecessary additional labor costs. As an additional benefit, the reinforced exterior siding panels of this invention are less resistant to wind damage and "blow offs", since the rigid supports will tend to distribute the wind load more efficiently to all of the nail heads.
In more preferred embodiments of this invention, siding panels are provided which include a plurality of elongated, simulated board members formed in an extruded sheet containing a rigid polyvinyl chloride. The panels of this embodiment include hook-and-groove fastening means for permitting the siding panel to be joined in overlapping fashion to an adjoining panel. These panels also include a preferred rigid support member including a flexural modulus which is relatively greater than the flexural modulus of the rigid polyvinyl chloride of the extruded sheet. The support member contains a polymer-matrix-composite which can be sawed with a standard saw blade made of steel.
The rigid support members of this invention can be fabricated from a multitude of materials including metal, thermoplastic, or thermosetting polymers and can be adhered to an inwardly-facing surface of the panel, extruded within the thickness of the thermoplastic sheet of the panel, or otherwise applied to the panel to reinforce it during handling, installation and use.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings illustrate preferred embodiments of the invention, as well as other information pertinent to the disclosure, in which:
FIG. 1: is a partial side perspective view of a conventional siding installation, illustrating locking hook-and-groove panels;
FIG. 2: is a partial, side perspective view of a preferred exterior siding panel having a rigid support member disposed along a portion of its length;
FIG. 3: is a partial, side perspective view of an alternative embodiment for the exterior siding panel of this invention;
FIGS. 4(a)-(f): are partial, side perspective cross-sectional, views of alternate constructions for the rigid support member of this invention;
FIG. 5: is a partial, side perspective view of an alternative embodiment for the exterior siding panel of this invention;
FIG. 6: is a partial side perspective view of another alternative embodiment exterior siding panel of this invention;
FIG. 7: is a partial, side perspective view of a preferred reinforcing tape of this invention;
FIG. 8: is a partial, side view of a preferred exterior siding panel of this invention including the reinforcing tape of FIG. 7;
FIG. 9: is a partial, side view of an alternative exterior siding panel of this invention including the reinforcing tape of FIG. 7;
FIG. 10: is a partial, side view of an alternative exterior siding panel construction of this invention, including a rigid support member which has been co-extruded with the thermoplastic sheet of the panel;
FIG. 11: is a partial, side view of an alternative exterior siding panel whereby a plurality of rigid support members are co-extruded with the thermoplastic sheet;
FIG. 12: is a side, cross-sectional view of a further exterior siding panel construction of this invention which includes a number of co-extruded, rigid support members located along the width of the thermoplastic sheet; and
FIGS. 13(a)-(d): are partial side plan views of exterior siding panel embodiments showing alternative placements for the reinforcing member along the siding panel.
DETAILED DESCRIPTION OF THE INVENTION
Exterior finishing panels are provided by this invention which include a thermoplastic sheet reinforced with a rigid support which greatly stiffens the panel without significantly detracting from its low cost or ability to be worked with conventional carpentry tools, such as steel drill bits and saw blades used in woodworking. As used herein, "finishing panels" refer to exterior finishing layers, such as soffits, vertical and horizontal siding, and accessories.
With reference to the Figures, and particularly to FIGS. 1 and 2, there is shown a prior art siding panel 10 having a pair of simulated board members bound by a lateral flange located at the bottom of the top board member. The panel 10 also includes hook-and-groove fastening means for permitting it to be joined in overlapping fashion to an adjoining panel.
In a first embodiment of this invention, a siding panel 20 is provided having a hook-like lip 21 along the top portion of the panel 20. As shown in FIG. 2, this hook-like lip 21 forms a longitudinal aperture of about 0.125-0.50 inches in diameter along the panel's length. In this embodiment, a tubular rigid support member 25 is inserted into this aperture substantially along the length of the panel.
As described in FIG. 4, the rigid support member can take on a number of various cross-sectional configurations, that are only limited by design parameters. To save weight, and to optimize manufacturability or performance, the rigid support member can include an I-beam configuration 29, U-shaped configuration 28, or tubular configuration 25. Alternatively, a solid square or circular configuration 27 and 26 can be employed with similar effect.
As shown by the panel embodiment 30 in FIG. 5, a customized cross-sectional configuration can be designed to fit within a non-geometric, cross-sectional hollow space of hook-like lip 31, as shown in FIG. 5. This irregularly shaped, rigid support member 32 can be inserted to form a frictional fit in the contour of the hollow space. It is understood that the rigid support need not fill the entire cavity of the hook-like lip, and this is illustrated in FIG. 6, in which the U-shaped insert 28 is designed to fill only about half of the cavity formed by the marginal hook-like lip 33. This would provide more "give" to the lip of panel 37 for easier insertion of an adjoining panel.
Panel embodiments 20, 30, and 37 all describe a confined aperture, into which the rigid support member 25 can be inserted through a transverse end opening of the panel at the factory or construction site. In FIG. 3, the panel 22 exhibits a free end terminating to form a longitudinal slot for accepting rigid support member 25, which can be merely slipped under the lip 23. This hook-like lip 23, unlike those earlier described, provides for the facilitated introduction of the rigid support member 25, since the support member 25 can be merely pushed upwardly, beneath the lip 23, without the need for telescoping it through the entire length of the hollow space. The resiliency of the hook-like lip 23 will cause a clamping action that will aid in the insertion of the rigid support member 25 into the described longitudinal aperture. Those of ordinary skill in the art will understand that the siding panels of this invention can be extruded or molded into a variety of shapes and sizes, exhibiting various contours and aesthetic appearances. The hook-like lip portion can define a closed loop, or an open loop having its slot facing into the panel surface, or facing outwardly away from the panel surface. Other designs will be dictated by the individual application to be tackled.
With reference to FIGS. 7-9, additional embodiments are described in which the rigid support member consists of a reinforcing tape. In the preferred embodiment described in FIG. 7, the reinforcing tape 34 comprises an adhesive 35 and a plurality of reinforcing threads, diagrammatically depicted as dotted lines. These threads can be one of a number of reinforcing agents available commercially, including glass, nylon, graphite, or aramid fibers.
As shown in FIG. 8, a panel is provided having a hook-like lip portion as substantially described above in FIG. 2, but instead of a rigid tubular support 25, a piece of reinforcing tape 40 is adhered to the inner surface of the cavity to reinforce the lip and provide greater stiffness to the overall panel 36.
An alternative embodiment is described in FIG. 9, in which a pair of reinforcing tape pieces 42 are disposed along the lateral marginal flanges of the individual board members of panel 38. Preferably, the tape is disposed so that its reinforcing fibers, or threads, are located along the longitudinal axis of the panel, although some measure of increased stiffness over the panel itself can be accomplished by locating the tape transversely or obliquely to this longitudinal axis. The tape can also contain a woven grid or random orientation of fibers. It may also be advantageous to provide a double-sided adhesive tape that could be used to simultaneously stiffen the siding panel, while helping to adhere the panel against the high spots on the supporting wall. The tape may be located at selected profile positions or encompass an entire panel surface.
Preferred adhesive compositions for the tape of these embodiments of this invention include those containing an elastomeric blend of selected rubber olefin terpolymer, plasticizer, reinforcing filler, tackifier and stabilizer. Other compositions suitable for this application include water-based, pressure-sensitive adhesives, such as acrylate adhesives, thermoplastic "hot melt" adhesives, and those adhesives containing natural or synthetic rubbers. Such compositions should be suitably tacky at temperatures ranging from about -50° F. to about 150° F. The tape may also be applied with heat, taking advantage of thermal properties by creating a melt bond.
As shown in FIGS. 10-12, the thermoplastic sheet of the panel can be co-extruded or molded with the rigid support member to form an integral composite. In the embodiment described in FIG. 10, the rigid support member 51 is located in the hook-like lip of panel 50. The support member 51, like the tubular rigid support member 25 in FIG. 2, can be disposed substantially along the longitudinal edge of this lip so as to provide greater stiffness to both the lip and the panel. In the panel embodiment 52 described in FIG. 11, several rigid support members 53 are disposed longitudinally along the lip to provide even greater rigidity, and more uniform support. This technique can be extended to the entire panel, as described in panel embodiment 54. In this version, a series of substantially parallel rigid support members 57 are disposed longitudinally throughout the width of the thermoplastic sheet 54. Although the support members 57 are depicted to be substantially parallel, there is no reason why they can not crisscross throughout the structure to provide even greater structural support. In fact, it is envisioned that fibers can be layered throughout the sheet of the panel to increase the rigidity and resistance to bending moments, much like glass and graphite fibers reinforce epoxy in polymer-matrix-composites ("PMCs"). The sheet can also contain woven and non-woven mats of fiber, such as glass fiber, embedded in the resin or adhered to the surface of the panel.
The preferred materials for use in connection with the panels of this invention will now be described. All of the panels of this invention contain resinous materials, such as thermoplastic and thermosetting resins. A preferred thermoplastic material for the panels of this invention is polyvinyl chloride (PVC). PVC thermoplastics comprise the largest volume of thermoplastic polymer in commercial use. With various plasticizers, fillers, stabilizers, lubricants, and impact modifiers, PVCs can be compounded to be flexible or rigid, tough or strong, to have high or low density, or to have any of a wide spectrum of physical properties or processing characteristics. PVC resins can also be alloyed with other polymers, such as ABS, acrylic, polyurethane, and nitrile rubber to improve impact resistance, tear strength, resilience, or processability. They can be produced water-white in either rigid or flexible compositions, or they can be pigmented to almost any color.
In the preferred embodiments of this invention, rigid PVC, containing very little plasticizer, is employed. This material is a hard and tough and can be compounded to have a wide range of properties, including impact resistance and weatherability. It also has a tensile strength of about 6,000-7,500 psi, a percent elongation of about 40-80%, and a tensile modulus of about 3.5-6.0×10 6 psi. It can be acceptably used without chlorination, to about 140° F., and with chlorination to about 220° F. It also has a coefficient of thermal expansion of about 5-10×10 -5 inch/inch-° C.
The siding panels of this invention can be injection molded, extruded and drawn, using customary manufacturing techniques for thermoplastic and thermosetting materials. In the preferred embodiment, a mixture of PVC pellets is heated and extruded through a die to produce panels having a length of about 4-20 feet, and preferably about 12 feet. These panels can contain multiple simulated boards for greater structural integrity and faster installation. The extruded thermoplastic sheets can include a pigment for coloration, and can be subject to further molding, calendaring, and finishing to provide a wood grain or fanciful texture.
The preferred rigid support members will now be described. As shown in FIG. 4(a)-(f), the rigid support members of this invention are preferably elongated members of narrow thickness or diameter, (preferably about 0.1-2.0 inches), that are distributed substantially along the length of the thermoplastic sheet in the siding panel. The preferred rigid supporting member should have a flexural modulus of at least about 50%, and preferably at least 100% greater than the flexural modulus of the thermoplastic sheet. Materials that would satisfy this requirement for PVC panels include wood, most metals, including brass, aluminum, steel, and many thermoplastic and thermoserring resins. Of these, reinforced PMCs show the most promise for this application, because of their high strength-to-weight ratio.
Unreinforced engineering thermoplastics typically have a tensile strength in the range of about 55-100 MPa (8×10 3 to 15×10 3 psi). The workhorse of engineering resins, unreinforced nylon 6/6, has a tensile strength of about 83 MPa (12×10 3 psi) and a tensile modulus of about 34 GPa (5×10 6 psi). However, unlike metals, such as aluminum or steel, stiffness in plastics is guided by the flexural modulus. In applications involving low strain, however, such as those found in vinyl siding, tensile and flexural moduli are close to being identical for design purposes.
It is known that by reinforcing thermoplastics and thermosets, the stiffness of these resins can be dramatically increased. Short glass fibers at 5-30% (by weight) boost the tensile strength of engineering plastics by about a factor of two; carbon fibers, even further.
On the high end of the composite material spectrum are advanced PMCs. Reinforced with high-modulus and high-strength graphite fibers, a unidirectional laminate typically has a tensile modulus of about 138-200 GPa (20-29×10 6 psi) and about a 1,138-1,552 MPa (165-225×10 3 psi) tensile strength. Other reinforcing fibers for advanced composites include boron, S-glass, E-glass, carbon fibers, long glass fibers, and aramid.
Advanced PMCs have higher specific strength and stiffness than most metals, and the ability to selectively place fibers for design versatility. Varying fiber orientation, concentration, and even generic fiber type, permits tailoring of stiffness and strength to a specific application. Braiding and weaving of the reinforcements have also been used to produce stronger components. Techniques using unreinforced liquid-crystal polymers (LCPs), high strength graphite fibers, polyphenylene benzobisthiazole (PBT), and polyphenylene benzobisoxozole (PBO) fibers have also produced high strength polymer-matrix-composites with environmental stability.
The preferred rigid support members of this invention contain thermoplastic materials. Preferred resins for the rigid support members can contain, for example, thermoplastic polyimides, polyesters, and nylons. Because of their inherently faster processing (no time-consuming curing or autoclaving) thermoplastic matrix-composites are beginning to replace conventional thermoset composites. Some current examples of processing techniques include lamination, filament winding, and pultrusion. Thermoforming, hot stamping of consolidated sheet, and roll forming processes are also promising techniques for producing the support members of this invention.
A comparison of the mechanical properties for selected polymer-matrix-composites, polyvinyl chloride, steel and aluminum is shown below in Table I.
TABLE I__________________________________________________________________________Mechanical Properties of Polyvinyl Chloride, UnidirectionalAdvanced PMCs.sup.1, Glass Fiber-Reinforced PMCs, Steel, and Aluminum Tensile Tensile Flexural Flexural Strength, × Modulus, × Strength, × Strength, × 10.sup.3 psi 10.sup.6 psi 10.sup.3 psi 10.sup.6 psi__________________________________________________________________________Boron/Epoxy 199 29.2 -- --Boron/Polyimide 151 32.1 -- --S-Glass/Epoxy 187 8.8 -- --High-ModulusGraphite/Epoxy 122 27.5 -- --High-ModulusGraphite/Polyimide 117 31.3 -- --High-StrengthGraphite/Epoxy.sup.2 218 21.0 -- --Aramid/Epoxy.sup.3 172 12.2 -- --High-StrengthGraphite/Epoxy.sup.4 220 16.0 -- --Polyvinyl Chloride (Rigid) 7.5 0.6 -- --Polyvinyl Chloride 1.5 -- -- --(Flexible)Glass/Comp. Molded 6.0 1.75 12.8 1.58Polyester BMC.sup.4Glass/Inj. Molded 4.86 1.53 12.65 1.44Polyester BMC.sup.4Glass/Comp. Molded 23.0 2.27 45.0 2.0Polyester SMC.sup.5Glass/Comp. Molded 12.0 1.7 26.0 1.6Polyester SMC.sup.5Glass/Comp. Molded 5.3 1.7 16.0 1.4Polyester SMC.sup.5Glass/Polyester Pultrusions 30.0 2.5 30.0 1.6Glass/Filament-Wound Epoxy 80.0 4.0 100.0 5.0Glass/Polyester, 12.5 1.0 27.0 0.75Spray-Up/Lay-UpGlass/Polyester, Woven 37.0 2.25 46.0 2.25Roving (Lay-UP)Cold-Rolled, 48.0 30.0 -- --Low Carbon Steel.sup.7Wrought Aluminum 49.0 10.2 -- --__________________________________________________________________________ .sup.1 Property values shown are in longitudinal direction; .sup.2 UNION CARBIDE THORNEL T300 fibers; .sup.3 DUPONT KEVLAR 49; .sup.4 Bulk molding compound; .sup.5 Sheet molding compound; .sup.7 SAE 1008.
As shown by the embodiments described in FIGS. 13(a)-(d), it is understood that the rigid support members of this invention can be inserted in apertures along the siding panels, adhered to an inwardly-facing surface of the panels, and/or molded or extruded integrally with the panel to reinforce it at a single location, or at multiple locations along its width.
From the foregoing, it can be realized that this invention provides stiffer exterior siding panels and methods for installing siding panels. These panels will have a greater ability to float over uneven wall surfaces with a minimum amount of distortion since they are reinforced substantially along their length to resist bending. The panels also preferably contain polymer-matrix-composites which can be cut and sawed with conventional hand tools at a construction site. Stiffer panels, possibly 300% stiffer than conventional vinyl siding can be produced, with a minimum amount of increased cost. These panels will be perceived as having a higher quality, since siding purchasers have associated stiffness as being a significant factor in quality measurement. Any additional cost generated by the addition of rigid support members is likely to be compensated by the reduction of waste normally associated with kinked panels and "blow offs" due to wind or rough handling. Although various embodiments have been illustrated, this was for the purpose of describing, and not limiting the invention. Various modifications, which will become apparent to one skilled in the art, are within the scope of the invention described in the attached claims. | Exterior finishing panels are provided which contain an elongated, thermoplastic sheet which is supported by a rigid support member disposed along a portion of the length of the sheet. The rigid support member has a flexural modulus which is significantly greater than the modulus of the thermoplastic sheet, so as to support the panel during handling and installation. The panels of this invention will be more kink-resistant, and will ride uneven walls better to present a flatter-looking finished wall surface. These panels are also capable of being worked with ordinary hand tools, such as a standard wood saw made of steel or carbide. | 4 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Application No. 61/243,585 filed Sep. 18, 2009.
[0002] U.S. provisional patent application 60/903,786 filed Feb. 27, 2007, U.S. non-provisional patent application Ser. No. 12/069,371 filed Feb. 8, 2008, and U.S. patent publication US2008/0202435, published Aug. 28, 2008, are incorporated herein by reference.
BACKGROUND
[0003] This specification relates to the field of remote monitoring and assessment, and more particularly to a remote monitoring addition for a ground-based game feeder.
SUMMARY OF THE INVENTION
[0004] A game feeder configured for remote monitoring, the game feeder comprising a feeder body comprising a container for holding feed, a motor configured to disperse the feed, and a motor relay configured to actuate the motor; a computer, the computer comprising a wireless driver configured to communicatively couple the computer to a wireless communication network; and a sensor array having a plurality of sensors adapted to provide data on a plurality of local conditions at the game feeder, the sensor array being communicatively coupled to the computer; wherein the computer is configured to receive the data on the plurality of local conditions from the sensor array and send the data on the plurality of local conditions to the wireless communication network.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] FIG. 1 is a network diagram disclosing a network topology of an embodiment of a remote monitoring system for a ground-based game feeder;
[0006] FIG. 1A is a network diagram disclosing a network topology of an alternative embodiment of a remote monitoring system for a ground-based game feeder;
[0007] FIG. 2 is a block diagram disclosing entry relations between components of a remote monitoring system for a ground-based game feeder; and
[0008] FIG. 3 is a block diagram of a single board computer used in one embodiment of a remote monitoring system for a ground-based game feeder.
[0009] FIG. 4A illustrates Applicant's game feeder with the varmint guard engaged therewith.
[0010] FIG. 4B illustrates Applicant's game feeder with the tray and skirt assembly engaged therewith.
[0011] FIGS. 5A-5E illustrate various views of Applicant's tray portion of the tray and skirt assembly.
[0012] FIGS. 6A-6E illustrate various views of Applicant's skirt portion of the tray and skirt assembly.
[0013] FIGS. 7A-7B illustrate detailed views of Applicant's water tank base for use in conjunction with the game feeder providing water to small game, such as quail.
[0014] FIGS. 8 , 8 A, and 8 B illustrate various views of Applicant's extra capacity insert.
DETAILED DESCRIPTION OF THE EMBODIMENTS
[0015] A remote monitoring system can enhance the benefits of a ground-based game feeder or other game feeder system. The advantages and operation of a ground based game feeder were described in the previous application. The remote monitoring system of the present application provides additional flexibility to the user of the ground-based game feeder. In general, the remote monitoring system includes an instrumentation suite that monitors local conditions around the game feeder. The instrumentation suite may include such elements as a rainfall sensor, barometer, thermometer, hydrometer, and camera. These sensors are selected to provide environmental data for the game feeder so that the user is aware of conditions at the hunting site. In particular, the camera may provide data as to which animals are approaching the game feeder. The camera can be selected to have a motion-activated trigger, so that it will take pictures when animals approach the feeder to feed. This allows the hunter to see which animals are feeding at the site and particularly to discover whether desirable game is available at the location. Advantageously, the present disclosure provides means for the hunter to receive information about the site conveniently and instantaneously. In contrast, without the benefits of the present disclosure, the hunter would have to physically travel to the location of the game feeder, download pictures, view sensor data, and program the feeder.
[0016] In one embodiment, the sensor array is connected to a single board computer or other similar computation device, which may be ruggedized or shielded for use in rough external environments. The single board computer may be powered by a rechargeable battery, which can be connected to solar panels for extended long term use. The single board computer also may be connected to an antenna that allows it to communicate with a cellular or other wireless network. For example, the antenna may place a single board computer in communication with a general packet radio open service (GPRS) server, which may provide access to the internet over a cellular network. The GPRS server may then relay traffic through the internet to a user workstation, where the user can use the workstation to access available sensor data, download pictures, view present and historical environmental conditions, program the feeder, and even instruct the feeder to take action such as drive a single, unscheduled disbursement of feed.
[0017] A remote monitoring system will now be described with more particular reference to the attached drawings. Hereafter, details are set forth by way of example to facilitate discussion of the disclosed subject matter. It should be apparent to a person of ordinary skill in the art, however, that the disclosed embodiments are exemplary and not exhaustive of all possible embodiments. Throughout this disclosure, a hyphenated form of a reference numeral refers to a specific instance or example of an element and the un-hyphenated form of the reference numeral refers to the element generically or collectively. Thus, for example, 102 - 1 may refer to a “pen,” which may be an instance or example of the class of “writing implements.” Writing implements may be referred to collectively as “writing implements 102 ” and any one may be referred to generically as a “writing implement 102 .”
[0018] FIG. 1 discloses a network topology of an embodiment of a monitoring system for a ground-based game feeder. As disclosed in this drawing, a ground-based game feeder 100 is provided with an instrumentation suite 110 and an antenna 112 . The instrumentation suite 110 collects environmental and other useful data, which can be relayed through antenna 112 to a cellular tower 120 . Although a cellular tower and a cellular network are disclosed, it should be noted that the methods of the present disclosure could also be used with any suitable wireless technology, such as satellite technology, ad-hoc wireless networks, such as IEEE 802.11 or Bluetooth, and other similar wireless technologies. In this exemplary embodiment, cellular tower 120 relays network traffic to GPRS server 132 . GPRS server 132 is operated by a GPRS service provider 130 . GPRS server 132 translates traffic on the cellular network into internet traffic. GPRS server 132 then forwards appropriate data packets through internet 180 to user workstation 140 , which is operated by user 150 . Under the disclosed configuration, user 150 is able to communicate with ground-based game feeder 100 via workstation 140 . Communication between user 150 and ground-based game feeder 100 may be bidirectional and can include transfer of data, transfer of commands, and remote control.
[0019] FIG. 1A discloses a network topology of an alternative embodiment of a monitoring system for a ground-based game feeder. In this embodiment, user 150 uses workstation 140 to log into a remote server 190 through internet 180 . User 150 may then issue commands to and receive data from ground-based game feeder 100 . For example, a command from user 150 may be transmitted from workstation 140 through internet 180 to remote server 190 . Remote server 190 may send the command through internet 180 to a Short Message Service (SMS) server 135 , operated by a SMS service provider 136 . The SMS server 135 translates internet traffic into traffic on the cellular network, forwarding appropriate data packets to cellular tower 120 . Antenna 112 of ground-based game feeder 100 receives transmissions from cellular tower 120 . The command from user 150 may instruct the ground-based game feeder 100 to take action; for example, user 150 may instruct ground-based game feeder 100 to take measurements with instrumentation suite 110 , such as taking a picture or measuring the temperature, or to disburse feed. It should be noted that the methods of the present disclosure could use different wireless technologies for sending and receiving data. For example, ground-based game feeder 100 may transmit pictures and environmental and other useful data using GPRS, but may receive commands and remote control instructions using SMS.
[0020] FIG. 2 is a block diagram of a remote monitoring system for a ground-based game feeder. Ground-based game feeder 100 includes a motor 220 , which is configured to disburse feed upon receipt from a signal. Motor detector 222 is connected to motor 220 and provides feedback data for monitoring the functionality of motor 220 . A motor control relay 224 is connected to motor 220 , and provides the necessary signal for motor 220 to disburse feed. Motor control relay 224 actuates motor 220 , causing the disbursal of feed. A single board computer 210 connects to motor control relay 224 to provide the necessary signal to cause motor control relay 224 to actuate motor 220 . Single board computer 210 is connected to antenna 112 , through which single board computer 210 is enabled to communicate with a wireless network. While a single board computer 210 is disclosed as an exemplary embodiment, any suitable control device could be used. For example, a simple off-the-shelf computer could be used in place of single board computer 210 . Single board computer 210 is also connected to a sensor array 250 . Sensor array 250 may include a plurality of environmental and other sensors. For example, sensor array 250 may include such sensors as a rainfall sensor 252 , a barometer 254 , a camera 256 , a thermometer 258 , and a hydrometer 259 . The suite of instruments in sensor array 250 are selected in this case to provide data that are useful to a hunter wanting to monitor ground-based game feeder 100 . For example, rainfall sensor 252 will provide information on the rate of rainfall in the area and when it is actually raining. Barometer 254 may be used to assess current weather patterns. Thermometer 258 may be used to assess current temperature. A hydrometer may be used to indicate relative humidity and camera 256 may include a motion activated sensor, which will permit camera 256 to take pictures of animals approaching ground-based game feeder 100 . This may permit the hunter to determine whether there is desirable game feeding at the game feeder, and to assess hunting conditions.
[0021] The camera 256 in FIG. 2 may have several modes of operation which may be selected by user 150 . For example, the modes of operation of camera 256 may include a mode for taking pictures at a fixed time interval, a mode for taking pictures when feed is being disbursed, and a mode for taking pictures when the motion activated sensor is triggered. Each mode of operation of camera 256 may have several programmable settings. For example, in the mode for taking pictures at a fixed time interval, the time interval may be programmable. In the mode for taking pictures when the motion activated sensor is triggered, there may be a programmable start time and total duration time, which may allow the camera 256 to take pictures at times when the desirable game is more active. Each mode of operation of camera 256 may also include a programmable delay interval to allow time between photographs for transmitting the photographs to the cellular tower 120 . Typically, a delay interval of 5 minutes is sufficient to transmit a low resolution picture over GPRS. The mode of operation for camera 256 and the programmable settings may be remotely modified by user 150 .
[0022] Single board computer 210 , motor 220 and other components can be powered by power supply 230 . For example power supply 230 may be a 12-volt DC power supply, which may include a rechargeable battery in order to maximize the ability of ground-based game feeder 100 to operate for extended periods of time without intervention. A solar array 240 may be provided to recharge power supply 230 . The level of power in power supply 230 may be monitored by the single board computer 210 and transmitted to user 150 via remote server 190 or workstation 140 . For example, the ground-based game feeder 100 may periodically transmit a communication with system information or statistics, part of which may be power level information. If the power level of power supply 230 is low, a sleep instruction may be sent to ground-based game feeder 100 . The sleep instruction may be automatically transmitted by remote server 190 or workstation 140 , or manually transmitted by user 150 .
[0023] FIG. 3 discloses a block diagram of single board computer 210 in an exemplary embodiment of a remote monitoring system for a ground-based game feeder. Single board computer 210 is controlled by a processor 310 which connects to other system components via a system bus 370 . Processor 310 may be any kind of suitable processing device, such as a microprocessor, digital signal processor, field-programmable gate array, applications-specific integrated circuit, or the like. In some embodiments, processor 310 may also be directly connected to a memory 350 , thereby providing direct memory access. In some embodiments, memory 350 may be a high-speed volatile memory technology such as random access memory (RAM), or other similar low latency technology. Stored in memory 350 may be such elements as an embedded operating system, software drivers, a web server, a master data collection program, and stored sensor data. For example, software drivers may enable the embedded operating system to communicate with a sensor bus 380 , which provides a hardware and/or software conduit to sensor array 250 . The master program may then be able to collect data from sensor array 250 and store the data in memory 350 . A web server provides an interactive means for a user to view data and interact with the remote monitoring system. Processor 310 is also connected to a wireless driver 330 , which may also be enabled to communicate to embedded operating system through software drivers. Wireless driver 330 is connected to antenna 112 , and communicatively couples processor 310 to the wireless network. In this embodiment, processor 310 uses the web server to provide a graphical user interface to user 150 over wireless driver 330 via the internet 180 . This two-way communication permits user 150 both to view sensor data, and to manipulate functions of single board computer 210 . Single board computer 210 further includes a timer circuit 360 , which provides processor 310 time-based signals. For example, if user 150 wants ground-based feeder 100 to disburse feed two times per day at a specified time, then timer 360 can track the time between disbursements and provide a signal to processor 310 when it is time for a new disbursement of feed. When processor 310 receives a signal from timer 360 , it may then provide a signal to serial controller 320 , which is connected to the motor detector 222 and motor control relay 224 . This causes motor control relay 224 to actuate motor 220 , causing the feed disbursement. There is also shown in this figure a storage 340 which may be a higher-latency technology than memory 350 , but which may be a non-volatile storage area. Storage 340 may include such information as data logs and stored programs, which will be maintained over long term operation. There is also shown an exemplary DC-DC power supply 370 which receives power from power supply 230 , and distributes power to other system components.
[0024] It should be noted that the above description of single board computer 210 is divided into functional blocks. While each functional block may represent a separate hardware or software component in some embodiments, other embodiments may combine the functions of several blocks into a single hardware or software component. In other embodiments, one function may be spread across a plurality of hardware and software components. It is therefore not the intention of this specification to limit the claims to the specific configuration disclosed.
[0025] The signals are digitized in a manner known in the art and power may be supplied to any sensing devices. Images may be dumped real time to a remote server 190 and accessed by the user when the user 150 signs on. The level of feed in ground-based feeder 100 may be directly measured or estimated. For example, the level of feed may be estimated based on (1) the total amount of time that motor 220 has run and (2) the volume or weight of feed disbursed per unit time. Low level feed signal information may be provided to user 150 to indicate level of feed in the game feeder.
[0026] FIGS. 4A and 4B illustrate additional mechanical (non-electronic) features of Applicant's wildlife feeder 310 . As seen in FIG. 4A , Applicant's wildlife feeder 310 may have a varmint guard 300 which will be typically comprised of stiff coated steel or metal wires 302 in the form of a mesh. The steel or metal coated wires 302 define openings through which particulate feed may be thrown out, but whose wire or metal mesh will prevent animals from accessing the spinner. That is to say, windows 30 may be covered with steel mesh, here defining a cylindrical shape and being attached to legs or support members 16 b of housing 16 .
[0027] Turning to FIG. 4B , an additional feature, Applicant's tray and skirt assembly 400 is illustrated. Tray and skirt assembly 400 includes a tray 402 and a skirt 404 . The tray and skirt assembly is designed to engage the upper portion or housing and window area of the game feeder 310 as illustrated. Skirt 404 functions to intercept the feed as its hurled through windows 30 and drop it into tray 402 . In this manner, the feed does not get on the ground and sits in the tray, which may be especially useful for pets, cattle or the like. That is to say, Applicant's tray and skirt assembly 400 is designed to deflect feed into a capsule mounted tray 402 .
[0028] FIGS. 4 B and 5 A- 5 E illustrate further details of Applicant's tray 402 . Tray 402 is seen to have a central interior cutout defined by inner rim 406 . Inner rim 406 is dimensioned sufficiently to allow the tray to slide over the upper housing 16 and rest at the base thereof or on the top of the lower section 14 as illustrated. Cutouts 408 are designed to supply engage legs 16 b of housing 16 to “lock” the tray in position (prevent rotation). Tray 402 is also seen to have an outer rim 412 and, between the outer rim 412 and inner rim 406 , a cup-shaped body (when viewed in cross-section), which cup-shaped body allows feed to collect therein. A cutout 414 may be provided in outer rim 412 to span and clear lid or door 26 of lower section 14 . Ribs 416 may be provided in body 410 to add rigidity to the tray 402 .
[0029] FIGS. 6A-6E illustrate further details of Applicant's skirt 404 . Skirt 404 may be seen to have an upper rim 420 and a lower rim 422 . Upper rim 420 will be small enough circumference to engage the housing and/or the upper legs so as to suspend the remainder of the skirt in place. Lower rim 422 typically has a greater circumference than upper rim 420 , so as to allow particulate feed striking the inner surface of the skirt to fall downward into the tray. That is to say, lower rim 422 will typically have a larger circumference than upper rim 420 and also of inner rim 406 of tray 402 . Therefore, there will be a gap between lower rim 422 and inner rim 406 , in which feed can fall into body 410 of tray 402 . Cutouts 424 between the upper rim and lower rim, that is cutouts on body 426 , will accommodate mounting hardware. Ribs 428 may be provided for stiffening purposes.
[0030] It is seen with reference to FIGS. 5A-5E and 6 A- 6 B that there are dimensions given. These dimensions are only representative and are given in inches.
[0031] FIG. 7 illustrates the use of Applicant's game feeder 310 with a watertight tank/base 500 typically cylindrical for engaging lower section 14 Tank/base 500 will typically engage bottom wall 18 of the feeder in flush relation and will be engaged thereto by fasteners, straps or other means. That is to say, tank/base 500 will typically provide the support on which the flat bottom wall 18 and cylindrical lower section 14 will sit with the side walls 504 typically flush with the lower vertical walls of the lower section of the game feeder. Tank/base 500 may be molded from plastic and will typically contain a fill opening 508 , such as a neck, which will have a cap 510 at a removed end thereon (threaded or otherwise watertight). Fill opening would be in the upper portion of the side walls.
[0032] Multiple protrusions 512 are typically provided spaced circumferentially along the side walls, which protrusions 512 have an underside 514 for receipt of poultry nipples 516 thereupon. Poultry nipples 516 include a downward depending arm or toggle 516 a and a base 516 b , and may be threaded into underside 514 in a watertight fashion. Tank/base 500 will then be filled with water, which water will for the most part be above the level of the underside 514 , which is typically within a few inches of the ground. Wildlife, such as quail, will learn to toggle arm or member 416 a to receive water therefrom.
[0033] The quail water base is filled with water after the small quail slippers (nipples) 516 are threaded in. The capacity of the base tank is typically 40-60 gallons, which is usually enough to last one covey of quail more than six months.
[0034] FIGS. 8 , 8 A, and 8 B illustrate Applicant's novel game feeder where an extra capacity insert 87 is placed between lower section 14 and bottom walls 18 . This is typically a cylindrical member and when used with a longer auger, provides additional capacity to the game feeder. This insert 87 may be used with or without tank/base 500 .
[0035] The materials of which the base and other elements of the game feeder are comprised is typically UV resistant polyethylene plastic. Brass inserts may be used to secure fastening. Typically the entire game feeder may be about 50 inches tall with a base about 48 inches in diameter. The motor may be a heavy duty 12 volt, 5.1 amp with a permanent DC magnet. Solar panel 12 volt, kk 70 milliamps may be provided and timers known in the trade, including heavy duty programmable timers, may be provided.
[0036] Although the present disclosure has described a remote monitoring system in particular reference to a ground-based game feeder, it should be noted that a similar configuration can be used for a multitude of monitoring purposes. For example, a remote monitoring system could be employed to increase security of a storage facility or other facility that is not frequently visited by people, or that is left alone for extended periods of time. Similarly, a remote monitoring system can be used to provide monitoring and assessment of any area where a user needs a frequent stream of information and means of control but cannot visit regularly. Another application may be, for example, a vacation home that the user visits only during certain seasons of the year. The remote monitoring system could be used to provide security while the user is away from the vacation home and when the user is preparing to visit the vacation home, it can be used to, for example, remotely activate utilities and perform such tasks as automatically turning on the heat or air-conditioning to prepare the home for the arrival of the user. Based on the present disclosure, other abundant users will become apparent to those having skill in the art.
[0037] While the subject of this specification has been described in connection with one or more exemplary embodiments, it is not intended to limit the claims to the particular forms set forth. On the contrary, the appended claims are intended to cover such alternatives, modifications and equivalents as may be included within their spirit and scope. | A game feeder configured for remote monitoring, the game feeder comprising a feeder body comprising a container for holding feed, a motor configured to disperse the feed, and a motor relay configured to actuate the motor; a computer, the computer comprising a wireless driver configured to communicatively couple the computer to a wireless communication network; and a sensor array having a plurality of sensors adapted to provide data on a plurality of local conditions at the game feeder, the sensor array being communicatively coupled to the computer; wherein the computer is configured to receive the data on the plurality of local conditions from the sensor array and send the data on the plurality of local conditions to the wireless communication network. | 0 |
BACKGROUND OF THE INVENTION
[0001] Motorized operators are widely used for controlling the movement of swing doors by remote or automatic control. Typically, swing door operators include an electric motor driving an output shaft through a reduction gear drive for controlling movement of the door between a closed position and an open position, the operator also including a return spring or the like for at least assisting the motor to move the door to the closed position. Several types of swing door operator mechanisms have been developed but prior art operators tend to be mechanically complicated, particularly if adapted for so called universal applications, that is, applications where the operator may be reversed in its working position for swinging doors of opposite “hands” or for controlling doors to swing inwardly or outwardly with respect to the operator, and/or the door frame.
[0002] It is desirable to provide a swing door operator with low maintenance requirements, and which may be easily adapted for controlling doors in inswing and outswing applications and where the swing movement of the door is of one hand or the other without modification to the operator and while the operator remains reliable for a long life. It is to these ends that the present invention has been developed.
SUMMARY OF THE INVENTION
[0003] The present invention provides an improved swing door operator including a mechanism operable for returning the door from an open position to a closed position regardless of the hand or swing direction of the door.
[0004] In accordance with one aspect of the present invention a motorized swing door operator is provided which includes a frame which may be mounted on a support member for controlling doors of one hand or the other without major modifications to the operator. The operator is characterized by a frame which supports an electric drive motor driving an output shaft through a reduction gear drive wherein the output shaft of the operator is drivingly connected to a return spring by way of a mechanism including a flexible member, such as a chain trained over a sprocket, connected to the output shaft. The mechanism is mechanically uncomplicated and provides for use of the operator for controlling doors of opposite hand or swing direction when moving from a closed position to an open position and back to a closed position.
[0005] In accordance with another aspect of the present invention a motorized swing door operator is provided which comprises a frame for supporting a speed reduction gear drive mechanism, a drive motor, a single return spring and a mechanism for storing energy in the spring and returning the spring energy to the operator for moving the door in one direction or the other. The frame may be conveniently mounted on a support plate in two opposed positions, depending on the so-called “hand” of the door to be operated.
[0006] The present invention also provides a swing door operator which is mechanically uncomplicated, compact, reliable in operation and easily modified as to its working position for controlling an inswing door, an outswing door, and for controlling a door regardless of the direction of swing movement or so-called hand of the door.
[0007] Those skilled in the art will further appreciate the advantages and superior features of the invention as well as other important aspects thereof upon reading the detailed description which follows in conjunction with the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] FIG. 1 is a perspective view of a swing door operator in accordance with the present invention;
[0009] FIG. 2 is a front elevation view of the swing door operator shown in FIG. 1 ; and
[0010] FIG. 3 is view taken generally along the line 3 - 3 of FIG. 1 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0011] In the description which follows like parts are marked throughout the specification and drawings with the same reference numerals, respectively. The drawing figures may not necessarily be to scale and certain elements may be shown in generalized or schematic form in the interest of clarity and conciseness.
[0012] Referring to FIGS. 1 and 2 , there is illustrated a swing door operator in accordance with the invention and generally designated by the numeral 10 . The operator 10 includes an elongated, generally rectangular support plate member 12 which is adapted to mount on a door frame, not shown, generally above a swing door in a conventional manner known to those skilled in the art. The support plate 12 is provided with plural spaced apart fastener receiving holes 14 , several shown in FIGS. 1 and 2 , for receiving fasteners, not shown, for securing the support plate to a door frame or door jamb. Support plate 12 is adapted to support an operator frame, generally designated by the numeral 16 , which is reversely mountable on the support plate 12 as will be described in further detail herein. Support plate 12 includes spaced apart flanges 12 a and 12 b configured for receiving a snap-on removable cover, not shown, for the operator 10 .
[0013] The operator frame 16 is characterized by spaced apart, generally horizontally extending frame plate members 18 and 20 which are spaced apart by opposed end plates 22 and 24 . The frame plates 18 and 20 are suitably secured to the frame plates 22 and 24 by conventional mechanical fastener 23 , several shown in FIG. 1 . Frame 16 may be reversely mounted on support plate 12 at opposed faces 16 a and 16 b , FIGS. 1 and 3 , by fasteners 16 c , FIG. 3 , one shown, which may be threadedly engaged in opposed bores 18 a and 20 a formed in plates 18 and 20 , FIG. 1 .
[0014] The operator frame 16 supports an electric drive motor 26 having a rotatable output shaft 27 drivably connected to a pinion 28 . Drive pinion 28 is meshed with a face gear 30 which is mounted on and drivingly connected to a shaft 32 , FIG. 2 . Shaft 32 is adapted for rotation about an axis perpendicular to the axis of rotation of pinion 28 and motor output shaft 27 . Shaft 32 is mounted in suitable bearings 33 and 35 which, in turn, are supported in the frame plates 20 and 18 , respectively. As shown in FIG. 2 , shaft 32 also drivingly supports a second stage pinion 36 which is meshed with a gear 38 . Gear 38 is mounted on an intermediate shaft 40 supported for rotation parallel to shaft 32 in spaced apart bearings 41 and 43 supported on the respective frame plates 20 and 18 .
[0015] Referring further to FIG. 2 , intermediate shaft 40 is also adapted to drivingly support a third stage pinion 44 and third stage pinion 44 is meshed with a gear 46 which is supported on a rotatable operator output shaft 48 mounted parallel to shaft 40 in suitable bearings 49 and 51 mounted on frame plates 20 and 18 , respectively. Output shaft 48 is provided with a suitable drive part 52 , such as a tapered polygonal cross section distal end of shaft 48 , and adapted to be connected to a swing door power arm, not shown, for the operator 10 . Output shaft 48 also supports spaced apart rotary cams 54 and 56 at its opposite end for rotation with shaft 48 and engagable with respective door position limit switches 58 and 60 , see FIGS. 1 and 2 .
[0016] Referring also to FIG. 3 , output shaft 48 is adapted to drivingly support a sprocket 62 suitably keyed for rotation with output shaft 48 . In FIG. 3 , frame plate 20 has been removed to provide for viewing certain components described herein. Sprocket 62 is engaged with an elongated flexible member comprising a conventional roller chain 64 which is trained around sprocket 62 and is characterized by opposed chain runs 66 and 68 , FIG. 3 . Respective chain runs 66 and 68 extend through an opening 69 in end plate 24 and terminate at a pivot link member 70 , FIG. 3 . Chain links 66 a and 68 a are suitably connected to the member 70 at spaced apart points on opposite sides of an axis 71 by respective pin members 66 b and 68 b , FIG. 3 .
[0017] Referring further to FIGS. 2 and 3 , link member 70 is mounted for limited pivotal movement on one end of a return spring transfer shaft 72 by a suitable pivot pin 74 , FIG. 3 . Link member 70 is disposed in a suitable slot 75 , FIG. 2 which opens to the distal end of the shaft 72 . As further shown in FIGS. 2 and 3 , return spring transfer shaft 72 extends through a suitable bore formed in a spring cup member 76 and is secured in engagement with cup member 76 by a hex nut 77 and a locknut 78 , both disposed on a threaded portion 72 a of shaft 72 formed generally on the end of shaft 72 opposite the slot 75 . Cup member 76 is provided with a transverse flange 76 a engageable with one end of an energy storage member comprising a coil compression spring 80 . The opposite end of spring 80 is forcibly engaged with frame plate 24 . Frame plate 24 is preferably provided with a circumferential groove 24 c for locating and retaining the return spring 80 in its working position.
[0018] As will be appreciated by those skilled in the art, the position of the nuts 77 and 78 on shaft 72 may be adjusted for adjusting the position of cup member 76 to provide a predetermined preload force on spring 80 which is reacted through the cup member 76 and shaft 72 to the chain 64 to properly tension the chain runs 66 and 68 . Alternatively, or additionally, the spring 80 may be replaced by springs of different lengths and spring rates to provide the requisite door closing force, which force is transferred as a torque by way of chain 64 , sprocket 62 and shaft 48 .
[0019] In operation, the operator 10 is suitably controlled by a control unit, generally designated by the numeral 11 in FIG. 1 , to energize the motor 26 upon receiving a command from a remote controlled switch or an automatic sensor, for example, both not shown. Energization of motor 26 rotates pinion 28 which rotates gears 30 , 36 , 38 , 44 and 46 to provide a high torque low speed rotation effort exerted on shaft 48 . Shaft 48 will rotate in one direction or the other, clockwise, for example in FIG. 3 , whereby chain run 66 becomes slack while chain run 68 becomes taut and pulls the shaft 72 and spring retainer or cup member 76 toward frame plate 24 thus compressing spring 80 and storing energy therein. Specifically, the operation typically results in a door controlled by the operator 10 to be moved from a closed position to an open position as shaft 48 rotates approximately ninety degrees to one hundred twenty degrees about its axis 52 a , FIG. 2 .
[0020] When the door, not shown, reaches its open position one of switches 58 or 60 is actuated by its associated cam 54 or 56 which may result in control unit 11 energizing the motor 26 to apply braking power to hold the door in an open position, preferably for a predetermined period of time. Once the motor 26 is de-energized or energized at low power in the opposite direction of rotation of pinion 28 , energy stored in spring 80 will cause shaft 72 to translate to the right, viewing FIG. 3 . Since chain run 68 is taut while chain run 66 is relaxed, the sprocket 62 will rotate in a counterclockwise direction driving the shaft 48 and associated power arm, not shown, attached thereto also in the counterclockwise direction to return the door to its closed position.
[0021] Those skilled in the art will appreciate that the operation just described may be reversed in its entirety. For example, upon driving the pinion 28 in the opposite direction from that just described during the operation to rotate the shaft 48 in the opposite direction, the chain run 68 will become slack while chain run 66 becomes taut and pulls shaft 72 and cup member 76 toward frame plate 24 also compressing spring 80 . Energy stored in spring 80 is thus returned to shaft 48 to rotate it in the opposite direction when the control unit 11 indicates that the aforementioned door is to be closed. In this way doors of opposite hand or direction of swing may be controlled by the operator 10 as needed, without any significant modification to the operator or adjustment thereof. Moreover, those skilled in the art will also appreciate the mechanical simplicity and dependability of the mechanism for providing storing of energy in spring 80 and returning energy from spring 80 during door opening and closing operations.
[0022] The fabrication and operation of the operator 10 is believed to be within the purview of one skilled in the art based on the foregoing description. Conventional engineering materials may be used to fabricate the components described herein as well as conventional mechanical assembly and disassembly procedures. Those skilled in the art will also recognize that the roller chain 64 and sprocket 62 may be replaced by various members, including but not limited to a cog belt and drive pulley, for example, or other types of chains and sprockets.
[0023] Although a preferred embodiment of the invention has been described in detail, those skilled in the art will also recognize that various substitutions and modifications may be made without departing from the scope and spirit of the appended claims. | A motorized universal swing door operator includes a motor driving a gear reduction drive mechanism having an output shaft adapted to be connected to a swing door operating arm. The output shaft supports a sprocket around which is trained a chain having opposite ends connected to a link supported on a shaft which is connected to a return spring. The return spring stores and returns energy regardless of the direction of rotation of the output shaft so as to provide the universal operating capability of the operator. | 4 |
CROSS-REFERENCES TO RELATED APPLICATIONS
This application claims the benefit of German patent application 10015933.8 filed Mar. 30, 2000, herein incorporated by reference.
FIELD OF THE INVENTION
The present invention relates to a method for the stepwise precision winding of yarn into the form of a package commonly referred to as a cheese. More particularly, the present invention relates to such a method wherein a staple fiber yarn is fed at a constant yarn speed from a feeder mechanism of an open-end spinning system to a winding apparatus which rotates the cheese at a constant circumferential winding speed and, over the course of the progressive building of the cheese by the winding operation, the winding ratio is reduced in stages by graduations of decreasing size as the cheese diameter increases.
BACKGROUND OF THE INVENTION
When a cross-wound bobbin, also known as a cheese, is produced with a random winding, the speed of yarn traversing and the circumferential speed of the cheese over the course of building the bobbin, i.e., from the beginning to the end of the winding process, are in a fixed ratio to one another. As a result, the yarn crossing angle remains constant, while the winding ratio decreases as the bobbin diameter increases. The winding ratio indicates the number of bobbin revolutions per double yarn traversing stroke. A cheese produced with random winding has a stable yarn package and a largely uniform density. For instance, when integral values of the winding ratio are followed, so-called winding ribbons or mirror windings occur. To avoid their disadvantageous consequences, so-called ribbon breaking methods are employed, but such methods do not break up the ribbons completely.
The term “cheese” used here also applies to the bobbin package that builds up during the winding of the cheese. In producing a cheese with precision winding, it is not the yarn crossing angle but the winding ratio that is kept constant over the entire bobbin travel. The yarn crossing angle decreases as the cheese diameter increases. As the crossing angle decreases, the winding density increases outwardly. As a result, the pressure on the relatively soft bobbin core accordingly increases to an undesirable and disadvantageous extent. Problems can result in unwinding the cheese resulting from uneven yarn tension and increasingly frequent yarn breakage as well as uneven penetration of dye through the yarn package. In principle, the advantages of precision winding reside in the possibility of a high payout speed, high package density, and thus greater running length for the same bobbin volume, compared to a cheese with random winding. However, as the cheese diameter increases, the decreasing crossing angle limits the diameter in the production of precision bobbins made of staple fiber yarns due to the defects that occur at the package edges since staple fiber yarns in particular cannot be wound with arbitrarily small crossing angles. For this reason, in open- end spinning, crossing angles of less than 28 degrees should be avoided. As a result, precision winding with staple fiber yarns can be used only with severe limitations.
Graduated precision winding represents a combination of random winding and precision winding, in which the advantages of both types of winding are intended to be achieved and the disadvantages are intended to be decreased. Along with random winding and precision winding, graduated precision winding is a conventional term in textile technology, which is discussed at length for example in German Patent DE 42 23 271 C1 and German Patent Disclosure DE 39 20 374.
In graduated precision winding, as the term already expresses, a precision winding is produced in stages or steps. For example, a maximum permissible crossing angle is set and, as each stage progresses, the crossing angle gradually becomes smaller while the winding ratio remains constant. Once the crossing angle reaches the smallest permissible value, the crossing angle is abruptly restored to the initial value. The winding ratio thus drops to a smaller value. As a result, a cheese with a virtually constant crossing angle is obtained in which the winding ratio has been reduced in stages.
With graduated precision winding produced in this manner, however, the above-described density problems and problems of stability of the bobbin edge are merely lessened. Along with the density problems with the above-described causes and an increasing pressure on the internal yarn layers, still another problem arises. With the reduction in the crossing angle, the wound length per unit of time also drops. This is especially disadvantageous in open-end spinning machines. Since the yarn produced on open-end spinning machines is always fed at a constant yarn speed, the yarn tension between the cheese and the draw-off rolls, for instance, is reduced by the decreasing windup length per unit of time. By the time the cheese has been nearly fully wound, there can be differences in the tension distortion of about 3.5%. This leads to marked differences in density and impairs the reeling-off (i.e., unwinding) properties of the cheese considerably. Depending on the graduation in the graduated precision winding, it can happen that the winding ratio or winding number will randomly drop to one of the aforementioned mirror values or to the critical vicinity of such a value.
From the extensive prior art mentioned above, which addresses the problems that occur in graduated precision winding, several selected references warrant comment. In German Patent 42 23 271 C1, a method for winding a yarn by means of graduated precision winding is described, in which the traversing frequency is increased abruptly within a range that is determined by a minimum winding angle and a maximum lay angle. The traversing frequency is decreased within a stage from an initial frequency to a final frequency in proportion to the bobbin speed (rpm) and is then increased abruptly to the initial frequency of the next stage. This initial frequency in each stage is at most equal to a fixed maximum frequency. The final frequency in each stage is at least equal to a fixed minimum frequency. Because winding is performed in all stages with winding numbers near a mirroring value, the intent is to provide the bobbin with a uniformly high packing density.
In German Patent Disclosure DE 41 12 768 A1, a method for producing stepwise precision winding is described, in which the switchover to the next winding stage in each case takes place when a diameter value stored in memory is reached. The intent is for instance not to have to input certain individual yarn-specific parameters of the yarn to be wound into the computer, or to make additional measurements. According to this reference, the procedure for producing graduated precision windings is expediently accomplished by selecting a crossing angle α, or a crossing angle tolerance range α1 to α2, on the basis of which characteristic variables of the winding stages are calculated. In this German Patent Disclosure DE 41 12 768 A1, it is recommended that the method be performed such that the tolerance range α1 to α2 of the selected crossing angle a is between ±4°.
Along with the above-described method in which the beginning of a new stage is initiated when the values of predetermined threshold crossing angles are exceeded, it is also possible to designate graduations in respect to the winding ratio, for example as a function of threshold values formed of cheese diameters. The graduations in the winding ratio can then be of constant size, for instance.
European Patent Disclosure EP 0 055 849 B1, which defines the basic type of graduated precision winding method to which the present invention relates, defines a method for graduated precision winding of yarns by means of a winding apparatus wherein the yarns are delivered continuously at constant speed. This method seeks to avert excessive differences in the winding speed, and the disadvantageous effects of such differences on the quality of the yarns and on the bobbin construction, by keeping the change in the winding ratio from one stage of the precision winding to the next so slight that the attendant change in winding speed of the yarn does not exceed a tolerance range above and below the value of the mean winding speed. However, irregularities in the bobbin structure occur in the range of small bobbin diameters, especially irregularities at the bobbin edges, are not prevented by the method disclosed in this European Patent Disclosure EP 0 055 849 B1.
With the known prior art discussed above, the problems in producing cheeses by means of graduated precision winding are overcome only inadequately, if at all, especially in open-end spinning machines, even though the engineering and control work related to such systems is at considerable industrial effort and expense.
OBJECT AND SUMMARY OF THE INVENTION
It is accordingly an object of the present invention to provide an improved method for producing graduated precision windings, especially for but not limited to use on open-end spinning machines to produce coarse yarns.
This object is addressed by a method, preferably adapted for but not limited to use in an open-end spinning system, for graduated precision winding of a staple fiber yarn fed at a constant yarn speed onto a cheese or like package rotating at constant circumferential speed. In accordance with the present invention, the winding ratio during progressive building of the cheese is reduced in stages by graduations of decreasing size as the diameter of the cheese increases. Each such graduation decreases the winding ratio by a value not exceeding 0.3, with each such graduation being selected to be sufficiently small to produce a change in a crossing angle of the yarn during winding of between about ±0.8° of a predetermined set-point value for the crossing angle and selected to be sufficiently large to completely fill a smallest number of yarn winding diamonds occurring in the respective yarn winding stage.
By employing a staged reduction of the winding ratio during building of the cheese utilizing increasingly smaller graduations as the cheese diameter increases, the method according to the present invention overcomes deleterious problems in bobbin construction that in the prior art are not overcome by merely and simply reducing the size of the graduations The prevailing winding ratio, WD akt , is calculated continuously from the then-current cheese diameter d SPakt , the set-point crossing angle α SOLL , and the double stroke length of the winding traverse DH, and the calculated winding ratio is compared continuously with a winding ratio WD n+1 that is predetermined for the applicable stage.
For calculating the current winding ratio WD akt , the following formula applies: WD akt = DH d SPakt * · π * tan ( α SOLL / 2 )
The cheese diameter D SP is calculated in friction driving of the bobbin via the speed (rpm) n w of the friction drive shaft, the known diameter d w of this shaft, and the bobbin rpm n SP : D SP = n w · d w n sp
A new winding ratio WD n+1 for the next succeeding stage is calculated and predetermined. A change into the next stage is made whenever a calculation operation shows that the current calculated winding ratio WD akt is equal or already smaller than the predetermined winding ratio WD n+1 . For instance, with the goal of obtaining a more-uniform bobbin construction in the open-end spinning process, if a graduation in the applicable predetermined winding ratio WD n+1 is selected, in which ratio successive decreasing values of the winding ratio WD n+1 each differ by the very slight value 0.1, as represented by the formula
WD n+1 =WD n −0.1,
then the course 22 of the predetermined winding ratio WD n+1 as shown in FIG. 2 is obtained. A disadvantage of a cheese wound in this manner, however, is a marked increase in the range of fluctuation in the deviation from the set-point crossing angle α SOLL . Such angle deviations, above a cheese diameter of about 100 mm, already cause markedly visible bumps on the cheese at the bobbin flank despite the fact that the graduations in the predetermined winding ratio are kept quite slight.
This disadvantage can be overcome by the method according to the invention. The need to reduce the graduation in the winding ratio markedly still further with a view to eliminating the development of undesired bumps, or reducing it to a tolerable amount, can also be avoided. But even further-reduced graduations in the winding ratio, in the cheese diameter range below 100 mm, are then disadvantageously so close together that a change to a new winding ratio will occur even upon an increase of less than 1 mm in the cheese diameter. However, the winding-ratio-specific yarn laying pattern is usually not yet concluded by such time. Not until the next winding ratio WD n+1 with a different laying pattern or a different number of diamonds are the voids located beneath covered, but not closed, while at the same time new ones are allowed to form in a different arrangement. These voids necessarily lead to losses in density and to a “soft” bobbin core. As the cheese diameter increases, the pressure on this soft core also increases. This can be so extensive that so-called bloomings and loose edges arise. In such cheeses, it is not necessarily assured that the yarns can be reeled off (i.e., unwound) without breaking. These disadvantages are avoidable, however, with the method according to the invention.
Each graduation is preferably selected by calculating each successive winding ratio WD n+1 , by subtracting an amount from the then-prevailing winding ratio (either the initial winding ration when determining the first graduation or a succeeding winding ratio WD n for a subsequent winding stage) which amount is calculated by multiplying the integral component G WD of the applicable winding ratio WD n by a graduation factor F ST . For this calculation, the following formula applies:
WD n+1 =WD n −( F ST * G WD ).
Advantageously, the graduation factor is no greater than 0.05, and in particular is preferably between 0.02 and 0.05, in order to obtain graduations in the winding ratio with the desired effect.
In an alternative version of the method of the invention, the calculation of the applicable winding ratios or the applicable graduations in the winding ratio can also be done on the basis of a percentage wise graduation in the cheese diameter. In this embodiment, each successive winding ratio WD n+1 , is calculated in accordance with the formula
D
n+1
=D
akt
+D
akt
·F
D
Wherein the initial or subsequently prevailing current cheese diameter D SPakt is multiplied by a percentage factor f D ; this product is added to the initial or current cheese diameter D SPakt , and the value of the cheese diameter D SPn+1 thus obtained is converted into a corresponding value to which the winding ratio WD n+1 is to be set. The conversion is done by the following formula: WD n + 1 = DH D SPn + 1 * π * tan α 1 / 2
In a preferred feature of the method of the invention, the graduation in the core area or region of the cheese is increased, preferably in the first segment of the bobbin travel, by means of an additional multiplier.
In a further advantageous version of the method of the invention, each winding ratio is ascertained by adding to or subtracting from the winding ratio a supplemental step-up ratio derived from the quotient of the yarn spacing and the number of diamonds in the current winding ratio by a calculation which incorporates these parameters into the determination of this step-up ratio. Thus the yarn winding diamonds can be closed or filled completely, and very uniform winding of the cheese can be attained. The number of yarn winding diamonds is also known as the order number. The calculation of the supplemental step-up i z of the winding ratio is accomplished according to the formula: i z = s n R * D SP * π * sin ( α / 2 )
wherein,
i z =supplemental step-up of the winding ratio
s=yarn spacing
D SP =cheese diameter
α=set-point crossing angle
n R =number of diamonds
The yarn spacing s is preselected by the user in a manner known per se as a function of the material comprising the yarn and then is ascertained empirically. The number of diamonds n R can also be calculated in a manner known per se or can for instance be taken from a table.
The graduation is advantageously selected such that winding ratios with which a desired, known number of diamonds can be associated are always obtained. For example, it can thus be assured that the number of diamonds is no greater than 50, and by the choice of such a value that is not overly large for the number of diamonds, excessively small yarn spacings are counteracted. The incidence of an arbitrarily high number of diamonds, which undesirably limits the possibilities of intervention in cheese construction using the supplemental step-up of the winding ratio, is averted.
The method of the present invention for producing a graduated precision winding represents an easily executed and inexpensive method that also produces satisfactory results on open-end spinning machines. The bobbins made by this method are distinguished by uniformly high density, smooth flanks without bumps and without bloomings at the bobbin edges in the region of the bobbin core, as well as very good payout properties. The engineering outlay can be kept low. There is no need for a separately driven winding roller or a sensor system for monitoring winding tension. In particular, the average winding quantity of the cheeses produced changes only slightly. The absolute error in the tension distortion when the method of the present invention is employed is rarely more than 0.1%. A further advantage of the method of the present invention is that simple calculation, over the entire bobbin construction, of the next successive winding ratio is possible on the basis of predetermined data such as D, DH, WD and α, with a single, fixed multiplier for the graduations of the winding ratio.
The invention will be described in further detail below in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a simplified, schematic view of an apparatus for performing the method according to the present invention;
FIG. 2 depicts the progressive changes in the winding ratio and yarn crossing angle in a winding operation wherein the winding ratio graduation is a constant 0.1;
FIG. 3 depicts the progressive changes in the winding ratio and yarn crossing angle in a winding operation according to the present invention; and
FIG. 4 depicts the progression of the error in the tension distortion in a winding operation according to the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows a winding system 1 of an open-end spinning system that produces cross-wound bobbins, also known as cheeses. The winding system 1 has a friction roller 3 , which rotates in the direction of the arrow 4 , for driving the cheese 2 . The cheese 2 is retained by means of a pivotable creel 5 and rests on the friction roller 3 . The yarn 6 is drawn off at a constant yarn speed in the direction of the arrow 7 from a feeder mechanism 12 of the open-end spinning apparatus, e.g., embodied as a spinning box, by means of a pair of draw-off rollers 8 , 9 , which rotate in the direction of the arrows 10 , 11 . The yarn 6 is wound onto the cheese 2 via a traversing yarn guide 13 . The yarn guide 13 is driven by means of a traversing device 14 . The friction roller 3 is driven via a shaft 15 by means of a motor 16 . The traversing device 14 is connected via an operative connection 17 to a motor 18 . Both the motor 16 and the motor 18 are controlled by a microprocessor 19 , which is embodied to include a program for controlling the winding ratio as a function of the currently prevailing cheese diameter. The current cheese diameter is calculated from the yarn length that has been wound onto the cheese 2 . The yarn length is ascertained with the aid of a sensor 20 , which detects the revolutions of the friction roller 3 . A further sensor 21 is provided for detecting the speed (rpm) of the cheese 2 , which like the sensor 20 is connected to the microprocessor 19 .
In a first exemplary embodiment of the method, the calculation of a new winding ratio WD n+1 to accomplish a graduation of the then prevailing winding ratio will be described. This method begins with an initial winding ratio WD 0 ; for purposes of this description and by way of example only the initial winding ratio is assumed to be WD 0 =6. Further values for the exemplary embodiment are:
α=30°
DH=294 mm
The cheese diameter D SP is calculated continuously in accordance with the formula: D SP = n FW xD FW n SP
In this formula,
n FW =rpm of the friction roller
D FW =diameter of the friction roller
n SP =rpm of the cheese
The currently prevailing winding ratio WD akt is calculated continuously by the following formula: WD akt = DH D akt * π * tan α / 2
The current winding ratio WD akt is compared continuously with the next winding ratio WD n+1 that is to succeed the particular prevailing winding stage. Since the cheese diameter D SPakt increases continuously, the current winding ratio WD akt correspondingly becomes constantly smaller. Once
WD akt ≦WD n+1
is attained, a new winding ratio WD n+2 is calculated, by the following formula:
WD
n+2
=WD
n+1
−F
ST
×G
WD
wherein
F ST =factor for the graduation of the winding ratio WD
G WD =integral component of WD akt .
For the first exemplary embodiment of the method, F ST =0.025.
Thus, beginning with an initial winding ratio WD 0 =6, the value for the next winding ratio WD 1 is calculated as follows:
WD 1 =6−(0.025×6)=6−0.15=5.85.
With the values for this exemplary embodiment, WD is obtained by the formula WD = 294 D akt * π * tan 15 •
At a cheese diameter D 0 , the winding ratio WD 0 =6. If the result of the continuous calculation of the winding ratio WD is
WD≦WD 1 =5.85,
then for the next graduation, the winding ratio WD 2 is calculated:
WD 2 =5.85−(0.025×5.000)=5.85−0.125=5.725.
FIG. 3 is a graph depicting a curve representing the progressing course 24 of the winding ratio WD, plotted over the cheese diameter D. As FIG. 3 shows, the range within which the crossing angle α, indicated at 25 , varies during performance of the method of the present invention is considerably narrower than the fluctuation range shown in FIG. 2 for the crossing angle α, therein indicated at 23 .
In a corresponding manner, the successive winding ratios WD and cheese diameters D are formed, resulting in the values shown in Table 1.
TABLE 1
WD
D[mm]
WD
D[mm]
Winding Ratio
Bobbin Diameter
Winding Ratio
Bobbin Diameter
6.000
58.21
2.275
153.52
5.850
59.70
2.225
156.97
5.725
61.01
2.175
160.58
5.600
62.37
2.125
164.36
5.475
63.79
2.075
168.32
5.350
65.28
2.025
172.47
5.225
66.84
1.975
176.84
5.100
68.48
1.950
179.11
4.975
70.20
1.925
181.43
4.875
71.64
1.900
183.82
4.775
73.14
1.875
186.27
4.675
74.71
1.850
188.79
4.575
76.34
1.825
191.37
4.475
78.05
1.800
194.03
4.375
79.83
1.775
196.76
4.275
81.70
1.750
199.58
4.175
83.65
1.725
202.47
4.075
85.71
1.700
205.45
3.975
87.86
1.675
208.51
3.900
89.55
1.650
211.67
3.825
91.31
1.625
214.93
3.750
93.14
1.600
218.29
3.675
95.04
1.575
221.75
3.600
97.02
1.550
225.33
3.525
99.08
1.525
229.02
3.450
101.23
1.500
232.84
3.375
103.48
1.475
236.78
3.300
105.84
1.450
240.87
3.225
108.30
1.425
245.09
3.150
110.88
1.400
249.47
3.075
113.58
1.375
254.01
3.000
116.42
1.350
258.71
2.925
119.40
1.325
263.59
2.875
121.48
1.300
268.66
2.825
123.63
1.275
273.93
2.775
125.86
1.250
279.41
2.725
128.17
1.225
285.11
2.675
130.56
1.200
291.05
2.625
133.05
1.175
297.24
2.575
135.63
1.150
303.70
2.525
138.32
1.125
310.45
2.475
141.11
1.100
317.51
2.425
144.02
1.075
324.89
2.375
147.06
1.050
332.63
2.325
150.22
1.025
340.74
In an alternative variant of the method of the present invention, the calculation of the applicable winding ratios at which an abrupt increase in the winding ratio occurs because of an abrupt increase in the traversing frequency of the yarn guide, can also be performed on the basis of a percentage-based diameter graduation. For this embodiment of the present method, the following formula applies:
D n+1 =D n +( D n ×F D ).
The applicable cheese diameter D n is multiplied by the factor F D , and the value obtained is added to D n . Next, D n+1 is converted into the corresponding value of the winding ratio WD n+1 , to which the winding ratio is to be set in the next stage. The current cheese diameter D akt at the time is ascertained continuously by the formula already mentioned above:
D akt =n FW ×d FW /n SP
For sake of illustrating and explaining this alternative variant of the method of the present invention, the following values may be assumed to apply as examples:
F D =0.019
α=30°
DH=294 mm
D 0 =60 mm
The corresponding winding ratio WD 0 is calculated as follows: WD 0 = DH D 0 * π * tan ( α SOLL / 2 ) = 294 60 * π * tan 15 • = 5.82
The cheese diameter D 1 for the next stage is determined as follows:
D 1 =D 0 +( D 0 ×F D )=60+(60×0.019)=61.140
The corresponding winding ratio WD 1 is determined as follows: WD 1 = DH D 1 * π * tan ( α SOLL / 2 ) = 294 60 * π * tan 15 • = 5.71
If, as the current cheese diameter D akt is ascertained continuously, the formula
D akt ≦D 1
is satisfied, then the cheese diameter D 2 and the corresponding winding ratio WD 2 are ascertained and converted into a corresponding traversing frequency of the yarn guide 13 . In this way, the values listed in Table 2 are obtained.
TABLE 2
D[mm]
WD
D[mm]
WD
Bobbin Diameter
Winding Ratio
Bobbin Diameter
Winding Ratio
60.000
5.82
139.955
2.50
61.140
5.71
142.615
2.45
62.302
5.61
145.324
2.40
63.485
5.50
148.085
2.36
64.692
5.40
150.899
2.31
65.921
5.30
153.766
2.27
67.173
5.20
156.688
2.23
68.450
5.10
159.665
2.19
69.750
5.01
162.698
2.15
71.075
4.91
165.790
2.11
72.426
4.82
168.940
2.07
73.802
4.73
172.149
2.03
75.204
4.64
175.420
1.99
76.633
4.56
178.753
1.95
78.089
4.47
182.150
1.92
79.573
4.39
185.610
1.88
81.085
4.31
189.137
1.85
82.625
4.23
192.731
1.81
84.195
4.15
196.392
1.78
85.795
4.07
200.124
1.75
87.425
3.99
203.926
1.71
89.086
3.92
207.801
1.68
90.779
3.85
211.749
1.65
92.503
3.78
215.772
1.62
94.261
3.71
219.872
1.59
96.052
3.64
224.050
1.56
97.877
3.57
228.307
1.53
99.737
3.50
232.644
1.50
101.632
3.44
237.065
1.47
103.563
3.37
241.569
1.45
105.530
3.31
246.159
1.42
107.535
3.25
250.836
1.39
109.578
3.19
255.602
1.37
111.660
3.13
260.458
1.34
113.782
3.07
265.407
1.32
115.944
3.01
270.449
1.29
118.147
2.96
275.588
1.27
120.392
2.90
280.824
1.24
122.679
2.85
286.160
1.22
125.010
2.79
291.597
1.20
127.385
2.74
297.137
1.18
129.805
2.69
302.783
1.15
132.272
2.64
308.536
1.13
134.785
2.59
314.398
1.11
137.346
2.54
320.371
1.09
According to a further feature of the present invention, the graduation of the winding ratios in a core region of the cheese is increased yet again, by way of an additional multiplier F M , for instance by the formula:
WD n+1 =WD n −F M ×( F ST ×D WD )
wherein the multiplier F M is greater than 1.
According to the invention, the slight graduation of the winding ratios leads to minimal fluctuations in the crossing angle. For a graduation factor F ST =0.025, the absolute error F A in the tension distortion varies within the tolerance range of ±0.1%, as FIG. 4 shows. The error F A is plotted over the cheese diameter D in the form of the curve 26 .
In a further feature of the invention, the thusly-ascertained winding ratios WD n can be used merely to determine the switchover points. These winding ratios will hereinafter be called fundamental ratios. Depending on the applicable fundamental ratio, a certain number of yarn winding diamonds n is obtained. If the number of diamonds n R assumes lower values, such as 1, 2, 4, 5 or 8, then it can happen that the diamonds will not be filled completely or uniformly before a switchover to the next winding ratio is made.
In a further variant of the method of the present invention, a winding ratio supplement i z is added to the fundamental ratio (or alternatively is subtracted from it), e.g., by the formula:
WDV n =WD n +i z , wherein
i z =winding ratio supplement
WDV=modified winding ratio.
The winding ratio supplement i z is ascertained from the following formula: i z = s n R · π · D SP · sin ( α / 2 )
Wherein
s=yarn spacing in mm
D SP =cheese diameter in mm
α=set-point crossing angle in degrees
n R =number of diamonds
With the altered winding ratio WDV, the yarn winding diamonds can be closed or uniformly filled. The cheeses thus obtained are distinguished by an especially uniform high density, especially smooth flanks without bumps and bloomings at the bobbin edges, and very good unwinding (i.e., reeling off) properties. Table 3 shows a small representative selection of possible winding ratios with the associated number of diamonds.
TABLE 3
n
n
WD
Number of
WD
Number of
Winding Ratio
Diamonds
Winding Ratio
Diamonds
5.000
1
4.725
40
4.975
40
4.700
10
4.950
20
4.675
40
4.925
40
4.650
20
4.900
10
4.625
8
4.875
8
4.600
5
4.850
20
4.575
40
4.825
40
4.550
20
4.800
5
4.525
40
4.775
40
4.500
2
4.750
4
It will therefore be readily understood by those persons skilled in the art that the present invention is susceptible of broad utility and application. Many embodiments and adaptations of the present invention other than those herein described, as well as many variations, modifications and equivalent arrangements, will be apparent from or reasonably suggested by the present invention and the foregoing description thereof, without departing from the substance or scope of the present invention. Accordingly, while the present invention has been described herein in detail in relation to its preferred embodiment, it is to be understood that this disclosure is only illustrative and exemplary of the present invention and is made merely for purposes of providing a full and enabling disclosure of the invention. The foregoing disclosure is not intended or to be construed to limit the present invention or otherwise to exclude any such other embodiments, adaptations, variations, modifications and equivalent arrangements, the present invention being limited only by the claims appended hereto and the equivalents thereof. | A method for producing graduated precision windings on cheeses in an open-end spinning system. The winding ratio is reduced in stages, in increasingly smaller graduations, as the cheese diameter increases during the bobbin travel of the cheese. The graduations do not exceed the value of 0.3 and are each selected such that changes in the crossing angle are within a tolerance range of less than ±0.8°, and the least number of diamonds occurring during the building of the bobbin can be completely filled. The cheeses thusly produced are distinguished by a stable construction, high density with uniform distribution of density over the entire yarn package, and excellent payout properties. | 3 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to an improved concrete path paver, and, more particularly, to a concrete paving machine designed to be pulled behind a cement truck to lay a slip-formed path of concrete on the ground as the concrete is dispensed from the cement truck through the machine, the machine including a removable screed, adjustable sides and stabilizing fins.
2. Description of the Background Art
Presently there are a wide variety of paving machines designed to lay a path or roadway. Some machines are designed for laying concrete, others for laying asphalt. Typically, the bed of the path or roadway must be prepared prior to laying the material. The material must provide adequate support for the path or roadway. For heavy roadways, the bed is prepared with aggregate and aggregate compositions to provide greater load-bearing support for the roadway. For lighter applications, however, such as cart paths on golf courses, the pathway must only be cleared of grass and trees and leveled to a limited degree. For heavy roadways, the bed is generally flat with minimum curves. For golf course paths, the bed may be hilly with sharper curves.
A large number of devices are known for the dispensing of material onto the surface to be paved. By way of example, note my prior patent, U.S. Pat. No. 4,878,778 issued Nov. 7, 1989, directed to a concrete path paver. That patent relates to apparatus for dispensing concrete to form paths. Such apparatus, however, is a large, high-profile unit. In addition, like all prior pavers, such machine is capable of dispensing concrete at only one particular width. Furthermore, known pavers have a tendency to shift sideways when being pulled and not to faithfully follow the movement of its pulling truck.
Other devices for depositing concrete with the same problems as described above include U.S. Pat. Nos. 2,332,688 to Baily; 2,664,794 to Evans; and 4,609,303 to Shumaker. Beyond these patents, the depositing of particulate material such as asphalt is also disclosed in other prior patents, as for example, U.S. Pat. Nos. 1,767,243 to Kime; 3,246,584 to Lee; 3,456,566 to Lazaro; 3,877,830 to James; 3,989,402 to James; and 4,802,788 to Smith.
None of these patented prior devices, whether that of my prior patent or those of others, whether for concrete, asphalt or other materials, is directed to solving the problems as addressed herein.
The above-mentioned patents disclose paving machines adapted for specific applications. Except for the machine of my own prior patent, none of the disclosed prior paving machines are particularly adapted for laying cart paths on golf courses. With regard to golf cart paths in particular, it is desirable to minimize damage to the grass turf of the golf course except beneath the intended path to be paved. No prior paving machine can maintain its movement to within the confines of the path to be paved. Further, no prior paving maching is readily convertible to vary the width of the concrete dispensed and the path formed.
Therefore, it is an object of this invention to provide a concrete paving machine which overcomes the inadequacies of the prior art devices and which provides an improvement which is a significant contribution to the advancement of the concrete path paving art.
Another object of this invention is to provide a paver for slip-forming a path of concrete onto a pathway the upper surface of which constitutes a plane of construction, comprising in combination a box having an exterior front wall and an interior front wall extending downwardly at an angle through the box to the plane of construction, and a rear wall extending downwardly at an angle through the box to a location above the plane of construction, and opposing side walls coupling the front and rear walls extending downwardly to the plane of construction to define the closed box having an upper opened end for receiving concrete and a lower opened end with a vertically disposed opened mouth defined by the vertical edges of the side walls and the lower edge of the rear wall, with the lower opened end having a smaller cross-sectional area than the upper opened end; a screed for forming the concrete, means for securing the screed at its edges to the side walls adjacent to the lower edge of the rear wall with the forward end of the screed being positioned at the opened mouth; shoes removably positionable interiorly of the side walls and exteriorly of the screed to reduce the width of the path being formed; a ski formed by the bends in the exterior front wall and secured at its edges to the side walls across the lowermost front edge of the box, the plate being angled to create a ski-like effect upon movement of the paver on the pathway; a pair of skids affixed to a lowermost edges of the sidewalls causing the box to float upon the pathway during movement of the paver; fins extending downwardly from the box to stabilize the movement of the paver; and hitch means connected to the front of the box allowing the paver to be connected immediately behind a cement truck by means of a chain such that concrete being dispensed from the chute of a cement truck pulling the apparatus flows into the upper opened end of the box while the screed forms the concrete from the opened mouth of the lower opened end into a concrete path laid directly on the pathway.
Another object of this invention is to pave a concrete path with machinery capable of laying a path at one of a plurality of widths.
Another object of this invention is to pull paving apparatus in a path which faithfully follows the direction of the cement truck which is pulling it.
The foregoing has outlined some of the more pertinent objects of this invention. These objects should be construed to be merely illustrative of some of the more prominent features and applications of the present invention. Many other beneficial results can be attained by applying the disclosed invention in a different manner or by modifying the invention within the scope of the disclosure. Accordingly, other objects and a fuller understanding of the invention may be had by referring to the summary of the invention and the detailed description of the preferred embodiment in addition to the scope of the invention defined by the claims taken in conjunction with the accompanying drawings.
SUMMARY OF THE INVENTION
The invention is defined by the appended claims with the specific embodiment shown in the attached drawings. For the purpose of summarizing the invention, the invention may be incorporated into a paver for slip-forming a path of concrete onto a pathway the upper surface of which constitutes a plane of construction, comprising in combination a box having an exterior front wall and an interior front wall extending downwardly at an angle through the box to the plane of construction, and a rear wall extending downwardly at an angle through the box to a location above the plane of construction, and opposing side walls coupling the front and rear walls extending downwardly to the plane of construction to define the closed box having an upper opened end for receiving concrete and a lower opened end with a vertically disposed opened mouth defined by the vertical edges of the side walls and the lower edge of the rear wall, with the lower opened end having a smaller cross-sectional area than the upper opened end; a screed for forming the concrete, means for securing the screed at its edges to the side walls adjacent to the lower edge of the rear wall with the forward end of the screed being positioned at the opened mouth; shoes removably positionable interiorly of the side walls and exteriorly of the screed to reduce the width of the path being formed; a ski formed by the bends in the exterior front wall and secured at its edges to the side walls across the lowermost front edge of the box, the plate being angled to create a ski-like effect upon movement of the paver on the pathway; a pair of skids affixed to a lowermost edges of the sidewalls causing the box to float upon the pathway during movement of the paver; fins extending downwardly from the box to stabilize the movement of the paver; and hitch means connected to the front of the box allowing the paver to be connected immediately behind a cement truck by means of a chain such that concrete being dispensed from the chute of a cement truck pulling the apparatus flows into the upper opened end of the box while the screed forms the concrete from the opened mouth of the lower opened end into a concrete path laid directly on the pathway.
Further, the invention may be incorporated into apparatus for slip-forming concrete to form a path comprising in combination a box having a front wall extending downwardly through the box, and a rear wall extending downwardly at an angle through the box to a location above the front wall, and opposing side walls coupling the front and rear walls extending downwardly to define the closed box having an upper opened end for receiving concrete and a lower opened end with a vertically disposed opened mouth defined by the vertical edges of the side walls and the lower edge of the rear wall, with the lower opened end having a smaller cross-sectional area than the upper opened end; and a screed for slip forming the concrete, means for removably securing the screed at its edges to the side walls below the rear wall with the forward end of the screed being positioned at the opened mouth of the rear wall.
The box has an exterior front wall and an interior front wall defining a closed chamber therebetween. The exterior front wall includes a ski formed by bends therein to create a ski-like effect upon movement of the paver on the pathway. The apparatus further includes a pair of skids affixed to a lowermost edges of the sidewalls causing the box to float upon the pathway during movement of the paver. The apparatus further includes fins extending downwardly from the box to stabilize the movement of the paver. The apparatus further includes means to vary the curvature of the screed.
The foregoing has outlined rather broadly the more pertinent and important features of the present invention in order that the detailed description of the invention that follows may be better understood so that the present contribution to the art can be more fully appreciated. Additional features of the invention will be described hereinafter which form the subject of the claims of the invention. It should be appreciated by those skilled in the art that the conception and the disclosed specific embodiment may be readily utilized as a basis for modifying or designing other structures for carrying out the same purposes of the present invention. It should be realized by those skilled in the art that such equivalent structures do not depart from the spirit and scope of the invention as set forth in the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
For a fuller understanding of the nature and objects of the present invention, reference should be had to the following detailed description taken in conjunction with the accompanying drawings in which:
FIG. 1 is a perspective illustration of the rear end and left side of a concrete path paver constructed in accordance with the principals of the present invention.
FIG. 2 is a rear elevational view of the apparatus shown in FIG. 1.
FIG. 3 is a top plan view of the apparatus shown in FIGS. 1 and 2.
FIG. 4 is a front elevational view of the apparatus shown in FIGS. 1 through 3.
FIG. 5 is a sectional view of the apparatus taken along line 5--5 of FIG. 4.
FIG. 6 is a left side elevational view of the apparatus shown in the prior figures.
FIG. 7 is an enlarged perspective showing of a portion of the lower rear part of the apparatus of the prior figures showing, coupled therewith, a shoe for varying the width of the concrete slab to be formed.
FIG. 8 is a perspective view similar to FIG. 7 but with the shoe separated therefrom.
FIG. 9 is a perspective view of the screed removed from the lower rear of the apparatus.
FIG. 10 is an enlarged perspective showing of the central portion of the screed shown in FIG. 9.
Similar reference characters refer to similar parts throughout the several Figures.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
With reference to FIG. 1, the concrete path paver apparatus 10 of the present invention comprises a generally rectangular box 12. The box 12 is designed to be pulled by a chain connected to a hitch behind a cement truck, not shown. The chain connects to the box 12 through a pair of pull plates 14 extending forwardly from the front of the box 12. Each pull plate 14 has a plurality of vertically aligned holes 16 for receiving the chain for pulling at one of a plurality of heights for effecting stable movjement of the box as a function of the load, speed, ground conditions, etc.
Depositing cement from the truck into the apparatus 10 being pulled by the truck will slip-form a slab of concrete onto the ground as concrete is dispensed from the chute of the truck into an upper open end 20 of the box 12 and is then deposited by the lower open end 22 of the box 12.
The upper open 20 end of the box 12 is defined by a vertical front wall 26 and a generally complimentary inner sloping rear wall 28. Parallel side walls 30 couple the front and rear walls 28. The upper edges of the front 26 end rear walls 28 and the upper edges of side walls 30 define the upper open end 20. The width of the front 26 and rear walls 28 defines the width of the box 12 as well as the width of the upper open 20 end and the lower open end 22. Horizontal rods 24 couple the central extents of the front 26 and rear walls 28 for bracing support during operation and use. Ears 32 extend upwardly from the side walls 30 for facilitating the lifting of the apparatus 10.
The side walls 30 and front 26 and rear walls 28 define, at their lower ends, the lower open end 22 through which the concrete is fed into the mouth of the screed 34. The screed 34 is a generally horizontally extending member 36 projecting rearwardly from the lower edge of the rear wall 28. More specifically, the lower open end 22 is defined by the lower edge of the rear wall 28 which extends only partially toward the bottom of the opposing side walls 30. The bottom edges of the front end side walls 30 extend to the ground level. The lower edge of the rear wall 28, as well as the screed 34, are elevated with respect to the ground. The lower surface of the screed 34, when compared with the lower ends of the front 26 and side walls 30, defines the depth of the concrete slab 38 to be formed.
It is noted that the rear wall 28 and a lower extension constituting the interior front wall 27 are both sloped inwardly with respect to the verticle. The side walls 30 are, however, vertical of a generally rectangular configuration. This allows sufficient distance for the screed 34 to be positioned between the side walls 30 beneath the rear wall 28 without extending beyond the periphery of the box 12. Support is thus provided for the screed 34 at its side edges by the side walls 30.
The screed 34 comprises a horizontal member 36 having a width to fit between the verticle side walls 30. The horizontal member 36 is provided with upturned flanges 42 and 44 at its front and side edges. Slots 48 are formed in the side edges. Bolts 50 extend through the side walls 30 and through the slots 48 of the flanges 42 and 44 and are fitted with nuts. This allows the horizontal member 36 to be adjusted vertically to form a slab 38 of a predetermined height on the construction surface in accordance with the desires of the operator.
The turned flange 42 at the forward edge of the horizontal member 36 extends upwardly for contact with a lower most portion of the rear wall 28. A close fit is thus achieved between the flange 42 and the lower most edge of the rear wall 28 at all heights of the horizontal member 36. Leakage of concrete therebetween is thereby abatted.
The front flange 42 is actually one of two planer members with a slot 52 therebetween. A plate 54 is secured to one of the flange halves 42 and 44 to cover the space therebetween, to preclude the flow of concrete therethrough and to allow the pivoting of the screed 34 halves during adjustment. Similarly, angled reinforcing bars 56 are located at the rearward edge of the horizontal member 36. This construction of flanges 42 and 44 and bars 56 allows for the central portion of the screed 34 to be coupled through an adjusting member formed as a turnbuckle 60, coupling being through clevis brackets 64 at a lower central portion of the rear wall 28 and at an upper central portion of the horizontal member 36. In this manner, rotation of the handle 62 of the turnbuckle 60 allows the central portion of the screed 34 to be raised or lowered, varying the curvature of the screed, to thereby form a slab 38 which is crowned at its center, dished or, in the alternative totally flat. The clevis bracket 64 of the horizontal member 36 are spaced more widely than the clevis bracket 64 of the rear wall 28 to allow for the raising and lowering of the screed 34 without binding.
At the lowest portion of the forward exterior wall 26, the wall angles rearwardly and downwardly. This configuration of the lower front 66 of the apparatus 10 allows the functioning as a ski. The lower most edge of the exterior wall bends rearwardly for being coupled with the lower edge of an angled interior front wall 27. A chamber is thus formed between the interior and exterior front walls and the side walls. The shape of this ski functions to prevent the front of the box 12 from digging into the ground when being pulled instead of sliding along as is required for proper laying of concrete.
A pair of side skids 70 are formed as outward extentions of the side walls 30. The skids 70 extend substantially the full length of the apparatus 10 adjacent to lower extent of the side walls 30. The skids 70 have horizontal cross sections and angled fronts. The skids 70 function to prevent the lower most edges of the side walls 30 from digging into the ground as the apparatus 10 is pulled by the cement truck without significantly adding to the overall width of the apparatus 10.
Extending across the rear of the box 12 is a horizontal platform 72 pivotally supported in the side walls 30 by a pair of brackets. The platform 72 provides a standing area for an operator to work in association with the driver of the cement truck for controlling the flow of concrete into the upper open end 20 of the apparatus 10, through the apparatus 10 and out of the lower end 22 of the apparatus 10 to form the concrete path.
Vibrators 74 are mounted on the exterior surface of the rear wall 28. The vibrators 74 are powered by a suitable apparatus 76, as for example a gasoline engine/generator positioned on the platform and suitable electric lines 78. The vibrators 74 are slip fit into their supporting brackets 80 formed on the rear face of the rear wall 28 and function to agitate the rear wall 28 for effecting the formation of a slab 38 through the smooth flow of concrete, particularly thick concrete.
During use, as concrete flows from the cement truck into the apparatus 10, the concrete is agitated by the vibrators 74 and then flows onto the ground and into the mouth of the screed 34. The mouth 84 of the screed 34 is at the forward edge of the horizontal member 36. As the apparatus 10 is pulled concurrently with the deposition of concrete a continuing flow of concrete goes into the box 12 and at its upper end 20 and out at its lower end 22 to form a slab 38 of concrete slipped formed on the ground. After the slab 38 is slipped formed, only minimal smoothing and brushing thereof is required to create the final product.
Linear movement of the apparatus 10 during operation for faithfully following the direction of movement of the cement truck which is pulling the apparatus 10 is insured by a pair of fins 88. The fins 88 are secured to lower, rearward portions of the skids 70. The fins 88 have rearwardly angled front edges which dig into the ground beyond the sides of the concrete slab 38 being formed. They retain the box 12 on a straight line path as determined by the direction of the pulling cement truck and minimize inadvertant lateral movement or drift as may occur through normal operation. Concrete paths for golf courses are usually formed on ground which, when compared with roadways for cars, is more hilly and curving and has trees, shrubs, etc. to divert the paving apparatus 10 from its intended direction of movement as defined by the concrete truck which is pulling it. The fins 88 are vertically oriented, parallel with each other, at locations outboard of the side walls 30. This orientation maximizes the stability of the box 12 during operation and use.
As can be seen in FIGS. 7 through 10, the screed 34 of the apparatus 10 of the present invention is separable from the remainder of the apparatus 10. Extending upwardly at its edges are flanges 42 and 44 having two vertical slots 48 adapted to couple with two bolts 50 extending through horizontally aligned holes 16 in the side walls 30 of the apparatus 10. Elevational adjustment of the screed and path to be formed is thus accomplished. Operatationally coupled with the height adjusting screed is the use of blocks-out shoes or blocks 90 to allow a larger machine to lay down concrete of a lesser width. Such block-out shoes 90 are generally rectangular on their lower face 92. Front and rear faces 94 and 96 are located at the front and rear faces of the screed 34. Side faces 98 are parallel with each other and at a distance equal to the width of concrete not to be laid down. The top is open for saving weight and expense. The front face 94 of each shoe 90 is angled downwardly for forming a smooth continuation with the interior face of the intermediate plate 54. A brace or braces 102 is provided within each shoe 90 for rigidity, and a notch 104 is formed in the forward edge of each shoe 90 for mating with the lower edge of the front wall 26.
Each side edge is provided with bolt holes. The bolt holes 108 on the exterior sides 98 of the shoes 90 adjacent to the side plates are for mounting with the bolt holes 108 of the side plates 54. Bolt holes 108 on the exterior side edges of the shoes are for coupling with the side flanges 42 and 44 of the screed 34 to provide its support. The holes of the screed 34 are actually vertically oriented slots for allowing the raising and lowering of the screed 34 and shoes 90 to effect the laying of the concrete slab 38 to a predetermined height.
In addition to allowing for varying heights of concrete through the screed 34 construction, the shoes 90 allow for varying widths of the concrete slab 38. A screed 34 of a width equal to the width of the machine may be utilized without shoes 90 to allow for the laying of the widest path to be provided by the paving apparatus 10. In the alternative, a screed 34 of lesser width may be utilized in association with one, two or more blocks 90 on each side between the screed 34 and the side plates 54 to preclude the laying of concrete in the region where the shoes 90. This width varying capability extends the utility of the apparatus 10.
The present disclosure includes that contained in the appended claims as well as that of the foregoing description. Although this invention has been described in its preferred forms with a certain degree of particularity, it is understood that the present disclosure of the preferred form has been made only by way of example and numerous changes in the details of construction and combination and arrangement of parts may be resorted to without departing from the spirit and scope of the invention. | Apparatus for slip-forming concrete to form a path comprising in combination a box having a front wall extending downwardly through the box, and a rear wall extending downwardly at an angle through the box to a location above the front wall, and opposing side walls coupling the front and rear walls extending downwardly to define the closed box having an upper opened end for receiving concrete and a lower opened end with a vertically disposed opened mouth defined by the vertical edges of the side walls and the lower edge of the rear wall, with the lower opened end having a smaller cross-sectional area than the upper opened end, and a screed for slip-forming the concrete, means for removably securing the screed at its edges to the side walls below the rear wall with the forward end of the screed being positioned at the opened mouth of the rear wall. | 4 |
CROSS-REFERENCE TO RELATED APPLICATION
This application claims the priority of U.S. Provisional Patent Application Ser. No. 61/267,583, filed on Dec. 8, 2009 (pending), the disclosure of which is incorporated by reference herein.
TECHNICAL FIELD
Generally, the invention relates to driver systems for moving a driven element with quick, short acceleration, and more specifically, to jetting dispenser or valve in which a valve member is quickly accelerated to dispense or jet material onto a substrate.
BACKGROUND
Drivers for performing various work may be powered in any number of manners, such as pneumatic, hydraulic, electric, magnetic, or combinations thereof. Oftentimes, the drivers for dispensing liquids, such as hot melt materials, comprise pneumatic actuators or electro-magnetic solenoids.
Various types of jetting dispensers are known such as shown in U.S. Pat. Nos. 5,320,250; 5,747,102; and 6,253,957; and U.S. Publication No. 2006/0157517, the disclosures of which are hereby fully incorporated by reference herein. For many valve and pump devices, the size of the device is important and smaller sizes are typically preferred assuming they will perform the required function. Often, the valve element or piston is directly coupled to move with an actuator such as an air motor or pneumatic actuator, or a solenoid actuator. In such designs, when the overall size of the device is reduced, the forces available to perform the useful work (i.e., movement of the valve element or piston) are also typically reduced. Therefore, the actuator may need to be sized larger than desired if required by the amount of work to be performed. If the actuator is undersized, the performance of the device may be compromised. Direct coupling of the actuator to the device performing the work may also present challenges if the actuator is sensitive to heat and the driven element is part of a heated system. This occurs in the area of hot melt dispensing, for example, where the material being dispensed may be heated to temperatures above 250° F.
SUMMARY OF THE INVENTION
The present invention generally provides a force amplifying driver system including an actuator with a powered actuating member mounted for movement along a first distance. A driven member is mounted for movement along a second distance which is less than the first distance. The powered actuating member moves through a gap before mechanically coupling with the driven member and then moves in a mechanically coupled fashion with the driven member along the second distance. In this manner, energy is transferred from the powered actuating member to the driven member along the second distance. During its travel through the gap, the powered actuating member accelerates and creates kinetic energy which is then transferred to the driven member upon mechanical coupling (e.g., contact) and during the movement along the second distance. Thus, the powered actuating member and the driven member are mechanically coupled only during a portion of the overall travel distance of the powered actuating member. The actuator thereby delivers energy to the actuated device or driven member in an amount equal to a larger actuator in a conventional directly coupled driver mechanism. In addition, separating the actuator from the driven member enables the stroke length of the driven member to be shortened and the overall length of the actuated device or driven member to be reduced.
The driven member may comprise various elements and, in one preferred embodiment, comprises a valve member. The valve member may further comprise a valve stem with a tip engageable with a valve seat. The valve seat is located in a fluid chamber and the tip engages the valve seat at the end of the second distance to discharge a jet or small, discrete amount of the fluid. The actuator may be driven in any suitable manner, such as by using pneumatic or electric based actuators. A biased return mechanism, such as a coil spring, may be used to return the driven member to a starting position and a stop may be provided for stopping the driven member at a starting position designed to create the gap with the powered actuating member. Because the valve stem moves through a shorter stroke as compared to a directly coupled valve stem and actuator delivering the same force, a smaller dot of fluid may be dispensed. This can also be beneficial in various applications in which it would be desirable to dispense smaller, discrete amounts of fluid.
The invention further involves a method of actuating a driven member including moving an actuating member under power through a gap. The actuating member is then contacted with a driven member at the end of the gap. Once the actuating member and the driven member are mechanically coupled, they are moved together along a working distance to thereby transfer energy from the actuating member to the driven member. Other details of the method will become apparent based on the use of the device as described above and further described below.
Various additional features and details will become more readily apparent upon review of the following detailed description of an illustrative embodiment, taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic, longitudinal cross-sectional view of a fluid jetting dispenser incorporating an illustrative embodiment of the invention and showing the dispenser in a dispensing condition.
FIG. 2 is a schematic representation similar to FIG. 1 , but illustrating the dispenser reset in a non-dispensing condition.
FIG. 3 is a schematic view of a fluid jetting dispenser similar to FIG. 1 , but showing an alternative, electric actuator in place of the pneumatic actuator.
DETAILED DESCRIPTION
The following detailed description will be given in the context of a fluid jetting dispenser, schematically represented, in order to illustrate principles of the invention. However, the principles may be applied to other driver systems for performing other types of work in situations, for example, in which it is desired to quickly accelerate a driven member and in which it may be desirable to minimize the size of the actuator used to move the driven member and/or to provide other benefits.
Referring to FIGS. 1 and 2 , a fluid jetting dispenser 10 is illustrated and generally includes an actuator 12 and a jetting valve portion 14 . Dispenser 10 is only schematically illustrated, but may include any desired design features such as any of those illustrated and/or discussed in the above-incorporated patents or publication. As mentioned, actuator 12 may comprise any numerous types of pneumatic or electric powered actuators, for example, but for illustration purposes actuator 12 is schematically shown here as a pneumatic type. The pneumatic actuator 12 generally comprises a cylinder 16 closed at opposite ends by caps 18 , 20 . A piston 22 is mounted for linear movement within the cylinder 16 and makes an airtight seal with the interior wall of the cylinder 16 . A piston rod 24 is rigidly coupled to the piston 22 and extends through the lower cap 20 and, specifically, through a dynamic air seal 26 . The piston rod 24 is rigidly coupled to the piston 22 using a suitable fastener 28 . Actuator 12 is shown as a dual acting actuator with pressurizable air spaces 30 , 32 respectively above and below the piston 22 . As is known in the art, pressurized air is introduced through port 31 into the upper air space 30 to drive the piston 22 downward while exhausting air through port 33 from the lower air space 32 . Conversely, pressurized air is introduced through port 33 into the lower air space 32 to drive the piston 22 upwardly while exhausting air through port 31 from the upper air space 30 . Other manners of driving the piston 22 would include the use a conventional spring return mechanism.
The jetting valve portion 14 is schematically illustrated to include a housing 40 for containing a fluid 42 to be dispensed in a non-contact manner described below. The housing 40 includes a fluid inlet 44 for receiving fluid under pressure. The valve portion 14 further includes a valve stem 46 having a tip 48 engageable with a valve seat 50 to open and close an outlet 52 . Typically, the fluid 42 is pressurized to an extent that will not cause the fluid to ooze or otherwise be dispensed when the valve stem 46 is in the upper position ( FIG. 2 ), but instead will maintain the fluid chamber of the housing 40 in a full condition. As is known with certain types of jetting dispensers, when the valve tip 48 is accelerated against the valve seat 50 , a small amount of fluid 42 will quickly discharge to form a droplet on a substrate (not shown). The opposite end of the valve stem 46 includes a surface 54 adapted to contact a surface 56 of the rod 24 as shown in FIG. 1 . A coil spring 58 is positioned between a flange 60 and an upper surface of the housing 40 to maintain the valve stem 46 in the raised position shown in FIG. 2 with a stop member 62 engaged against an inside upper surface of the housing 40 . The valve stem 46 engages a dynamic seal 64 to prevent fluid leakage during its travel through the housing 40 .
In operation, the fluid jetting dispenser 10 starts in an initial position shown in FIG. 2 with the surface 56 separated from the surface 54 by a gap “Z.” The piston 22 and attached piston rod 24 are mounted and configured to move through a first distance “X”, while the valve stem 46 is configured and mounted to move through a second distance “Y” shorter than the first distance “X.” The second distance “Y” may be considered the working distance which, in this case, is the stroke length of the jetting valve 14 . In this regard, distance “X” equals distance or gap “Z” plus working distance or stroke length “Y.” When pressurized air is introduced into the upper air space 30 through port 31 , while exhausting air from air space 32 through port 33 , piston 22 and piston rod 24 start to accelerate along distance “X” until they reach maximum acceleration upon contact of surface 56 with surface 54 and after traveling through the gap or distance “Z.” At this point, piston rod 24 is mechanically coupled to valve stem 46 and both travel along distance “Y.” Thus the kinetic energy of piston 22 and its connected piston rod 24 is transferred to valve stem 46 until tip 48 engages valve seat 50 . The resulting acceleration of the tip 48 through distance “Y” and the abrupt stop occurring at valve seat 50 causes a jet of fluid 42 to be dispensed as shown in FIG. 1 . The fluid 42 may be any viscous fluid, depending on the application, but examples are described in the above-incorporated patents and publication. The piston 22 is then raised by introducing pressurized air into air space 32 through port 33 and exhausting the air from air space 30 through port 31 . As the piston rod 24 is being raised, the spring 58 lengthens under its normal bias to the position shown in FIG. 2 thereby raising the valve stem 46 in preparation for another dispensing cycle. The piston 22 and attached piston rod 24 are raised until they reach the starting position shown in FIG. 2 where another dispensing cycle may begin.
FIG. 3 illustrates an alternative embodiment of a fluid jetting dispenser 10 ′. In this embodiment, the pneumatic actuator 12 of the first embodiment has been replaced with an electric actuator, in the form of a solenoid 70 . The solenoid 70 , illustrated schematically, generally includes an electromagnetic coil 72 surrounding a core or poppet 74 . Activation and deactivation of the solenoid 70 , including the acts of energizing and de-energizing the coil 72 will cause the core or poppet 74 to reciprocate between two positions. These two positions are at the opposite ends of the distance “X” as previously described. During activation, the poppet 74 will move downward through the gap “Z” and then travel along the valve stroke length “Y” during contact between surface 76 of poppet 74 and surface 54 of valve stem 46 while dispensing a fluid droplet 42 . All other reference numerals shown in FIG. 3 are identical to the numerals referencing the same structure shown and described in FIGS. 1 and 2 . It will be appreciated that the poppet 74 is analogous to the previously described piston rod 24 and, except for the changes involved in substituting the electric actuator 70 for the pneumatic actuator 12 , all other operations associated with the fluid jetting dispenser 10 ′ are as described above with regard to jetting dispenser 10 .
While the present invention has been illustrated by a description of the preferred embodiment and while this embodiment has been described in some detail, it is not the intention of the Applicants to restrict or in any way limit the scope of the appended claims to such detail. Additional advantages and modifications will readily appear to those skilled in the art. The various features discussed herein may be used alone or in any combination depending on the needs and preferences of the user. This has been a description of illustrative aspects and embodiments the present invention, along with the preferred methods of practicing the present invention as currently known. However, the invention itself should only be defined by the appended claims. | A force amplifying driver system including an actuator ( 12 ) with a powered actuating member ( 22 ) mounted for movement along a first distance “X”. A driven member ( 46 ) mounted for movement along a second distance or working distance “Y” which is less than the first distance “X”. The powered actuating member ( 24 ) is movable through a gap “Z” before being mechanically coupled with the driven member ( 46 ) and subsequently moves with the driven member ( 46 ) along the second distance “Y”. Energy is transferred from the powered actuating member ( 24 ) to the driven member ( 46 ) along the second or working distance “Y”. The force amplifying driver system may be used for actuating a fluid jetting dispenser ( 14 ). | 1 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims the benefit of U.S. Provisional Application No. 61/245,711, filed on Sep. 25, 2009, which is herein incorporated by reference in its entirety.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to novel hepatocyte-specific tri-valent ligands based on nitrilotriacetic acid (NTA) having three N-acetylgalactosamine (GalNAc) or three or six lactose (Lac) moieties attached to the NTA structure.
2. Related Art
Asialoglycoprotein receptor (ASGPR) of the liver is known to specifically bind to glycopeptides or glycoproteins having Gal or GalNAc on an end. When liver lesion occurs, the number of ASGPR will decrease. Therefore, it is desirable to develop high-affinity ligands for ASGPR with multiple Gal or GalNAc terminal residues useful for imaging of ASGPR activities.
This type of liver receptor activity imaging agents has the potential of quantifying the liver storage function and also has the ability to determine the residual liver function in a patient to allow clinicians to determine whether a liver transplantation is necessary or not. In Taiwan, there are 3,000,000 patients with hepatitis B, 500,000 patients with hepatitis C, and numerous patients with drug-induced hepatitis, all of whom are at high risk of liver failure and need regular assessment of liver storage function.
Presently, the peptides or proteins to be acquired multivalency with saccharide groups known in the art include albumin, tyrosine-glutamyl-glutamic acid (YEE), tyro sine-aspartyl-aspartic acid (YDD), and tyro sine-glutamyl-glutamyl-glutamic acid (YEEE).
Tc-99m-Galactosyl-Serum-Albumin (Tc-99m GSA) is known as a liver receptor imaging agent and has been used clinically in Japan. But, GSA is a carbohydrate-modified protein based on human serum albumin, which is a biological product having a very high molecular weight of about 67 kD. In such a product, it is difficult to know the exact position of modification and the precise number of the sugar attachment, not to mention DTPA (diethylene triamine pentaacetate) further attaches to GSA for labeling. In contrast, YEE, YDD, and YEEE are based on peptides having a molecular weight of only about 1-2 kD, and the exact structures, including the DTPA, are known. Thus the quality control procedures are significantly simplified compared to those procedures used with GSA.
YEE(ahGalNAc) 3 and YDD(ahGalNAc) 3 were first reported by Lee (1983), but their poor solubility limited their development. YEEE(ahGalNAc) 3 is an improved version reported by Chen (TW1240002, 2000). However, the overall yield is still unsatisfactory, the cost of GalNAc is considerably high, and it is not commercially available.
In 1983, Lee et al. reported that the binding affinity of divalent GalNAc-containing peptide by rat hepatocytes is 1000 times stronger than that of its monovalent GalNAc counterpart and the binding affinity between trivalent GalNAc ligand with hepatocytes receptor is 10 6 times greater than that of monovalent GalNAc ligand peptide with a single chain.
It should be noted that in YEE, YDD, and YEEE derivatives, a branching scaffold is provided by peptides rather than sugars as in natural glycoproteins, for example, γ-glutamyl-glutamic acid (abbreviated as “EE”), and β-aspartyl-aspartic acid (abbreviated as “DD”). Both EE and DD have three COOH functional groups being exposed and can thus be joined with three w-amino glycosides of GalNAc. However, the disadvantage of these compounds and tedious chemical synthetic process impeded their further development.
Therefore, it is desirable to develop a new type of high affinity reagents for hepatocytes (targeting ASGPR) which are convenient to synthesize and processing adequate solubility.
SUMMARY OF THE INVENTION
In certain aspects of the current invention, only one amino acid, L-lysine is used to provide trivalency, thus greatly abbreviating the synthetic procedure. N ε -protected lysine can be carboxymethylated with glycolic acid (CHOCOOH) under reductive conditions or with bromoacetic acid to obtain a “nitrilo-triacetic acid (NTA)” group. All carboxyl groups in the NTA structure can be conjugated with three glycosides of GalNAc or Lac in one step. In addition, Nα-dicarboxymethyl L-Lysine is commercially available, which can save some time and expense in the chemical synthesis, if such a path is to be sought for mass production of the multi-valent liver targeting agents. In the present application, CBZ-NTA was designed to link ahGalNAc or ahLac.
In particular aspects, a detailed one-pot preparation of raw materials and products is described herein.
In other aspects, the present invention relates to novel hepatocyte-specific glyco-ligands comprising lysine-based hexa-valent lactose or tri-valent galactosamine ligands.
In some aspects, the present invention is amenable to mass-production.
Certain aspects of the presently disclosed subject matter having been stated hereinabove, which are addressed in whole or in part by the presently disclosed subject matter, other aspects will become evident as the description proceeds when taken in connection with the accompanying Examples and Drawings as best described herein below.
BRIEF DESCRIPTION OF THE DRAWINGS
Having thus described the presently disclosed subject matter in general terms, reference will now be made to the accompanying Drawings, which are not necessarily drawn to scale, and wherein:
FIG. 1 is a structural representation of the presently disclosed liver targeting drug;
FIG. 2 is scheme of a one-pot preparation of N ε -benzyloxycarbonyl-N α -Dicarboxymethyl-L-Lysine;
FIG. 3 is scheme of a one-pot synthesis of 6-(trifluoroacetylamido)hexanol;
FIG. 4 is scheme of the synthesis of ahLac;
FIG. 5 is scheme of the synthesis of ahGalNAc;
FIG. 6 is scheme of the synthesis of NTA-(ahLac) 3 ;
FIG. 7 is scheme of a one-pot preparation of NTA-(ahGalNAc) 3 ;
FIG. 8 is scheme of a one-pot preparation of TFA-AHA-Asp;
FIG. 9 is scheme of a one-pot preparation of hexa-valent lactoside;
FIG. 10A is scheme of a presently disclosed trivalent GalNAc liver-targeting ligand;
FIG. 10B is scheme of a presently disclosed trivalent GalNAc liver-targeting ligand with a longer arm; and
FIG. 10C is scheme of a presently disclosed hexavalent Lac liver-targeting ligand.
DETAILED DESCRIPTION OF THE INVENTION
The presently disclosed subject matter 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. Like numbers refer to like elements throughout. The presently disclosed subject matter 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. Indeed, many modifications and other embodiments of the presently disclosed subject matter set forth herein will come to mind to one skilled in the art to which the presently disclosed subject matter pertains having the benefit of the teachings presented in the foregoing descriptions and the associated Drawings. Therefore, it is to be understood that the presently disclosed subject matter is 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.
I Design of Novel Liver Targeting Drug
In the present invention, N ε -benzyloxycarbonyl-N α -dicarboxylmethyl-L-lysine (Z-DCM-Lys) is used as a new basic structure to connect with 6-aminohexyl β-GalNAc (ah-GalNAc), glycyl-aminohexyl β-GalNAc (GahGalNAc), or aminohexyl Lac (ah-Lac), so as to form a three-chain glycopeptide. As the binding affinity of the trivalent Lac ligand to the ASGPR is not as strong as that of the trivalent GalNAc ligand, the trivalent Lac ligand is cojoined via an aspartic acid or a glutamic acid derivative from a hexa-valent Lac ligand. For example, two molecules of trivalent glycosides of N ε —Z—N α -DCM-Lys-(ahLac) 3 and 6-aminohexanoyl aspartic acid (AHA-Asp) form AHA-Asp[DCM-Lys(ahLac) 3 ] 2 (hereafter simply referred to as hexa-Lactoside). The free amino end of the hexa-Lactoside can be modified with DTPA anhydride in a sodium carbonate solution to form a DTPA derivative of AHA-Asp[DCM-Lys(ahLac) 3 ] 2 , the structure of which is as shown in FIG. 1 .
II Analysis of Binding Strength of Saccharide Chain Peptide and Murine Hepatocyte
With Eu-asialo-orosomucoid (Eu-ASOR) as a reference material, the binding affinity of the multivalent glyco-ligands (DCM-Lys(ah-GalNAc) 3 , DCM-Lys(GahGalNAc) 3 , DCM-Lys(ahLac) 3 , AHA-Asp[DCM-Lys(ahLac) 3 ] 2 ) and murine hepatocyte can be determined by competitive assay to obtain IC 50 (concentration of 50% inhibition), and the lower the IC 50 is, the higher the binding affinity. The murine hepatocyte (Lonza Biotechnology Company, Walkersville, Md.) is plated in a 24-well plate in advance, and the reaction occurs in each well, into which (i) Eu-ASOR 10 nM (ii) hepatocyte basic medium with 5 mM calcium chloride, and (iii) five different concentrations of multivalent ligands of 1 μM-0.8 nM are added. After culturing with shaking for 1 hr in the cold, the unbound ligands are removed by washing with the hepatocyte basic medium containing calcium chloride. Time-resolved fluorometry (TRF) is performed, using an enhancement solution (15 μM β-naphthoyl trifluoroacetone, 50 μM tri-n-octyl-phosphine oxide, 0.1% triton X-100 in 0.1 M acetic acid, titrated with potassium hydrogen phthalate to pH 3 . 2 ). The enhancement solution reacts with Eu 3+ to form an Eu chelate, which can emit at 615 nm when excited at 340 nm. With the logarithm of the concentration of saccharide chain peptide as X axis, the emitted fluorescence value as Y axis, the fluorescence value without adding glycopeptide being set as 100%, the IC 50 values of each ligand can be calculated accordingly. From these data, it is clear that the binding of AHA-Asp[DCM-Lys(ahLac) 3 ] 2 and ASGPR can reach the same binding strength as that of YEE or YDD, but the binding of DCM-Lys(GahGalNAc) 3 and ASGPR is 10 times higher than that of YEE or YDD, as shown in Table 1 .
TABLE 1
Comparison of binding strength of various
saccharide chains and murine hepatocyte
Compounds
IC50(nM)
YEE(ahGalNAc) 3
10 nM
YDD(GahGalNAc) 3
10 nM
DCM-Lys(ahGalNAc) 3
10 nM
DCM-Lys(GahGalNAc) 3
1 nM
AHA-Asp[DCM-Lys(ahLac) 3 ] 2
10 nM
III One-Pot Preparation of N ε -benzyloxycarbonyl-N α -Dicarboxymethyl-L-Lysine
The scheme is shown in FIG. 2 and the method follows Biomaterials (09) 30:836-842, with some minor modification. N ε -benzyloxycarbonyl-L-lysine(OtBu) (I), 2 g (15.1 mmol), was dissolved in 25 mL of 1.5 MNaOH, to which was added dropwise a solution of bromoacetic acid (II), 4.15 g (30.2 mmol) in 15 mL of 1.5 M NaOH. The mixture was allowed to stand 16 h at room temperature and then heated at 55° for 3 h. The near neutral solution was cooled to room temperature and mixed with 4 M HCl (12 mL), whereupon copious white precipitate appears. The precipitate was filtered and washed with cold water, and dried in a desiccator containing NaOH pellets overnight. The dry crystals (2.5 g, 40% yield) showed correct structure (III) by NMR.
IV One-Pot Synthesis of 6-(trifluoroacetylamido)hexanol
The scheme is shown in FIG. 3 . 6-aminohexanol (1 eq) and ethyl trifluoroacetate (99%, 1 eq) is added at room temperature with stirring for 5 hr. The resulting solution is added to cold water and continuously stirred for 14 hr in the cold. White precipitate formed is harvested by filtration (yield 42%). The structure of 6-(trifluoroactamido)hexanol (TFA-ah) was confirmed by 1 H-NMR.
V Synthesis of ahLac
The scheme is shown in FIG. 4 .
The β-acetobromo-β-lactose was prepared in one step according to the method of Kartha et al (Journal of Carbohydrate Chemistry, 9, 777-781, 1990). The β-lactose is treated with acetic anhydride and HBr/HOAC in one flask. After the acetobromo sugar is formed, extra reagents are flash evaporated. Addition of ether provided beautiful crystal.
TFA-ah-Lac was synthesized according to the method of Weigel et al (Carbohydr Res 70, 83-91, 1979). TFA-ah was reacted with β-acetobromo β-lactose in 1:1 (v/v) benzene-nitromethane, with mercuric cyanide as the catalyst.
De-O-acetylation was carried out in dry methanolic solution containing 10 mM sodium methoxide for 2 hr at room temperature. The reaction mixture was neutralized with Dowex 50 (H + form), filtered and the filtrate was evaporated.
De-N-trifluoroacetylation was done in aqueous solution containing 10% ethanol and 10% triethylamine (TEA) for overnight at room temperature. The mixture was evaporated to dryness, and the residue was dried in a vacuum dessicator over NaOH pellets and concentrated sulfuric acid. In order to remove the counterion of the amino group, the residue was dissolved in 50% ethanol and treated with Dowex 1 (OH − form) until supernatant solution is alkaline, and then filtered and the filtrate is evaporated.
VI Synthesis of ahGalNAc
The scheme is shown in FIG. 5 . Galactosamine hydrochloride is treated with acetic anhydride and pyridine at room temperature for 16 hr. The white precipitate is the per-o-acetyl GalNAc with a yield 76.7%. Formation of oxazoline derivative from per-o-acetyl GalNAc and subsequent glycoside formation were done according to the published method of Wu and Gao (Bioconjug Chem 17, 1537-44, 2006) with minor modification. To a solution of per-o-acetyl GalNAc in dichloroethane was added trimethylsilyl trifluoromethane sulfonate (TMSOTf) and the mixture was heated at 50° C. for 10 hr. Triethylamine was added to quench the acid. The reaction mixture was evaporated, the residue was dissolved in chloroform, and the chloroform solution was washed with cold saturated sodium bicarbonate (twice) and with 1M NaCl (once). The chloroform layer was dried with anhydrous sodium sulfate, filtered and evaporated. The dark red syrup was oxazoline derivative with yield 99%. This compound is unstable and it is better to proceed to the next step immediately. The oxazoline derivative obtained above and TFA-ah were dissolved in methylene chloride. Molecular sieve (4 Å) was added and the mixture was flushed with nitrogen gas, and stirred at room temperature for 1 hr. Concentrated sulfuric acid was then added, and the mixture was stirred overnight. The reaction mixture was filtered through a pad of Celite on a sintered-glass filter. The filtrate was diluted with methylene chloride and the solution was washed with cold saturated sodium bicarbonate (twice) and 1M NaCl (once). The residue was dissolved in 95% ethanol and fractionated on a Sephadex LH20 column using 95% ethanol as eluant. Only the product TFA-ah-GalNAc(OAc) 3 were combined and evaporated.
De-O-acetylation was carried out in dry methanolic solution containing 10 mM sodium methoxide for 2 hr at room temperature. The reaction mixture was neutralized with Dowex 50 (H + form), filtered and the filtrate was evaporated.
De-N-trifluoroacetylation was done in aqueous solution containing 10% ethanol and 10% triethylamine (TEA) for overnight at room temperature. The mixture was evaporated to dryness, and the residue was dried in a vacuum dessicator over NaOH pellets and concentrated sulfuric acid. In order to remove the counterion of the amino group, the residue was dissolved in 50% ethanol and treated with Dowex 1 (OH − form) untilsupernatant solution is alkaline, and then filtered and the filtrate is evaporated.
VII Synthesis of NTA-(ahLac) 3
The scheme is shown in FIG. 6 . 1.3 mmol 6-ah-β-lactoside was conjugated with 0.34 mmol Cbz-NTA with the aid of DCC/1-OH-Bt in DMSO. The reaction mixture was fractionated on Sephadex G-15 in 0.1M acetic acid. Fractions containing the trivalent product were combined and evaporated. Solid product was obtained by dissolving the residue in water-ethanol mixture and precipitating the product by adding ether.
Removal of benzyloxycarbonyl (Z) group was by hydrogenation in a Brown hydrogenator at atmospheric pressure, using either 60% acetic acid or 95% ethanol, and 10% Pd on carbon (about 10% of the weight of Z-containing compound) as catalyst. After the overnight treatment, the removal of Cbz-group was complete, as judged by TLC in ethyl acetate-acetic acid-water (2:1:1, v/v). After filtration, the filtrate was evaporated. The resulting compound is NTA-(ahLac) 3 .
VIII One-pot preparation of NTA-(ahGalNAc) 3
The scheme is in FIG. 7 . 0.45 mmol 6-ah-GalNAc was conjugated with 0.1 mmol Cbz-NTA with the aid of DCC/1-OH-Bt in dry DMF. The mixture was stirred at room temperature overnight. DCU formed was filtered and filtrate was evaporated. Filtrate was fractionated on the Sephadex G-15 column in 0.1M acetic acid. Fractions containing the trivalent product were combined and evaporated.
Removal of benzyloxycarbonyl (Z) group was by hydrogenation in a Brown hydrogenator at atmospheric pressure, using either 60% acetic acid or 95% ethanol, and 10% Pd on carbon (about 10% of the weight of Z-containing compound) as catalyst. After the reaction, the mixture was filtered and the filtrate was evaporated.
IX One-Pot Preparation of TFA-AHA-Asp
The scheme is shown in FIG. 8 . L-aspartic acid dibenzyl ester p-toluenesulfonate salt was conjugated with TFA with the aid of DCC/1-OH-Bt in dry DMF. The mixture was stirred at room temperature overnight. DCU formed was filtered and filtrate was evaporated. Filtrate was fractionated on the Sephadex G-15 column in 0.1M acetic acid.
X One-Pot Preparation of Hexa-Valent Lactoside
The scheme is shown in FIG. 9 . The process for preparing hexa-valent lactoside involves: 1) conjugation of NTA-(ahLac) 3 with TFA-AHA-Asp, [CF 3 CONH(CH 2 ) 5 CONHCH(CH 2 COOH)COOH], in DMSO with the help of DCC/1-OH-Bt. The mixture was stirred at room temperature overnight. DCU formed was filtered and filtrate was evaporated. Filtrate was fractionated on the Sephadex G-15 column in 0.1M acetic acid. Fractions containing the hexa-valent lactoside were combined and evaporated; 2) De-N-trifluoroacetylation was done in aqueous solution containing 10% ethanol and 10% triethylamine (TEA) for overnight at room temperature. The mixture was evaporated to dryness, and the residue was dried in a vacuum dessicator over NaOH pellets and concentrated sulfuric acid.
XI Trivalent GalNAc Liver-Targeting Ligand with a Longer Arm
The scheme is shown in FIG. 10 .
In a radiolabelling experience, DTPA-labeled tri-valent GalNAc ligand [ε-DTPA-α-DCM-Lys(G-ahGalNAc) 3 ] ( FIG. 10A ), hereinafter referred to as “tri(GalNAc)”, did not complex well with 111-Indium, even with a very high ratio of the Glyco-ligand to indium ratio. In comparison, the HexaLac ( FIG. 10C ) was readily labeled with indium. Without wishing to be bound to any one particular theory, this indicated that perhaps the DTPA residue in tri(GalNAc) is too close to the main body of the tri-valent GalNAc structure, so that indium could not access the chelating agent easily.
Therefore, the ε-amino group of α-DCM-Lys(G-ah-GalNAc) 3 was extended with a 6-carbon arm, as depicted in FIG. 10B . Starting from the existing stock of ε-Z-α-DCM-Lys(G-ah-GalNAc) 3 ( FIG. 10A ), this process involved: 1) removal of benzyloxycarbonyl (Cbz) protective group; 2) conjugation of 6-trifluoroacetamido-hexanoic acid (TFA-AHA) to the exposed amino group (TFA-AHA used was a lab stock synthesized previously); and 3) Removal of the trifluoroacetyl protective group. Accordingly, the extension of NTA-tri(GalNAc) with 6-amino-hexanoyl group improved the labeling yield of 111 In-labeled tri(GalNAc),
All publications, patent applications, patents, and other references mentioned in the specification are indicative of the level of those skilled in the art to which the presently disclosed subject matter pertains. All publications, patent applications, patents, and other references are herein incorporated by reference to the same extent as if each individual publication, patent application, patent, and other reference was specifically and individually indicated to be incorporated by reference. It will be understood that, although a number of patent applications, patents, and other references are referred to herein, such reference does not constitute an admission that any of these documents forms part of the common general knowledge in the art.
Although the foregoing subject matter has been described in some detail by way of illustration and example for purposes of clarity of understanding, it will be understood by those skilled in the art that certain changes and modifications can be practiced within the scope of the appended claims.
In view of the above, in terms of its general combination and features, the present invention has no been found in the similar products, and has not been disclosed before its filing date. It indeed meets the requirements of a patent and we thus propose this application according to the provisions of the patent law. | This invention provides novel liver targeting agents and their synthetic methods. A liver targeting agent, with a lysine based nitrilotriacetic acid structure as backbone which acquires multivalency with saccharide groups, to bind with a galactosamine chain or lactose chain is disclosed. In particular, only one amino acid L-lysine is involved to provide trivalency. All carboxyl groups in N ε -benzyloxycarbonyl-N α -dicarboxymethyl-L-lysine can be conjugated with three glycosides of ahGalNAc or ahLac in one step. This invention also provides a hexa-lactoside. In particular, the TFA-AHA-Asp was used to conjugate 2 molecules of NTA(ahLac) 3 . This invention also provides a method for adding a spacer between NTA and DTPA. The extended hepatocyte-specific glyco-ligand has higher 111 In-radiolabelling yield than those non-extended. | 2 |
This is a divisional of application Ser. No. 517,577 filed Oct. 23, 1974 and now U.S. Pat. No. 4,049,557 which is in turn a continuation-in-part of application Ser. No. 272,388, filed July 17, 1972 and now abandoned.
BACKGROUND OF THE INVENTION
This invention relates to novel fabric conditioning compounds that are compatible with anionic detergents.
Textile softener compositions are utilized in the textile industry to give the fiber or fabric a better handle or feel and a better drape. They quite often also act as lubricants and antistatic agents. In the manufacture of textiles, after completion of the various process steps, the fabric is finished by various treatments which often include the application of a softener. These finishes, particularly softeners, are removed by washing and, recently, a number of softeners for use in home and industrial washing machines have been placed on the market, which softeners restore to the washed goods the original feel and drape properties. The home laundry softeners are recommended for use in the washing machine after the wash period and usually after at least one or more rinse periods. These softeners are generally referred to as "after rinse" softeners.
The after-rinse softeners are usually formulated into 4-8% active, liquid products and bottled for use in the home. To date, these products have been generally based on the dimethyl-di(hydrogenated tallow)-ammonium chloride type fabric softeners. Although these products are excellent for improving the hand of fibers and fabrics, they are incompatible with anionic detergents and have the tendency to build up on successive washes resulting in reduced absorbency of the washed and treated fabrics. In addition, these products are not always compatible with germicidal compounds, even cationic germicidal compounds such as n-alkyldimethyl-aryl-ammonium chlorides. In the latter case, a gelling effect takes place in the detergent-germicide system, and the product is no longer pourable from a bottle.
In recent years, many detergent compositions have been formulated based upon linear alkyl benzene sulfonates, compounds thought to possess the best detergency characteristics. While such anionic detergents do possess excellent detergency characteristics, the use of linear alkyl benzene sulfonates and other anionic detergents based upon the alkyl aryl sulfonates has certain distinct shortcomings. Since the alkyl aryl sulfonates or linear alkyl benzene sulfonates do not possess any fabric-softening characteristics, it is necessary to employ an additional fabric softener when using such anionic detergents. Since, however, the preferred fabric softeners are of the cationic quaternary ammonium type, such fabric softeners cannot be formulated in the same detergent composition with the anionic detergent. Thus the conjoint employment of the anionic detergent and the cationic fabric softener is precluded, since such fabric softeners and detergents complex and precipitate when employed conjointly, thereby eliminating the functional characteristics of each of the materials. Accordingly, it has been found necessary to employ the quaternary ammonium fabric softener in the rinse cycle of the fabric-washing process so that no contact between the anionic detergent and the cationic fabric softener will occur. This, of course, provides a great inconvenience in textile washing, since it necessitates the addition of active ingredients at two separate points in the washing cycle.
SUMMARY OF THE INVENTION
Compounds have now been discovered which have been found particularly suitable for fabric softeners. The novel softener compositions of the present invention can be utilized in the following manner:
(1) As a softener during the wash cycle;
(2) As an after-rinse softener;
(3) In built detergents for heavy-duty cleaning that can be added:
(a) to the slurry before spray drying
(b) to heavy-duty liquids
For the above uses a softener composition must perform as follows:
(1) The softener must be substantive;
(2) The softener must provide a good hand and fluffiness to the fabric;
(3) The softener must have non-yellowing properties; and
(4) The softener must be effective and stable in a pH range of 10 to 11.
The compounds of this invention not only improve the handle of the fiber or fabric, but are versatile enough that they can be applied as previously mentioned, as a softener during the wash cycle, as an after-rinse softener, and are also compatible with additives such as optical whiteners, germicidal compounds, etc.
Built-in detergents with the softener component enable the launderer to wash and soften in one operation. In other words, in a single addition of built-in detergent with softener, the goods can now be secured, and, since the softener is substantive, softened in one cycle; thus eliminating the two-step operation wherein the detergent is added in the wash cycle and the softener in the after-rinse cycle.
In these anionic type built detergent systems the dimethyl-di(hydrogenated tallow)-ammonium chloride base softeners are not applicable. Being cationic in chemical nature and opposite in electronic charge they are not compatible with anionic materials.
The fabric softening compounds of the present invention are valuable in the respect that they are compatible with anionic built detergents containing, if desired, optical whiteners, germicidal compounds, etc.
It has been found that the reaction of higher alkyl-1,2-epoxides with lower alkanediamines produces compounds having utility as fabric softeners which may be incorporated into a laundry product and used in conjunction with a detergent or added separately in either the wash cycle or the rinse cycle.
Said compounds have the formula R 1 -NH-(CH 2 ) x -NH-R 2 wherein R 1 contains about 10 to 22 carbon atoms and is selected from the group consisting of 1-hydroxymethyl alkyl and 2-hydroxy alkyl, R 2 is H or R 1 , and x is an integer from 2 to 12.
The reaction may be postulated as follows: ##STR1## where R is an alkyl group having from about 8 to about 20 carbon atoms, and x is an integer from 2 to 12.
The above reaction gives mixtures of mono- and di-substituted alkanediamines, the proportions varying with the reaction conditions and the mole ratio of epoxide to diamine. Compounds (a)-(d) are the most probable products of the reaction. Where the mole ratio of alkanediamine to epoxide is 2:1, mono-substituted reaction products predominate [(a) and (b)]. Where the mole ratio of alkanediamine to epoxide is 1:2, di-substituted reaction products predominate [(c) and (d)].
The resulting compounds, in addition to their fabric softening properties, also possess anti-static properties, which make them particularly valuable for treating synthetic textile materials which readily assume a static electric charge, such as nylon, glycol terephthalate (Dacron), acrylonitrile polymers such as Orlon, Acrilan, and Dynel, and cellulose acetate.
The compounds of the present invention may be used in detergent compositions with a variety of active ingredients, including synthetic detergents, soaps, detergent builders, sequestering agents, fluorescent whiteners, bluing agents, and foam control agents.
The compounds of the present invention can be used with one or a mixture of anionic detergents. The anionic detergents may be designated as water-soluble, salts of organic reaction products having in their molecular structure an anionic solubilizing group such as SO 4 H, SO 3 H, COOH and PO 4 H, and an alkyl or aralkyl radical having about 8 to 22 carbon atoms in the alkyl group. Suitable detergents are anionic detergent salts having alkyl substituents of 8 to 22 carbon atoms, such as water-soluble higher fatty acid alkali metal soaps, e.g., sodium myristate and sodium palmitate; water-soluble sulfated and sulfonated anionic alkali metal and alkaline earth metal detergent salts containing a hydrophobic higher alkyl moiety, such as salts of higher alkyl mono- or poly-nuclear aryl sulfonates having from about 8 to 18 carbon atoms in the alkyl group which may have a straight or branched structure, e.g., sodium dodecylbenzene sulfonate, magnesium tridecylbenzene sulfonate, lithium or potassium pentapropylene benzene sulfonate; alkali metal salts of sulfated condensation products of ethylene oxide (e.g. 3 to 20 and preferably 3-10 mols of ethylene oxide per mol of other compound) with aliphatic alcohols containing 8 to 18 carbon atoms, or with alkyl phenols having alkyl groups containing 6 to 18 carbon atoms, e.g., sodium nonyl phenol pentaethoxamer sulfate and sodium lauryl alcohol triethoxamer sulfate; alkali metal salts of sulfated alcohols containing from about 8 to 18 carbon atoms, e.g., sodium lauryl sulfate and sodium stearyl sulfate; alkali metal salts of higher fatty acid esters of low molecular weight alkylol sulfonic acid, e.g. fatty acid esters of the sodium salt of isethionic acid, fatty ethanolamide sulfates; fatty acid amides of amino alkyl sulfonic acids, e.g., lauric acid amide of taurine; alkali metal salts of hydroxy alkane sulfonic acids having 8 to 18 carbon atoms in the alkyl group, e.g., hexadecyl alpha-hydroxy sodium sulfonate. In general these organic surface active agents are employed in the form of their alkali metal salts or alkaline earth metal salts because such salts possess the requisite stability, water solubility, and low cost essential to practical utility.
The novel fabric softening compounds of the present invention may also be used with nonionic detergent compounds, such as low-foaming ethylene oxide condensate type detergents. Examples thereof are the reaction products of benzyl chloride and ethoxylated alkyl phenol having the formula ##STR2## where R is an alkyl chain having from 6 to 12 carbon atoms and X is a whole number from 12 to 20; polyether esters of the formula
(ClC.sub.6 H.sub.4).sub.2 CHCO.sub.2 (CH.sub.2 CH.sub.2 O).sub.x R
where x is an integer from 4 to 20 and R is a lower alkyl group of not over four carbon atoms, e.g., a compound of the formula
(ClC.sub.6 H.sub.4).sub.2 CH-CO.sub.2 (CH.sub.2 CH.sub.2 O).sub.15 CH.sub.3
and polyalkylene oxide condensates of an alkyl phenol, such as the polyglycol ethers of alkyl phenols having an alkyl group of at least about 6 and usually about 8 to 20 carbon atoms and an ethylene oxide ratio (number of ethenoxy groups per mole of condensate) of about 7.5, 8.5, 11.5, 20.5, 30, and the like. The alkyl substituent on the aromatic nucleus may be di-isobutylene, diamyl, polymerized propylene, isooctyl, nonyl, dimerized C 6 -C 7 -olefin, and the like. Among other condensates with phenols is an alkylated β-naphthol condensed with 8 moles of ethylene oxide, the alkyl group having 6 to 8 carbon atoms.
Further suitable detergents are the polyoxyalkylene esters of organic acids, such as the higher fatty acids, rosin acids, tall oil, or acids from the oxidation of petroleum, and the like. The polyglycol esters will usually contain from about 8 to about 30 moles of ethylene oxide or its equivalent and about 8 to 22 carbon atoms in the acyl group. Suitable products are refined tall oil condensed with 16 to 20 ethylene oxide groups, or similar polyglycol esters of lauric, stearic, oleic and like acids.
Additional suitable non-ionic detergents are the polyalkylene oxide condensates with higher fatty acid amides, such as the higher fatty acid primary amides and higher fatty acid mono- and di-ethanol-amides. Suitable agents are coconut fatty acid amide condensed with about 10 to 30 moles of ethylene oxide. The fatty acyl group will similarly have about 8 to 22 carbon atoms, and usually about 10 to 18 carbon atoms in such products. The corresponding sulphonamides may also be used if desired.
Other suitable polyether nonionic detergents are the polyalkylene oxide ethers of higher aliphatic alcohols. Suitable alcohols are those having a hydrophobic character, and preferably 8-22 carbon atoms. Examples thereof are iso-octyl, nonyl, decyl, dodecyl, tridecyl, tetradecyl, hexadecyl, octadecyl, and oleyl alcohols which may be condensed with an appropriate amount of ethylene oxide, such as at least about 6, and preferably about 6, and preferably about 10-30 moles. A typical product is tridecyl alcohol, produced by the Oxo process, condensed with about 12,15, or 20 moles of ethylene oxide. The corresponding higher alkyl mercaptans or thioalcohols condensed with ethylene oxide are also suitable for use in compositions of the present invention.
The water soluble polyoxyethylene condensates with polyoxypropylene polymers may likewise be employed in compositions of the present invention. The polyoxypropylene polymer, which is prepared by condensing propylene oxide with an organic compound containing at least one reactive hydrogen, represents the hydrophobic portion of the molecule, exhibiting sufficent water insolubility per se, at a molecular weight of at least about 900, such as about 900 to 2400, and preferably about 1200 to 1800. The increasing addition or condensation of ethylene oxide or a given water insoluble polyoxypropylene polymer tends to increase its water solubility and raise the melting point such that the products may be water soluble, and normally liquid, paste or solid in physical form. The quantity of ethylene oxide varies with the molecular weight of the hydrophobic unit but will usually be at least about 20% and preferably at least about 40% by weight of the product. With an ethylene oxide content of about 40 up to 50%, there are usually obtained normally liquid products, above 50% soft waxlike products, and from about 70-90% normally solid products may be obtained which can be prepared in flake form if desired. These condensates may be designated by the following structure:
Y[(C.sub.3 H.sub.6 O).sub.n --E--H].sub.x
where
Y is the residue of an organic compound which contained x active hydrogen atoms.
n is an integer
x is an integer, the value of n and x being such that the molecular weight of the compound, exclusive of E, is at least 900, as determined by hydroxy number,
E is a polyoxyethylene chain and constitutes 20-90%, by weight of the compound, and
H is hydrogen.
It is preferred to use products of the type just described having a total molecular weight within the range 2000 to 10,000, and preferably about 4000 to 8000. A suitable material is a condensate having a typical average molecular weight of about 7500, the hydrophobic polypropylene glycol being condensed with sufficient ethylene oxide until a normally solid water-soluble product is obtained which has an ethylene oxide content of about 80-90% and a melting point usually of about 51°-54° C. Another material is a liquid condensate having an ethylene oxide content of 40-50% and a molecular weight of about 4500.
The fabric softening compounds may be used in detergent formulations containing soaps, such as soaps of tallow fatty acid, coconut fatty acid, cottonseed fatty acid, oleic acid, and the like. The fabric softeners may be employed with detergent soaps derived from all types of fatty monocarboxylic acids ranging in chain length from C 10 to C 22 , both saturated and unsaturated.
The fabric softeners of the present invention are compatible with the commonly used alkaline builder salts and sequestering agents, inorganic or organic, illustrative of which are:
Tetrasodium phosphate
Tetrasodium pyrophosphate
Sodium acid pyrophosphate
Sodium tripolyphosphate
Sodium monobasic phosphate
Sodium hexametaphosphate
Sodium metasilicate
Sodium silicates of Na 2 O/SiO 2 of 1.6/l to 3.2/l
Sodium carbonate
Sodium sulfate
Sodium citrate
Borax
Sodium perborate
Nitrilotriacetic acid trisodium salt
Ethylene diamine tetracetic acid tetrasodium salts, and the like
The alkali metal polyphosphate builder salts are preferred for use in combination with anionic detergents, as the polyphosphate salts enhance the detersive efficiency of anionic detergents, aid in controlling sudsing powers, and aid in keeping soil suspended in the washing bath after its removal from the soiled textiles.
Examples of various other materials with which the fabric softener of the present invention are compatible and which may be incorporated in detergent compositions containing these fabric softeners include higher fatty acid amides such as coconut or lauric monoethanolamide, isopropanolamide and the like; hydrotropic solubilizing agents such as xylene or toluene sulfonates; organic solubilizing agents such as ethanol, ethylene glycol, and hexylene glycol; sodium carboxymethylcellulose and polyvinyl alcohol antiredeposition agents; optical and fluorescent brightener materials; coloring agents; corrosion inhibiting agents; germicides; perfumes; bluing agents; and the like.
The detergent compositions containing the fabric softening compounds of this invention may be spray-dried, mechanical mixtures, liquids, pastes, tablets, etc.
In one process of formulating a detergent composition containing the novel fabric softeners, a fluid aqueous slurry comprising water and an anionic organic detergent with a fatty acid salt is formed. The slurry flows or is pumped into a conventional soap crutcher or any other suitable mixing apparatus such as a ribbon blender. The other ingredients are then added in suitable order and form. The fabric softener is then added with stirring. The resulting slurry should be sufficiently fluid at elevated temperatures to insure adequate mixing and formation of a uniform product, and is subjected to a heat treatment at an elevated temperature such as within the range of about 100° to about 200° F., and usually from about 130° to 155° F. The slurry is heated by external means or even by the exothermic heat of reaction of certain ingredients. For example, the addition of hydratable inorganic salts such as the anhydrous forms of sodium tripolyphosphate and sodium pyrophosphate results in exothermic reactions as hydration occurs. It is desirable generally to add the polyphosphate and/or other builder salt or salts in the final stages of the crutching operation. A fatty acid salt can be added at any suitable stage of the crutching operation, preferably before addition of the polyphosphate. Mixing time is sufficient to ensure adequate mixing and will usually be at least a few minutes, e.g., five minutes. To facilitate density control of the desired products, effective agitation is maintained throughout the crutching operation. Such agitation provides a vortex such that a substantial amount of air is incorporated into the mixture present in the crutcher. Aerated mixtures have lower specific gravities and the resulting spray dried products have lower densities. The aqueous mixture prior to drying can be aged at the elevated temperature for a time sufficient to cause adequate solubilization or hydration of certain ingredients. Such aging period can be a number of hours, such as up to about 8 hours. In general, it is preferred to employ time intervals of less than three hours and preferably less than one hour. It is understood that excessively high temperatures or unduly long aging periods are to be avoided to prevent any possible decomposition and ensure efficient processing.
The solids content of the aqueous slurry is usually within the range of from about 20 percent to 90 percent of total solids. In the manufacture of heat-dried products involving vaporization of the water, the solids content is usually within the range of about 40 to 65 percent by weight, the remainder being substantially free water content. The slurry is usually maintained at a temperature of from about 160° to 180° F. This slurry is subjected to known spray-drying operations utilizing temperatures above 212° F. to produce the detergent composition in particulate form, generally in the form of hollow, thin-walled spherical particles. The detergent composition can be transformed into beads, granules, flakes, chips, powders, or the like as desired by use of conventional techniques.
In spray-drying the aqueous slurry, it is atomized or forced through spray nozzles into towers, with small liquid particles discharged from the nozzles becoming solidified and drying as they contact or fall through a stream or vortex of heated air or other inert gas which is about 600° F. The composition is produced thereby in the form of hollow thin-walled spheres or beads having a small residual moisture content usually of about 3 to 15 percent by weight.
Where the softening compounds of the present invention are mixed with a detergent, the softener is present in amounts ranging from about 1% to about 20%, and preferably from about 2% to about 15%, the surfactant is present in amounts ranging from about 5% to about 40% and preferably from 10% to 30%, and builder salts and other ingredients are present in amounts ranging from about 40% to about 94%.
Besides application in combination detergent/softener compositions, the fabric softeners of the present invention may be used in fabric softening compositions to be used either in the wash cycle with regular detergents or in the rinse cycle.
For use in the wash cycle, the fabric softener is dispersed in suitable solvents or, in dry form, is absorbed on a suitable carrier. Suitable carriers for this purpose include sodium sulfate, sodium carbonate, phosphate builder salts, clays, sugar, and the like. The fabric softener is generally present in the range of 5-30% active ingredient in the ultimate formulation. About 5 to 15 grams of active ingredient fabric softener can be used per average eight pound wash load. Brighteners, bluing agents, germicides, dispersing agents, and the like could be incorporated in the final formulation.
For use in the rinse cycle, the fabric softener is dispersed in suitable solvents or, in dry form, is absorbed on a suitable carrier. The concentration of fabric softener can be reduced somewhat, so that between 1 gram and 5 grams of active ingredient are used per average eight pound wash load.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In order to quantitatively determine the efficacy of fabric softener/detergent compositions prepared according to the present invention, the Mini-Wash test was developed. One-half of a terrycloth hand towel is washed in the Mini-Wash attachment of a General Electric automatic washer, using about 3 gallons of tap water (about 100 ppm. hardness) at 120° F. After air-drying, the half towel is rated on a softness scale of "1"=no softness to "10"=excellent softness, the softness attained by the standard fabric softener, stearyl dimethyl amine oxide. In those instances where the test softener exceeds the "10" standard, plus (+) values are assigned to help quantify the superiority.
EXAMPLE I
A mixture of 27 g. (0.12 mole) 1,2-epoxytetradecane and 18.5 g. (0.25 mole) 1,3-propane diamine was heated on a steam bath for five days. When chilled, the mixture crystallized. The product was broken up and washed thoroughly with ether. The 25 g. of material remaining was recrystallized from 200 ml. 3A alcohol.
A mixture of the above fabric softening compound and detergent was formulated from the following ingredients:
2 grams linear tridecylbenzene sulfonate
6.6 grams sodium tripolyphosphate builder
1 gram fabric softener
When this mixture was used in the Mini-Wash test, the half towel was rated at a softness of 10++++.
Another mixture of the fabric softening compound of Example I and detergent was formulated as follows:
2 grams linear tridecylbenzene sulfonate
6.6 grams sodium tripolyphosphate builder
0.5 gram fabric softener
When this mixture containing a lower concentration of softener was used in the Mini-Wash test, the half towel was given a softness rating of 8.
The fabric softener of Example I was mixed with a nonionic detergent as follows:
2 grams polyethoxylated C 14 -C 15 primary alcohol (average 11 moles ethylene oxide)
6.6 grams sodium tripolyphosphate
1 gram fabric softener
In the Mini-Wash test, use of this formulation resulted in a towel having a softness rating of 7.
The fabric softener of Example I was then formulated with a blend of nonionic and anionic detergents:
1 gram linear tridecylbenzene sulfonate
1 gram polyethoxylated C 14 -C 15 primary alcohol (average 11 moles ethylene oxide)
6.6 grams sodium tripolyphosphate builder
1 gram fabric softener
When this mixture was used in the Mini-Wash test, the hand towel was rated at a softness of 8.
EXAMPLE II
A mixture of 0.11 mole of 1,2-epoxyhexadecane and 0.336 mole of 1, 3-diaminopropane was heated on a steam bath overnight. When chilled, the mixture crystallized. The product was broken up and washed thoroughly with ether, and then recrystallized from alcohol. The resulting fabric softener was formulated with a detergent as follows:
1 gram fabric softener
2 grams linear tridecylbenzene sulfonate
6.6 grams sodium tripolyphosphate
When this formulation was used in the Mini-Wash test, the terrycloth towel was given a softness rating of 10+.
EXAMPLE III
A mixture of 0.10 mole of 1,2-epoxyoctadecane and 0.20 mole of 1,3-diaminopropane was heated on a steam bath for 6.5 hours. When chilled, the mixture solidified. The product was broken up and washed thoroughly with ether, and then recrystallized from alcohol. The resulting fabric softener was formulated with a detergent as follows:
1 gram fabric softener
2 grams linear tridecylbenzene sulfonate
6.6 grams sodium tripolyphosphate
When this formulation was used in the Mini-Wash test, the terrycloth towel was given a softness rating of 3. This low softness rating would indicate that the reaction time was too short for a good yield of product.
EXAMPLE IV
A mixture of 0.10 mole of 1,2-epoxy-octadecane and 0.05 mole of 1,3-propane diamine was heated on a steam bath for 22 hours. When chilled, the mixture crystallized. The product was broken up and washed thoroughly with ether and then recrystallized from alcohol.
EXAMPLE V
A mixture of 0.10 mole of 1,2-epoxyoctadecane and 0.05 mole of 1,6 hexane diamine was heated in a 100° C. oven for three days. The product was left at room temperature for three days, and was then recrystallized from alcohol.
The fabric softeners formed in the reactions of Examples IV and V were added to detergents according to the following formula:
1 gram fabric softener
2 grams linear tridecylbenzene sulfonate
6.6 grams sodium tripolyphosphate
The formulations were then used in the Mini-Wash test, and the softness ratings of the fabric softeners described in the preceding examples is given in the following tables:
______________________________________Example No. Softness______________________________________IV 10V 10______________________________________
It is thus apparent that the di-substituted diamine reaction products are equal or superior to the mono-substituted diamine reaction products in softening ability. | Novel fabric conditioning compounds are formed by reacting a higher alkyl-1, 2-epoxide with a lower alkanediamine. The compounds may be incorporated into a laundry product and used in the wash cycle or may be applied in either the wash cycle or the rinse cycle. | 3 |
CROSS-REFERENCE TO RELATED APPLICATIONS
The present Application is based on International Application No. PCT/EP2007/059147, filed on Aug. 31, 2007, which in turn corresponds to French Application No. 0607764, filed on Sep. 5, 2006, and priority is hereby claimed under 35 USC §119 based on these applications. Each of these applications are hereby incorporated by reference in their entirety into the present application.
TECHNICAL FIELD
The present invention relates to the field of devices for optically detecting the position and orientation of objects in space. It applies more particularly to the aeronautical field where, in this case, the object detected is a pilot's headset.
BACKGROUND OF THE INVENTION
The determination of the positioning of a point in space and the determination of the attitude of any object are problems that affect many technical fields.
The various solutions generally provided have to eliminate any position or attitude ambiguity, respond to a more or less stringent dynamic of the systems and provide a high accuracy, in particular in the aeronautical field.
In the systems for detecting position and attitude of objects in space that provide an accuracy of a few millimeters in position and a degree in attitude, there are many applications in various fields.
These systems are used in aeronautics, to detect head posture, notably for the headsets of fighter airplanes, military, civilian or para-civilian helicopters. In the latter para-civilian application case, it may relate to offshore rescue missions for example. They are also used for the detection of simulation headsets, this detection can then be combined with an oculometry device, also called eyetracker, to detect the position of the look. In the field of virtual reality and games, there are also many applications for these systems.
More generally, in the field of generic posture detection, there are also many applications, notably in the medical field for teleoperations and instrument monitoring, in the field of position monitoring for servo-controlled machine tools or remote control, and finally for cinema, in order to reproduce movements in synthesis images.
These various applications have technical solutions that meet more or less stringent requirements.
Regarding applications with low constraints, notably in terms of accuracy, there are various systems for detecting position and/or orientation of objects.
For example, devices with camera-based patch or form recognition use drawings printed on an object. A number of cameras observe the scene and determine the spatial configuration of the observed drawing.
There are also devices with camera-based sphere recognition, which are used, for example in the cinema, to reconstruct human movement. The device uses a number of cameras which observe reflecting spheres and determine their trajectory.
Finally, there are ultrasound positioning devices that rely on the principle of triangulation between ultrasound emitters and receivers.
Concerning more powerful applications, in particular in the aeronautical field, the devices for detecting posture of headsets in aircraft use two main techniques which are electromagnetic posture detection and electro-optical posture detection.
Electromagnetic posture detection requires devices comprising means of emitting an electromagnetic field and receiving sensors on the headset making it possible to determine their position relative to the emitter.
Electro-optical posture detection generally requires motifs of light-emitting diodes, also called LEDs, positioned on the headset and a number of camera-type sensors mounted in the cockpit making it possible to determine the spatial configuration of an LED motif.
To improve performance, it is commonplace to combine other devices comprising sensors of gyroscopic, accelerometric or magneto-metric types. This hybridization of sensors makes it possible to improve the dynamic performance characteristics or eliminate an orientation ambiguity. These sensors do not modify the static positioning performance characteristics of the detection devices cited previously.
However, these solutions have a certain number of drawbacks and limitations, particularly in the aeronautical field.
Regarding the electro-optical devices, the map of the cockpit or more generally the topology of the area containing the object must be known. In aeronautics, this topology can be subject to deformations or be difficult to map.
Moreover, these same devices require a number of cameras and a number of sensors. The position calculations demand numerous resources and the real-time analysis is complex to implement.
Furthermore, the diffusion in the detection area of the light from the LEDs does not make it possible to completely overcome the disturbances from the light environment of the cockpit due to the sun or to spurious reflections on the canopy.
Regarding the electromagnetic posture detection devices, robust solutions are difficult to implement.
In particular, in the aeronautical field, spurious radiations and electromagnetic disturbances can degrade the performance characteristics of the existing systems.
SUMMARY OF THE INVENTION
The inventive device makes it possible notably to overcome the abovementioned drawbacks. In practice, the device is of the electro-optical type. It provides a way of overcoming the drawbacks of the electromagnetic devices.
Also, it preferably uses image projection means of the holographic video projector type.
In particular, monochromatic holographic video projectors have the advantages of emitting, in a very narrow frequency band, a clear image in a wide field and of making it possible to concentrate a high energy in a very small area. It is very easy to discriminate the signal originating from the holographic video projector from the spurious light.
Specifically, the device according to the invention includes electro-optical sensors positioned on the object and distributed in groups, called clusters, analysis and computation means making it possible to find the position and/or the attitude of the object, electronic image generation means and optical projection means comprising a display and a projection optic.
The optical projection means emit, in a projection cone, a clear image at any point of the travel range in which the object can move. The analysis of the portions of images received by the sensors of at least one cluster make it possible to identify the position and/or the attitude of the object in the frame of reference defined by the projection means, the latter comprising a plane perpendicular to the projection axis, called image plane, and the projection axis.
Advantageously, the projection means are a holographic video projector. The latter comprises a coherent light source, a display making it possible to produce a phase image, the projection optic then being arranged so as to create, from the wave emitted by the light source, a first reference wave and a second wave modulated by the display and comprising means making it possible to make these two waves interact.
Furthermore, this holographic video projector can project images in a solid angle of 10 degrees minimum to 120 degrees maximum and can reach a projection speed of at least 24 images per second.
The light source of such a holographic video projector can be monochromatic and emit in a frequency band in the infra-red or near-infra-red band, the sensitivity of the sensors being adapted to the emitted radiation.
Advantageously, the projected images can be polarized. Moreover, any type of image can be generated by such a holographic video projector including patterns occupying all or part of the image and comprising light motifs of constant intensity.
As an example, these patterns consist of light motifs, the form of which can be horizontal and/or vertical bars or even circle or concentric rings, each ring being able to alternately consist of dark and bright angular parts, the number of angular portions varying from one ring to the next ring.
Any type of combination of patterns is possible in the image generated by the holographic video projector.
The inventive device uses light, matrix or unit length sensors. The latter can be positioned in groups, also called clusters, having geometric forms adapted to increase the performance characteristics of the device and reduce the computation times.
For example, groups of three sensors can be arranged in star form or in parallelogram form in the inventive device
The electro-optical sensors and the analysis means can advantageous interpret and/or discriminate the polarization of the received signals.
Advantageously, a first method of optically detecting the position and the orientation of an object in space by means of the inventive detection device comprises:
a first step of generation by the holographic video projector of a succession of images, all different, each image giving a different signal on at least one cluster; a second step of analysis of the signals received by the sensors of the cluster making it possible to find the position and/or the attitude of the sensors in space without a priori indication.
Advantageously, a second method of optically detecting the position and the orientation of an object in space by means of the inventive device comprises:
a first step of generation of an image comprising light motifs, said motifs being generated so as to illuminate the clusters; a second step of analysis of the signals received by the sensors making it possible to find the position of the sensors in space; finally, a third servo-control step making it possible to reposition the motifs of the image generated on the clusters.
Advantageously, a first method combining the two preceding abovementioned methods comprises an initialization step performed according to the first method and an operating step corresponding to the second method.
Still other objects and advantages of the present invention will become readily apparent to those skilled in the art from the following detailed description, wherein the preferred embodiments of the invention are shown and described, simply by way of illustration of the best mode contemplated of carrying out the invention. As will be realized, the invention is capable of other and different embodiments, and its several details are capable of modifications in various obvious aspects, all without departing from the invention. Accordingly, the drawings and description thereof are to be regarded as illustrative in nature, and not as restrictive.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention is illustrated by way of example, and not by limitation, in the figures of the accompanying drawings, wherein elements having the same reference numeral designations represent like elements throughout and wherein:
FIG. 1 , the general device according to the invention in 3D view;
FIG. 2 , two position patterns and one roll pattern;
FIG. 3 , the projection of a position pattern on a cluster;
FIG. 4 , is an exemplary sequence of patterns projected on a star-configuration cluster;
FIG. 5 , is a representation of the combination of patterns according to FIG. 4 projected in succession.
DETAILED DESCRIPTION OF THE INVENTION
In the description that follows, the device described is used for aeronautical applications where the object is a pilot's headset. Obviously, it is possible to adapt the device, with no major modification, to the detection of other objects.
As indicated in FIG. 1 , the inventive device comprises an image projector 1 . Said image projector emits an image 3 , in focus in the entire area 4 , comprising a set of patterns 7 . The patterns are projected onto sets of electro-optical sensors 6 situated on the object 5 . A pattern is a set of geometrical light motifs on a black background. These patterns can be circles, rings, bars or a noteworthy geometrical form. The set of sensors is called a cluster. These sensors can be grouped in such a way that the cluster has geometrical properties for detection. In order to find the position and the orientation of the clusters in space, the inventive device comprises means of analyzing the data obtained from the sensors. The position and the orientation, of at least one cluster, being determined, the position and the orientation of the object are then known.
For the device to be able to operate correctly, it is essential for the motifs of the patterns to be clear at all points of the sensors. There are various optical means that make it possible to obtain this property.
To this end, an exemplary embodiment of the invention uses as projection means a holographic video projector 1 . Such holographic video projectors are produced and marketed, for example, by the company Light Blue Optics and are known by the brand name PVPro. This holographic video projector has the advantageous property of emitting a clear image at any point of the travel range 8 .
This holographic video projector comprises a coherent light source, which is generally a laser diode, a display making it possible to produce a phase image, optical means arranged so as to create, from the wave emitted by the light source, a first reference wave and a second wave modulated by the display and means making it possible to make two waves interact. The final image obtained is a Fraunhofer hologram of the phase image generated on the display. It is possible to generate any type of image by this means. The display can be a liquid crystal display, for example of LCOS type.
The image 3 generated by the holographic video projector consists of patterns 7 which can be patterns located on a sensor, called position patterns or roll patterns, or patterns that can cover all of the field, thus occupying all of the image or a large part thereof. The patterns can be emitted sequentially in time, the motifs that make up the pattern being able to change or remain identical between two successive emissions.
The device of FIG. 1 shows an example of clusters 6 , each consisting of three sensors, arranged in stars. Each of the clusters is contained in a plane on the surface of the object 5 . The sensors can, for example, be unit length matrix sensors.
Patterns generated in this way by the holographic video projector are projected locally on the planes of a sufficient number of clusters of the object. Each cell of each electro-optical sensor that is a part of a cluster detects the presence of the light signals obtained from the pattern. These signals are sent to the computer for analysis.
The size of the patterns and the form and the number of the sensors are optimized data dependent on the travel space and the form and the volume of the object as well as the desired accuracy. The number of clusters and the positioning and the number of patterns can be sufficient for the projection of the patterns to reach a sufficient number of clusters making it possible to find the position of the object from the analysis means 2 . The analysis means are generally an electronic computer.
The device has various operating modes. A first operating mode is a servo-controlled mode. The determination of the position and the orientation of the clusters or of the object in space depends on a position and an orientation that are known a priori from a recent past and estimated at the moment of projection, the generated patterns being emitted in the direction of said clusters.
In this mode, the computer 2 analyzes the positions and the orientations of one or more clusters. This computer, based on these data, servo-controlled the position of the patterns projected by the holographic video projector. To this end, the estimated position and orientation of the clusters in space are used to determine the next position of the patterns to be projected in the image plane.
FIG. 2 represents an example of patterns used in this first operating mode. Two position patterns 22 and 23 and one roll pattern 21 are represented within the area 20 delimited by the part of the object that is visible from the projector, this area being represented by a circle. These three patterns are local, in other words, they are centered around a cluster.
The position pattern 22 is an exemplary pattern having a single light ring. Some cells of a sensor of the cluster 24 receive light and supply the computer with information with which to easily estimate, by construction, the position of the cluster in the light ring.
The position pattern 23 is another exemplary pattern having several light rings. In the same way, the computer is capable, based on the information from each cell of each sensor, of restoring the position of the cluster in the light rings.
The pattern 21 is an exemplary roll pattern. The latter comprises various concentric rings, each ring comprising light and dark angular portions of constant width, positioned in such a way that, over the width of a portion, the sequence formed by all of the portions on a radius are unique. The angular position, that is, the orientation, is deduced by analyzing the information collected from each sensor of the cluster.
FIG. 3 represents an exemplary position pattern and a cluster on the same plane. The servo-control of the patterns projected by the video projector makes it possible to situate the pattern 31 locally around the cluster 32 .
Each cell of each sensor 30 restores to the computer the information from the signal received on the computer. From the distribution of the light on the sensor, the computer can, by construction, estimate the position of the cluster in the image plane. In practice, the generation of the patterns, and the estimation of the position and/or attitude parameters, takes account of the corrections of deformation linked to the projection.
The projection speed of the images generated by the holographic projector must be faster than the travel speed of the object.
To this end, the holographic video projector is capable of emitting a series of images at the speed of 24 images per second. This speed is sufficient to emit two successive patterns on at least one cluster.
In another operating mode, it is necessary to find the position and the orientation of the object, that is, without knowing the initial position and orientation of the object beforehand.
One means, using the holographic video projector, of estimating the position of the object in the travel range, is to emit a sequence of patterns in a sufficiently short time. On each projection, a single pattern entirely occupies all or a large part of the generated image. Moreover, between two successive projections, the light motifs of these patterns are different.
The analysis of the signals received from each cell of each sensor throughout the sequence makes it possible to calculate the position of the sensors in space.
FIG. 4 shows an example of circular patterns 42 and 44 , the motifs of which are light bands alternately separated by dark bands, respectively vertical and horizontal.
A first row of patterns represents a particular sequence of patterns with motifs that are straight vertical bands. This sequence of images is generated in a time 43 . The analysis of the sequence of signals received in a cell makes it possible to calculate the vertical position of each cell in the pattern.
A second row of patterns represents another sequence of patterns with motifs that are straight horizontal bands. This sequence of images is generated in a second time 43 . The analysis of the sequence of signals received in a cell makes it possible to calculate the horizontal position of each cell in the pattern.
The entire sequence of images consists of the two preceding sequences. These sequences of images can, for example, be generated in succession. Each image can alternately comprise a pattern with horizontal bands and the next with vertical bands.
The cluster 40 is represented in the plane of the pattern, called image plane, said cluster is exposed to the light signals of the motifs of each pattern. The principle is to emit, in a time 43 , a sequence of patterns 42 , each exposed for a time interval 41 . The width of the bands and the pitch between the bands that make up each pattern are increasingly small. They can diminish by a factor of two between each projection, for example.
FIG. 5 represents an exemplary representation of a compilation 52 of patterns 42 comprising light vertical bands and another representation of a compilation 54 of patterns 44 comprising light horizontal bands. The compilation of patterns comprising vertical bands represents the succession of light or dark signals received by a cell of a sensor when it is located in the band 55 during the time interval 41 . The sequence of signals received in the time 43 is analyzed. By construction, the horizontal position of the cell in the pattern is deduced.
In the same way, the cell interprets its vertical position when it is located in the band 56 of the compilation of patterns 54 .
To eliminate any position ambiguity on the projection of the first image on the sensors, that is, to differentiate the case of a signal received by the cell from a dark fringe and the case where no signal is received, it is necessary for the light bands of the first two patterns projected to be of the same size and alternate.
Advantageously, a binary coding can be used for the analysis of these signals. In the case of a signal obtained from a light fringe, the cell interprets a bit of value equal to 1, otherwise it interprets a bit of value equal to 0.
Since the bands diminish from one projection to the next in one and the same sequence, the high-order bits are interpreted at the start of the sequence. The information concerning the accuracy of the vertical and/or horizontal position is interpreted at the end of the sequence, by the low-order bits.
Such sequences of patterns, associated with this type of binary coding of the receiving signal, make it possible to directly determine the vertical and, respectively, horizontal position of a cell of a sensor in the pattern.
The accuracy of the position of a cell of a sensor is determined to within the error of the width of the light or dark band of the last projected pattern of the sequence.
Generally, any unambiguous image or series of images can be used as a means of determining the initial position.
The two operating modes, servo-controlled and absolute, can be combined. On initializing or reinitializing the detection of the object, that is, when the position of the object is not known, the position and the orientation of the object can be determined by the second detection mode. Then, secondly, the position and the orientation being determined by the detection initialization step, a servo-controlled mode detection step begins. The second step proceeds independently until the detection is deliberately interrupted or until the position of the object is lost. In the latter case, the first step, that is, the second operating mode, can be reactivated automatically or manually to find the position of the object.
The benefit of using the servo-controlled mode is that it makes it possible to generate a very limited number of patterns between two measurements. Consequently, very fast measurement rates can be used.
It will be readily seen by one of ordinary skill in the art that the present invention fulfils all of the objects set forth above. After reading the foregoing specification, one of ordinary skill in the art will be able to affect various changes, substitutions of equivalents and various aspects of the invention as broadly disclosed herein. It is therefore intended that the protection granted hereon be limited only by definition contained in the appended claims and equivalents thereof. | The present invention relates to a device for optically detecting position and/or attitude of an object ( 5 ) moving in a given travel range ( 4 ), said device comprising electro-optical sensors positioned on said object and distributed in groups, called clusters ( 6 ), analysis and computation means ( 2 ) making it possible to find the position and/or the attitude of said object, electronic image generation means ( 1 ) and optical projection means ( 1 ) comprising a display and a projection optic. The optical projection means emit, in a projection cone, a clear image ( 3 ) at any point of the travel range, the analysis of the signals received by the sensors of at least one cluster making it possible to identify the position and/or the attitude of the object in the frame of reference defined by the projection means, the latter consisting of a plane perpendicular to the projection axis, called image plane, and the projection axis. | 6 |
FIELD OF THE INVENTION
The invention relates to a bone milling tool for precise preparation of.
BACKGROUND OF THE INVENTION
From the DE-OS 27 48 452 is known a bone milling tool for round milling a hip joint head which is provided with a central hole into which a centering pin is inserted. The milling head is joined to a driveshaft which is,. at least near the area of the milling head, of tubular design.
Also known is a bone milling tool as illustrated in FIG. 4. A bone milling tool of this type is used for precisely fitting preparation of bones, in particular tubular bones. It is important, in particular with cementfree implantation of prosthesis, to create an extremely precisely fitting bone bed to accommodate the prosthesis, on the one hand to ensure the largest possible contact surface for fast grafting of the bone and on the other hand to eliminate micro movements. Rotary instruments are preferred as the precision of oscillating saws is insufficient.
Bone milling tool 10a illustrated in FIG. 4 is a front-end milling tool. It is composed of a cylindrical milling head 12a with cutting teeth configured at the front. A guide pin 30 is also arranged at this side. A driveshaft 14' is mounted to the rear of milling head 12a. When using this bone milling tool 10a, guide pin 30 is pushed into a guide bore which has been entered into the bone, thus ensuring guided and directionally stable processing. Exerting pressure (see arrows 26 in FIG. 4) onto driveshaft 14' in the direction of guide pin 30 establishes contact of front-end cutting teeth with the bone and mills a rotary-symmetrical surface into the depth.
The problem with both of the aforedescribed bone milling tools lies with the respective driveshaft, which protrudes from the field of operation and has to be connected to a drive unit. If the field of operation is small and access has to be of narrow design for anatomical or surgical reasons, then it can happen that, whilst milling downwards, the driveshaft is forced out of its direction by protrusions in the field of operation, which results in a directionally unstable or directionally incorrect milling surface. The result is an inaccurate bone bed, both relative to the contact surface and relative to positioning of a prosthesis.
SUMMARY OF THE INVENTION
It is an object of the invention to create a bore milling tool which makes it easily possible to establish a bone bed of maximum fitting accuracy even in the event of a small field of operation.
An aspect of the invention involves a bone milling tool for precise preparation of bones. The bone milling tool includes a milling head connected to a driveshaft. The driveshaft simultaneously serves as a guide element which is guided in a bone. The bone milling tool further includes a toothing which is arranged on the milling head facing the driveshaft.
According to the invention, the driveshaft simultaneously serves as guide element and is passed through a continuous guide bore which is established in the bone. As the toothing is arranged at the side of the driveshaft on the milling head, work is, in contrast to conventional bone milling tools, no longer carried out by pushing but by pulling.
When using the bone milling tool, the driveshaft extends from the milling head in the direction of the bone and through the guide bore which has been established in the latter. The driveshaft then no longer protrudes from the field of operation and can no longer be forced out of its direction by objects which protrude into the field of operation. This ensures production of a bone bed of high fitting accuracy.
The driveshaft is preferably of flexible design. The use of a flexible driveshaft is only made possible because work is no longer carried out by pushing but by pulling.
According to a further advantageous embodiment, a guide pipe is inserted into the guide bore which has been established in the bone. The driveshaft then no longer rubs against the bone or adjacent soft parts. The guide pipe can be pushed thereinto from the end of the bore located opposite the field of operation. When lowering the milling work, the milling head pushes the guide pipe in front of it without milling it.
As the driveshaft has to be guided all the way through the bone, and as it has to be connected on one side to the milling head and on the other side to a drive unit, at Least one of these connections has to be of detachable design. The detachable connection is preferably provided at the point of transition from driveshaft to milling head or at the point of transition from driveshaft to drive unit.
In the first case, the driveshaft is prior to milling inserted from the opposite end of the guide bore in the direction of the field of operation and connected to the milling head. In the second case, the driveshaft is pushed from the field of operation through the guide bore and on exit from the bone on the opposite side connected to the drive unit.
The milling head can be of varying design, but should be rotary-symmetrical. For cylindrical milling, a milling head is chosen, the toothing of which is configured in one plane. This produces a plane cutting surface standing perpendicularly to the driveshaft. Alternatively, a milling head can be used which comprises a cutting surface which is concave, convex or a combination of such surfaces. This allows milling of spherical, conical, cylindrical, polygonal, wavy or any other rotary-symmetrical shape surfaces.
A preferred embodiment is characterised in that the cutting surface is extended by a non-cutting protective collar. The protectice collar keeps soft parts away from the milling zone.
The toothing of the milling head can be of conventional design, i.e. it can be milled or hammered. However, particularly advantageous is the use of a rasplike toothing with additional waste-removal holes provided in the milling head. This makes it possible to remove bone waste from the milling area.
A special combination of the latter embodiment of a toothing is established when a catching device, in particular a collecting vessel, is arranged at the rear of the milling head. For example, the use of a small basket or dishlike container in which occurring bone waste can be collected, would be useful. This can not only prevent pollution of the field of operation by such waste and reduce the danger of an induced undesirable ectopic bone growth, but additional waste collected in the container can be used further as valuable autologem spongiosa pulp.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will now be described in more detail, also in view of further advantages and features, based on exemplary embodiments and with reference to the enclosed drawings. The drawings show in
FIG. 1 a diagrammatical side view of an exemplary embodiment of the inventive bone milling tool;
FIG. 2 a cross-sectional illustration of a further form of embodiment of the inventive bone milling tool with domeshaped cutting surface and screw connection between milling head and driveshaft;
FIG. 3 a diagrammatical perspective illustration of a third form of embodiment of an inventive bone milling tool with rasplike toothing and collecting container; and
FIG. 4 a diagrammatical side view of a bone milling tool of the prior art.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 illustrates an exemplary embodiment of a bone milling tool 10b, consisting essentially of a cylindrical milling head 12b and a driveshaft 14.
Milling head 12b has at its surface facing toward driveshaft 14 a toothing 20b which is, in the present exemplary embodiment, milled. However, it can also be hammered or arranged in a different manner. All teeth of toothing 20b lie essentially in one plane, so that its use produces a cutting surface which extends perpendicularly to driveshaft 14.
Driveshaft 14 is firmly connected to milling head 12b and serves at the same time as guide element corresponding with guide bolt 30 of FIG. 4. To allow use of bone milling tool 10b, initially a continuous guide bore has to be established in the bone. For example, to shape a hip joint head by milling, the continuous guide bore is introduced through the shank neck. Driveshaft 14 is pushed from the direction of the shank head through the guide bore and on exit from the bone at the lateral side connected to a drive unit (not illustrated).
In the present bone milling tool 10b, guide bolts and driveshaft 14 coincide and toothing 20b is not arranged at the end surface but at the rear (similar to the lamellae of a mushroom), so that bone milling tool 10b does not operate by means of pushing on driveshaft 14 but by pulling the latter (see arrows 28). This makes it possible to also operate with a flexible driveshaft 14.
When working with a flexible driveshaft, it is of advantage to line the guide bore laterally with a guide pipe (not illustrated), so that rotary driveshaft 14 does not rub against the bone or adjacent soft parts. When working downwards, milling head 12b simply pushes the guide pipe ahead of itself without milling it.
FIG. 2 illustrates a further exemplary embodiment of a bone milling tool 10c, and the same reference numbers correspond with identical parts. Bone milling tool 10c differs from the one of FIG. 1 in two ways.
For one, milling head 12c is of domeshaped design as can be seen in the cross-sectional illustration. A concave cutting surface with respective toothing 20c is provided at the side of milling head 12c which is associated with driveshaft 14. This permits milling a shape surface which corresponds with said surface. The cutting surface is extended by a protruding, non-cutting protective collar 32 in order to keep soft parts away from the cutting zone.
Furthermore, driveshaft 14 and milling head 12c are detachably joined together, i.e. by means of a bolt 18. The latter is passed through a centered bore 16 in milling head 12c and is screwed into an inside thread at the side of the milling head of driveshaft 14. With a bone milling tool 10c of this type, driveshaft 14 is prior to a milling operation entered laterally from the end of the guide bore in the direction of the shank head and then connected to milling head 12c by means of bolt 18.
A third embodiment of a bone milling tool 10d is illustrated in FIG. 3. This bone milling tool 10c offers special qualities relative to the aforedescribed forms of embodiment, in particular the one of FIG. 1. Toothing 20d at the driven surface of milling head 12d is of rasplike design and comprises waste removing holes 22 which extend through milling head 12d. Above the surface of milling head 12d opposite driveshaft 14 is arranged a removable collecting vessel 24, so that all bone waste severed by raspshaped toothing 20d and transported through waste remov ng holes 22 can be caught in said collecting vessel 24. This effectively prevents pollution of the field of operations thus limiting the danger of induced, undesirable ektopic bone growth. Bone waste caught in the removable collecting vessel 24 can subsequently be processed further into a valuable autologem spongiosa pulp.
In all, the described embodiments show bone milling tools by means of which a precisely fitting bone bed, for example for accommodating prostheses, can be created without elements of the bone milling tool protruding from the field of operation and making contact with objects in the field of operation. A directionally unstable or directionally incorrect milling surface can be effectively avoided.
Bone milling tools that are coated with hard material provide produce milled bone surfaces which distinguish themselves in that they bond completely with hydroxialpatit layered implant surface, for example within 10 and 14 days. This allows considerable acceleration in healing of implants.
Reference List
10a, b, c, d--Bone Milling Tool
12a, b, c, d--Milling Head
14--Driveshaft
14'--Driveshaft of the Prior Art
16--Bore
18--Bolt
20b, c, d--Toothing
22--Waste Removing Holes
24--Collecting Vessel
26--Arrow (symbolising Pushing Load)
28--Arrow (symbolising Pulling Load)
30--Guide Bolt
32--Protective Collar | A bone milling tool for precise preparation of bones includes a milling head connected to a driveshaft. The driveshaft simultaneously serves as a guide element which is guided in a bone. The bone milling tool further includes a toothing which is arranged on the milling head facing the driveshaft. | 0 |
This is a continuation of application Ser. No. 06/878,538 filed June 25, 1986, now abandoned.
FIELD OF THE INVENTION
The present invention relates to silver halide photographic materials, and in particular, to negative-type silver halide photographic materials of high sensitivity and good graininess.
BACKGROUND OF THE INVENTION
In the field of the silver halide photograhic materials, especially those intended for camera use, recently, photographic materials of ultra-high sensitivity have become widely used, and ISO 1600-color negative film is a typical example. In order to enhance the sensitivity of photographic materials, it has heretofore been propelled to enlarge the size of the silver halide grains contained in said materials, which, however, results in deterioration of the graininess of said grains. In conventional films of ISO 100 and 400, the size thereof has recently been required to be a small format one, and therefore it is requested to make the graininess of the silver halide grains used in said films further better.
It is generally known that a monodispersion emulsion having a uniform grain size distribution is superior to a polydispersion emulsion in that the graininess in the toe region of the characteristic curve thereof is especially excellent. Among said monodispersion emulsions, in particular, normal crystalline grains can be controlled during the formation step of the grains or during the chemical sensitization step thereof, without any remarkable variation of the grain (e.g., variation of the grain size, variation of the form, variation of the sensibility, etc.) and thereby can obtain excellent graininess. Accordingly, said normal crystalline grains bring a great merit in order to enhance the sensitivity in this industrial field. These are described in T. H. James, The Theory of the Photographic Process, Fourth Edition, Chapter 21, The Macmillan, 1977.
SUMMARY OF THE INVENTION
An object of the present invention is to provide a negative-type silver halide photographic materials having high sensitivity and good graininess with low fog.
The present inventors have extensively studied the matter, and have now found that said object of the present invention can be attained by incorporating into a silver halide emulsion layer wherein chemically-sensitized negative-type silver halide grains comprise normal crystalline grains, a polymer having a repeating unit of formula (I); ##STR10## wherein R 1 represents a hydrogen atom or an alkyl group; Q represents one group selected from formulae (i), (ii), (iii), and (iv) ##STR11##
wherein q is an integer of from 2 to 4; ##STR12##
wherein R 2 and R 3 each represents a hydrogen atom or an alkyl group; ##STR13##
wherein Z 1 represents an atomic group forming a lactam ring, an oxazolidone ring, or a pyridone ring;
A represents a single bond, ##STR14##
B represents --O-- or ##STR15## wherein R 4 represents a hydrogen atom or an alkyl group; and
l is an integer of from 1 to 6; and ##STR16##
wherein
A has the same meaning as defined for formula (iii);
D represents a single bond, --O-- or ##STR17## wherein
R 5 represents a hydrogen atom, an alkyl group, or ##STR18## wherein R 6 represents an alkyl group; and
m and n each represents an integer of from 1 to 6, provided that the sum of m and n is an integer of from 4 to 7.
Accordingly, the present invention provides a negative-type silver halide photographic material having at least one silver halide emulsion layer on a support, wherein the chemically-sensitized silver halide grains contained in the emulsion of the emulsion layer comprise normal crystalline grains, and said emulsion layer containing said normal crystalline silver halide grains contains a polymer having a repeating unit represented by formula (I).
DETAILED DESCRIPTION OF THE INVENTION
The polymers of formula (I) have heretofore been considered to be a substitutive substance for a conventional binder such as gelatin. U.S. Pat. No. 4,431,730 describes certain characteristics of said polymers, particularly that when the surface of an internal latent image-type direct positive silver halide emulsion is chemically-sensitized in the presence of said polymer, D max (maximum density) of the reversal image becomes higher and the other reversal photographic characteristics are not deteriorated at all.
In a surface latent image-type emulsion for obtaining negative images, however, whose surfaces have been chemically-sensitized (for example, by gold- and/or sulfur-sensitization), the present inventors have found the fact, as shown in the examples hereinafter given in the present specification, that, if the polymer of formula (I) of the present invention is incorporated in a conventional amorphous silver halide emulsion layer containing twinned-type crystalline grains, no sensitization effect is obtained. However, the inventors have surprisingly found that if the polymer of formula (I) is incorporated in a silver halide emulsion containing normal crystalline grains according to the present invention, a sensitization effect of the emulsion can be attained. This discovery was quite unexpected.
Furthermore, if the polymer of formula (I) of the present invention is combined with a normal crystalline emulsion having a distinct stratiform structure, which is explained in detail hereinafter, the sensitization effect is even more remarkable, and this is still further unexpected. The mechanism has not as yet been clarified.
Normal crystalline grains in the present invention include regular crystalline grains (normal crystals) such as cubic, octahedral, dodecahedral, and tetradecahedral crystalline grains, and in addition, further include somewhat roundish grains derived therefrom where the corner parts or edge parts are broken in some degree.
The emulsion of the present invention may contain any other grains in addition to the normal crystalline grains, such as pebble-like grains, tabular grains, etc.; and the volume fraction of the normal crystalline grains in the emulsion is preferably 50% or more, and more preferably 75% or more.
In case of normal crystals, grains having 50% or more of the face (111) are particularly suitable.
The face rate of the face (111) can be determined by a Kubelka-Munk's dye absorption procedure. In this process, a dye which is preferentially absorbed on either the face (111) or the face (100), wherein the association state of the dye on the face (111) is spectrometrically different from that of the dye on the face (100), is selected. Such a dye is added to the emulsion, and spectra to the amount of the dye added are examined in detail by generally known methods, by which the face rate of the face (111) can be determined.
The grain size of silver halide grains of the present invention is not particularly limited, but it is preferably 0.4 μm or more, more preferably 0.8 μm or more, and particularly preferably from 1.4 to 3.0 μm.
The halogen composition of the silver halide grains preferably comprises normal crystalline grains containing from 60 to 100 mole % silver bromide and up to 20 mole % silver chloride, and more preferably comprises normal crystalline grains containing 2 to 30 mole % of silver iodine, and particularly preferably comprises normal crystalline grains containing from 7 to 25 mole % of silver iodine. Further, the silver halide grains having the same halogen composition ratio in each of the grains are preferred.
The most preferred halogen composition in the silver halide grains has substantially two distinct stratiform structures comprising a core part of a high iodine layer and a shell part of a low iodine layer. Grains having such a structure are explained in more detail hereunder.
The distinct stratiform structure as described herein can be confirmed by X-ray diffractiometry. An example of applying the X-ray diffractiometry to silver halide grains has been described in H. Hirsch, Journal of Photographic Science, Vol. 10 (1962), pp. 129. When the lattice constant is determined on the basis of halogen composition, a diffraction peak is formed in the angle of diffraction which satisfies Bragg's condition (2d sin θ=nλ).
The manner of measuring the X-ray diffraction has been described in detail in "X-Sen Bunseki" (X-Ray Analysis), Kiso Bunseki Kagaku Koza (Lecture of Fundamental Analysis Chemistry), published by Kyoritsu Shuppan and X-Sen Kaiseki No Tebiki (Manual of X-Ray Diffraction), published by Rigaku Denki Co. A standard method of measurement is carried out in such a manner that a diffraction curve of the face (220) of the silver halide is determined by using Cu as a target with a Kβ ray of Cu as a ray source (tube electric potential: 40 KV, tube electric current: 60 mA). In order to increase the resolving power of the apparatus for measurement, it is necessary to confirm the accuracy of the measurement by using a standard sample such as silicon, etc., and selecting a suitable slit width (radiation slit, light receiving slit, etc.), time constant of the apparatus, scanning rate of the goniometer, and recording rate.
When emulsion grains which have a distinct stratiform structure having two parts are used, a diffraction maximum due to silver halide in the high silver iodide content core and a diffraction maxium due to silver halide in the low silver iodide content shell part of the uppermost layer appear, whereby two peaks are formed on the diffraction curve.
The distinct stratiform structure having substantially two parts in the present invention means that when a curve of diffraction intensity of the face (220) of silver halide to angle of diffraction (2⊖) is obtained using a Kβ ray of Cu in a range of an angle of diffraction of from 38° to 42°, two diffraction maximums of a diffraction peak corresponding to the high silver iodide content core containing from 10 to 45 mole % of silver iodide and a diffraction peak corresponding to the low silver iodide content shell part of the uppermost layer containing 5 mole % or less of silver iodide appear and one minimum appears between them, the diffraction intensity of the peak corresponding to the high silver iodide content core is from 1/10 to 3/1, preferably from 1/5 to 3/1, more preferably from 1/3 to 3/1, of the diffraction intensity of the peak corresponding to the low silver iodide content shell part of the uppermost layer.
As emulsions having a distinct stratiform structure having substantially two parts in the present invention, those wherein the diffraction intensity of the minimum value between two peaks is 90% or less of the diffraction maximum (peak) having the lower intensity of the two diffraction maximums are preferred.
For the minimum between the two peaks, 80% or less is more preferred and 60% or less is particularly preferred.
The manner of analyzing the diffraction curve composed of two diffraction components is well known and described in, for example, "Koshi Kekkan" (Failure of Lattice), Jikken Butsurigaku Koza (Lecture of Experimental Physics), No. 11, published by Kyoritsu Shuppan.
It is effective to analyze the curve with a curve analyzer produced by E.I. Du Pont de Nemours and Company on the assumption that it is a function such as a Gauss function or a Lorentz function .
In an emulsion containing two kinds of grains, having a different halogen composition, which do not have a distinct stratiform structure, two peaks also appear in the above described X-ray diffraction pattern. However, such an emulsion cannot show excellent photographic performances as obtained in the present invention.
Whether the silver halide emulsion is an emulsion having a distinct stratiform structure of the present invention or the aforesaid emulsion wherein two kinds of silver halide grains are present can be judged by an EPMA process (Electron-Probe Micro Analyzer process) in addition to X-ray diffractometry.
In the EPMA process, a sample in which emulsion grains are well dispered so as not to contact one another is produced, and irradiated with electron beams. Elemental analysis of very fine parts can be carried out by X-ray analysis of electron ray excitation.
According to the EPMA process, the halogen composition of individual grains can be determined by measuring the X-ray intensities of silver and iodine emitted from each grain.
It can be determined whether or not the emulsion is that of the present invention, if the halogen composition of at least 50 grains is confirmed by the EPMA process.
In the emulsions having a distinct stratiform structure of the present invention, it is preferred that the silver iodide content of each grain is uniform.
It is preferred, when measuring the distribution of the silver iodide content of the grains, that the standard deviation is 50% or less, more preferably 35% or less, and particularly preferably 20% or less.
As the halogen composition of silver halide grains having a distinct stratiform structure of the present invention, preferred examples are as follows.
The core part is silver halide having a high iodide content, wherein the iodide content is preferred to be in a range of from 10 to 45 mole % which is the limited amount of solid solution. The silver iodide content is preferably in a range of from 15 to 45 mole %, and more preferably from 20 to 45 mole %.
In the core part, the silver halide other than silver iodide may be either or both of silver chlorobromide and silver bromide, but it is preferred that the amount of silver bromide is higher.
The composition of the shell part of the uppermost layer preferably consists of silver halides containing 5 mole % or less of silver iodide and, more preferably, silver halides containing 2 mole % or less of silver iodide.
In the shell part of the uppermost layer, the silver halide other than silver iodide may be any of silver chloride, silver chlorobromide, and silver bromide, but it is preferred that the amount of silver bromide is higher than the amount of the other silver halide.
When the total silver iodide content of the whole grains is 7 mole % or more, the effect of the present invention is especially remarkable. A preferable total silver iodide content of the whole grain is 9 mole % or more, and, particularly preferably, from 12 to 25 mole %.
In order to obtain suitable photographic properties in the emulsions comprising silver halide grains having a distinct stratiform structure, the core composed of silver halide having a high silver iodide content should be sufficiently coated with the shell composed of silver halide having a low silver iodide content. The thickness of the shell depends upon grain size, but it is preferred that large grains having a grain size of 1.0 μm or more are coated with a shell having a thickness of 0.1 μm or more and small grains having a grain size of less than 1.0 μm are coated with a shell having a thickness of 0.05 μm or more. In order to obtain emulsions having a distinct stratiform structure, the ratio of silver content in the core part of the shell part is preferred to be in a range of from 1/5 to 5/1, more preferably from 1/5 to 3/1, and particularly preferably from 1/5 to 2/1.
As described above, silver halide grains which have a distinct stratiform structure having substantially two parts means that the grains have substantially two regions, each having a different halogen composition, wherein the center side of the grains is called the core part and the surface side is called the shell part.
The phrase "substantially two parts" means that a third region other than the core part and the shell part (for example, a layer between the central core part and the uppermost shell part) may be present.
However, the third region should be present only to the extent of not having a substantial influence upon the shape of the two peaks (which correspond to the part having a high silver iodide content and the part having a low silver iodide content) when an X-ray diffraction pattern is obtained as described above.
Namely, silver halide grains wherein a core part having a high silver iodide content, an intermediate part, and a shell part having a low silver iodide content are present, two peaks are present and one minimum part is present between the two peaks in the X-ray diffraction pattern, the diffraction intensity corresponding to the part having a high silver iodide content is from 1/10 to 3/1, preferably from 1/5 to 3/1 and, particularly preferably from 1/3 to 3/1 of that of the part having a low silver iodide content, and the diffraction intensity of the minimum part is 90% or less, preferably 80% or less, and, particularly preferably 70% or less of the smaller peak of two peaks, are grains having a distinct stratiform structure having substantially two parts.
The case wherein a third region is present in the inside of the core part is similar to the above-described case.
Regarding the grain size distribution of the normal crystalline grain of the present invention, the variation coefficient S/V, which relates to the grain size of silver halide grains, is preferably 0.25 or less, more preferably 0.15 or less. V is an average grain size and S is a standard deviation on the grain size.
The normal crystalline grains which is used in the present invention may be prepared in a conventional manner. The details are described in Research DisclosureVol. 176, RD No. 17643, Items I and II (December, 1978), which may be applied to the case of the present invention.
The emulsions having a distinct stratiform structure of the present invention can be prepared by selecting from the combining various processes known in the field of silver halide photographic material and Research Disclosure as described above.
In order to prepare core grains, the process can be selected from an acid process, a neutral process, an ammonia process, etc.
As one type of the simultaneous mixing process, a process wherein pAg in a liquid phase in which silver halide is formed is kept constant, namely, a controlled double jet process, can be preferably used. As another type of the simultaneous mixing process, a triple jet process which comprises adding separately soluble halogen salts having each a different composition (for example, a soluble silver salt, a soluble bromide, and a soluble iodide) can be used, too. Solvents for silver halide such as ammonia, rhodanides, thioureas, thioethers, amines, etc., may be used when preparing the core part. Emulsions in which the distribution of grain size of core grains is narrow are suitable. Emulsions in which halogen composition, particularly silver iodide content, of each grain is more uniform in the stage of preparing the core are preferred.
Whether the halogen composition of each grain is uniform or not can be judged by the above-described X-ray diffractiometry and the EPMA process. In the case that the halogen composition of core grains is more uniform, the diffraction width of the X-ray diffraction pattern is narrow, giving a sharp peak.
For the preparation of silver halide grains having a distinct stratiform structure used in the present invention, the shell part may directly be provided on the core grains, immediately after the formation of said core grains, but it is preferred that the shell part is provided thereon after the core emulsion has been washed with water for demineralization.
For the provision of the shell part on the core grain, various conventional means which are well known in the field of silver halide photographic materials may be used, and in particular, a simultaneous mixing process, especially a controlled-double jet method, is preferred.
The silver halide emulsion of the present invention is chemically-sensitized. Chemical sensitization can be carried out by processes as described, e.g., in H. Frieser (ed.), Die Grundlagen der Photographischen Prozesse mit Silberhalogeniden, pp. 675-734, Akademisch Verlagsgesellschaft (1968).
More specifically, chemical sensitization can be carried out by sulfur sensitization using compounds containing sulfur capable of reacting with active gelatin or silver ions (e.g., thiosulfates, thioreas, mercapto compounds, rhodanines, etc.); reduction sensitization using reducing materials (e.g, stannous salts, amines, hydrazine derivatives, formamidinesulfinic acid, silane compounds, etc.); noble metal sensitization using noble metal compounds (e.g., gold complexes, and complexes of Periodic Table Group VIII metals such as Pt, Ir, Pd, etc.); and the like individually or in combinations thereof.
Specific examples of sulfur sensitization are described in U.S. Pat. Nos. 1,574,944, 2,410,689, 2,278,947, 2,728,668, 3,656,955, etc. Specific examples of reduction sensitization are described in U.S. Pat. Nos. 2,983,609, 2,419,974, 4,054,458, etc. Specific examples of noble metal sensitization are described in U.S. Pat. Nos. 2,399,083, 2,448,060, British Pat. No. 618,061, etc.
The amount of the aforesaid polymer of formula (I) to be used in the present invention is to properly vary, in accordance with various conditions such as the kind of said polymer and the normal crystalline grains to be used together therewith; and in general, the amount of said polymer to be used may be smaller than the amount of said polymer which is to be used as a protective colloid or a binder, whereby the effect of the present invention may well be attained. In general, the amount of the present polymer to be used is from 0.02 to 10 g, preferably from 0.02 to 5 g, and more preferably from 0.1 to 2 g, per mole of silver used, as calculated in terms of the weight of the repeating unit of formula (I) which constitutes the present polymer.
Now, the polymers of the present invention will be explained in greater detail hereunder.
The polymers of the present invention are those having a repeating unit of the aforesaid formula (I). Preferably, R 1 in formula (I) represents a hydrogen atom and Q in formula (I) represents a group selected from the groups (1), (2), (3), and (4) below: ##STR19## wherein R 2 represents a methyl group or an ethyl group, and R 3 represents a hydrogen atom, a methyl group, or an ethyl group;
(4) ##STR20## wherein A represents a single bond or ##STR21## and Z 1 forms a 5-membered or 6-membered lactam ring or oxazolidone ring.
Among said cases, Q preferably represents ##STR22## a pyrrolidone group, or an oxazolidone group, and particularly preferably Q represents a pyrroidone group.
The polymers having the repeating units of formula (I) may be either homo-polymers or co-polymers.
More precisely, the polymers to be used in the present invention may be homo-polymers of momomers of the following formula (IA) or copolymers of two or more of said monomers or copolymers of said monomers with other ethylenic unsaturated compounds which may be copolymerizable therewith by addition-polymerization. ##STR23## In formula (IA) R 1 has the same meaning as in formula (I); Q 1 represents a group selected from the groups (i), (ii), (iii), and (iv): ##STR24##
wherein q, R 2 , R 3 , A, Z 1 , D, m, and n have the same meanings as in formula (I).l
Examples of the monomers of formula (IA) include N-vinyl-succinimide, N-vinylglutarimide, N-vinyladipimide, N-vinylacetamide, N-methyl-N-vinylformamide, N-methyl-N-vinylacetamide, N-ethyl-N-vinylacetamide, N-methyl-N-vinylpropionamide, N-vinylpyrrolidone, N-vinylpiperidone, N-vinyl-s-caprolactam, N-vinyloxazolidone, N-acryloylpyrrolidone, N-acryloyloxyethylpyrrolidone, N-acryloyl-morpholine, N-acryloylpiperidine, N-methacryloylmorpholine, N-(β-morpholinoethyl)acrylamide, N-vinylmorpholine, N-vinyl-2-pyridone, etc. Preferred monomers among them are, for example, N-vinylsuccinimide, N-vinylglutarimide, N-methyl-N-vinylacetamide, N-ethyl-N-vinylacetamide, N-vinylpyrrolidone, N-vinylpiperidone, N-vinyloxazolidone, etc. Especially preferred monomers are N-methyl-N-vinylacetamide, N-vinylpyrrolidone, and N-vinyloxazolidone.
Addition-polymerizable ethylenic unsaturated compounds which may be co-polymerizable with the monomers of formula (IA) to form copolymers include, for example, acrylates, methacrylates, acrylamides, methacrylamides, allyl compounds, vinyl ethers, vinyl esters, vinyl heterocyclic compounds, styrenes, maleates, fumarates, itaconates, crotonates, olefins, etc. Specific examples of said compounds include methyl acrylate, ethyl acrylate, isopropyl acrylate, n-butyl acrylate, octyl acrylate, 2-chloroethyl acrylate, 2-cyanoethyl acrylate, N-(β-dimethylaminoethyl) acrylate, benzyl acrylate, cyclohexyl acrylate, phenyl acrylate; methyl methacrylate, n-propyl methacrylate, isopropyl methacrylate, n-butyl methacrylate, cyclohexyl methacrylate, 3-sulfopropyl methacrylate; allyl-butyl ether, allyl-phenyl ether; methyl-vinyl ether, butyl-vinyl ether, methoxyethyl-vinyl ether, 2-hydroxyethyl-vinyl ether, (2-dimethylaminoethyl)-vinyl ether, vinyl-phenyl ether, vinyl-chlorophenyl ether, acrylamide, methacrylamide, N-methylacrylamide, N-(1,1-dimethyl-3-oxo-butyl)acrylamide, N-(1,1-dimethyl-3-hydroxybutyl)acrylamide, N,N-dimethylacrylamide, acryloyl-hydrazine, N-methoxymethyl-methacrylamide, N-(1,1-dimethyl-3-hydroxybutyl)methacrylamide, N-hydroxymethyl-acrylamide; vinylpyridine, N-vinylimidazole, N-vinyl-carbazole, vinyl-thiophene; styrene, chloromethylstyrene, p-acetoxystyrene, p-methylstyrene; p-vinyl-benzoic acid, methyl p-vinyl-benzoate; crotonamide, butyl crotonate, glycerin monocrotonate; methylvinylketone, phenylvinylketone; ethylene, propylene, 1-butene, dicyclopentadiene, 4-methyl-1-hexane, 4,4-dimethyl-1-pentene, etc.; methyl itaconate, ethyl itaconate, diethyl itaconate, etc.; methyl sorbate, ethyl maleate, butyl maleate, dibutyl maleate, octyl maleate, etc.; ethyl fumarate, dibutyl fumarate, octyl fumarate, etc.; halogenated olefins such as vinyl chloride, vinylidene chloride, isoprene, etc.; unsaturated nitriles such as acrylonitrile, methacrylonitrile, etc. These may be used in the form of a mixture of two or more thereof, if desired. Especially preferred compounds among them, in view of the hydrophilic property of the formed polymers therefrom, include acrylic acid, methyacrylic acid, 2-hydroxyethyl acrylate, 2-methoxyethyl acrylate, sulfopropyl acrylate, acrylamide, dimethylacrylamide, 2-acryloylamio-2-methylpropane-sulfonic acid, hydroxyethyl-acrylamide, methylacrylamide, methylvinyl ether, sodium styrene-sulfonate, N-vinyl-3,5-dimethyltriazole, and maleic anhydride. The constitution ratio of the polymers having the repeating unit of the formula (I) is not specifically limited, but the polymers preferably contain from 10 to 100 mole %, and more preferably from 50 to 100 mole %, of the component of formula (I).
The synthesis of the polymers or copolymers having the repeating units of formula (I) may be carried out, by reference to various methods as described, for example, in British Pat. Nos. 1,211,039 and 961,395, Japanese Patent Publication No. 29195/72, Japanese Patent Application (OPI) No. 76593/73 (the term "OPI" as used herein means a "published unexamined Japanese patent application"), British Pat. No. 961,395, U.S. Pat. Nos. 3,227,672, 3,290,417, 3,262,919, 3,245,932, 2,681,897, 3,847,615, 3,840,371, 3,963,495, and 3,230,275, Official Digest, by John C. Petropoulos et al, Vol. 33, pp. 719-736 (1961), and Synthetic High Molecular Compounds, by S. Murahashi, Vol. 1, pp. 246-290, ibid., Vol. 3, pp. 1-108, etc. The polymerization initiators, the concentration, the polymerization temperature, and the reaction time may widely and routinely be varied in accordance with the particular objects to be achieved.
For instance, the polymerization is generally carried out at a polymerization temperature of from 20° to 180° C., preferably from 40° to 120° C.; and from 0.05 to 5 wt % (to the weight of the monomers to be polymerized) of a radical-polymerization initiator is used in the polymerization. Examples of initiators are azobis-compounds, peroxides, hydroperoxides, and redox catalysts, such as potassium persulfate, tert-butyl-peroctoate, benzoyl peroxide, azobisisobutyronitrile, 2,2'-azobiscyano-valeric acid, 2,2'-azobis-(2-amidinopropane-hydrochloride), etc.
The aforesaid polymers to be used in the present invention have, in general, a molecular weight of about 2,000 to more, preferably from 8,000 to 700,000 or so. The molecular weight of the polymers, however, is not so critical in the present invention for the purpose of attaining the aimed effect thereof.
Typical examples of the polymers having the repeating units of formula (I) to be used in the present invention are listed hereunder.
(1) poly-(N-vinylpyrrolidone)
(2) poly(N-vinyloxazolidone)
(3) poly(N-vinylsuccinimide)
(4) poly(N-vinylglutarimide)
(5) poly(N-vinylpiperidone)
(6) poly(N-vinyl-ε-caprolactam)
(7) poly(N-methyl-N-vinylacetamide)
(8) poly(N-ethyl-N-vinylacetamide)
(9) poly(N-vinylacetamide)
(10) vinylacohol/N-vinylacetamide copolymer (molar ratio of 30/70)
(11) vinyl alcohol/N-vinylpyrrolidone copolymer (molar ratio of 20/80)
(12) vinyl alcohol/N-vinylpyrrolidone copolymer (molar ratio of 30/70)
(13) N-vinylpyrrolidone/vinyl acetate copolymer (molar ratio of 70/30)
(14) N-vinylpyrrolidone/2-hydroxyethyl acrylate copolymer (molar ratio of 70/30)
(15) N-vinylpyrrolidone/acrylic acid copolymer (molar ratio of 90/10)
(16) N-vinylpyrrolidone/N-vinyl-3,5-dimethyltriazole copolymer (molar ratio of 50/50)
(17) N-vinylpiperidone/2-methoxyethyl acrylate copolymer (molar ratio of 70/30)
(18) N-vinylpiperidone/methylvinyl ether copolymer (molar ratio of 90/10)
(19) N-vinyloxazolidone/vinyl alcohol copolmer (molar ratio of 65/35)
(20) N-vinyloxazolidone/acrylic acid copolymer (molar ratio of 80/20)
(21) N-vinylpyrroidone/N-vinylpiperidone/2-hydroxyethyl acrylate copolymer (molar ratio of 40/30/30)
(22) vinyl alcohol/vinyl acetate/N-vinyl-2-pyridone copolymer (molar ratio of 70/25/5)
(23) N-vinylpyrrolidine/2-hydroxyethyl acrylate/vinyl acetate copolymer (molar ratio of 70/21/10)
(24) N-vinylpyrrolidone/vinyl alcohol/vinyl propionate/sodium styrenesulfonate (molar ratio of 40/40/5/15)
(25) N-vinylpyrrolidone/acrylamide copolymer (molar ratio of 60/40)
(26) N-vinylpyrrolidone/2-acrylamide-2-methylpropane-sulfonic acid copolymer (molar ratio of 75/25)
(27) N-vinylpiperidone/acrylamide copolymer (molar ratio of 60/40)
(28) N-vinyloxazolidone/N-(2-hydroxyethyl)acrylamide copolymer (molar ratio of 70/30)
(29) N-vinylpyrrolidone/N-vinylmorpholine/acrylamide copolymer (molar ratio of 50/20/30)
(30) N-vinylsuccinimide/N-vinyl-ε-caprolactam/acrylamide copolymer (molar ratio of 40/20/40)
(31) N-vinyloxazolidone/acrylamide/acrylic acid copolymer (molar ratio of 60/20/20)
(32) N-vinylpyrrolidone/acrylamide/vinyl acetate/acrylic acid copolymer (molar ratio of 60/20/10/10)
(33) N-vinylpyrrolidone/dimethylacrylamide copolymer (molar ratio of 70/30)
The addition of said polymers to an emulsion may be carried out in a conventional manner for the addition of photographic additives to a photographic emulsion. For instance, the polymer is first dissolved in a solvent which does not have any harmful influence on photographic materials which are the final products (such as water, or an alkaline aqueous solution), and then the resulting polymer-containing solution is added to an emulsion.
In the present invention, at least one of the polymers having repeating units of formula (I) as described above is added to chemically-sensitized normal crystalline silver halide grains. After the addition, ripening of the emulsion may be further continued. Said addition may be carried out before or during the chemical-sensitization step of the emulsion.
In the formation of silver halide grains or physical ripening or the grains to the present invention, a cadmium salt, a zinc salt, a lead salt, a thallium salt, an iridium salt, or a complex thereof, a rhodium salt or a complex thereof, an iron salt, or a completx thereof, and the like may be present in the system. These process are described in Research Disclosure, Vol. 1, RD No. 17643 (December, 1978), p. 22.
Photographic emulsions used in the present invention can contain various compounds for the purpose of preventing fog during preparation, storage, or photographic processing, or for stabilizing photographic images formed. Such compounds include azoles, such as benzothiazolium salts, nitroimidazoles, nitrobenzimidazoles, chlorobenzimidazoles, bromobenzimidazoles, mercaptothiazoles, mercaptobenzothiazoles, mercaptobenzimidazoles, mercaptothiadiazoles, aminotriazoles, benzotriazoles, nitrobenzotriazoles, mercaptotetrazoles (especially 1-phenyl-5-mercaptotetrazole), etc; mercaptopyrimidines; mercaptotriazines; thioketo compounds, such as oxazolinethione, etc.; azaindenes, such as triazaindenes, tetraazaindenes (especially 4-hydroxy-substituted (1,3,3a,7)-tetraazaindenes), pentaazaindenes, etc.; benzenethiosulfonic acid; benzenesulfinic acid; benzenesulfonic acid amide; and other various compounds known as anti-foggants or stabilizers. Such compounds are described in more detail, e.g., in U.S. Pat. Nos. 3,954,474 and 3,982,947 and Japanese Patent Publication No. 28660/77.
The photographic emulsions which can be used in the present invention may be spectrally sensitized with methine dyes and other sensitizing dyes. Useful sensitizing dyes include cyanine dyes, merocyanine dyes, complex cyanine dyes, complex merocyanine dyes, holopolar cyanine dyes, hemicyanine dyes, styryl dyes, and hemioxonol dyes, with cyanine dyes, merocyanine dyes, and complex merocyanine dyes being particularly useful. Any of basic heterocyclic nuclei generally used for cyanine dyes can be applied to these dyes. Such nuclei include pyrroline, oxazoline, thiazoline, pyrrole, oxazole, thiazole, selenazole, imidazole, tetrazole, pyridine nuclei, and the like; the above-described nuclei to which an alicyclic hydrocarbon ring is fused; and the above-described nuclei to which an aromatic hydrocarbon ring is fused, such as indolenine, benzindolenine, indole, benzoxazole, naphthoxazole, benzothiazole, naphthothiazole, benzoselenazole, benzimidazole, quinoline nuclei, etc. These nuclei may be substituted at their carbon atoms.
Nuclei having a keto-methylene structure can be used for merocyanine dyes or complex merocyanine dyes. Such nuclei include 5- to 6-membered heterocyclic nuclei, such as pyrazolin-5-one, thiohydantoin, 2-thiooxazolidine-2,4-dione, thiazolidine-2,4-dione, rhodanine, thiobarbituric acid nuclei, and the like.
The above-described sensitizing dyes may be used alone or in combinations of two or more thereof. Combinations of sensitizing dyes are frequently employed for the purpose of supersensitization. Typical examples of supersensitizing combinations are described in Research Disclosure, Vol. IV (e.g., particularly E, F, and J), RD No. 17643 (December, 1978), p. 22.
The photographic emulsions may additionally contain a substance which has an effect of supersensitization when used in combination with sensitizing dyes even though it does not per se exhibit spectral sensitizing effects or does not substantially absorb visible light.
The photographic materials of the present invention may contain various kinds of color couplers, and examples thereof are described in patent publications as referred to in the aforesaid Research Disclosure, RD No. 17643, Items VII-C through VII-G (December, 1978). As the color couplers, those capable of yielding three primary colors in subtractive color process (i.e., yellow, magenta, and cyan) by color development are important, and examples of non-diffusive tetra-equivalent or di-equivalent couplers which may be used in the present invention are described in the patent publications as referred to in said Research Disclosure, RD No. 17643, Items VII-C and VII-D (December, 1978). In addition, the following couplers may also be used in the present invention.
As yellow couplers which may be used in the present invention, hydrophobic acylacetamide-type couplers having a ballast group are typical. Examples of said couplers are described in U.S. Pat. Nos. 2,407,210, 2,875,057, and 3,265,506. In the present invention, di-equivalent yellow couplers are preferably used, and typical examples thereof are oxygen atom-releasing type yellow couplers as described, for example, in U.S. Pat. Nos. 3,408,194, 3,447,928, 3,933,501, and 4,022,620; and nitrogen atom-releasing type yellow couplers as described, for example, in Japanese Patent Publication No. 10739/83, U.S. Pat. Nos. 4,401,752 and 4,326,024, Research Disclosure, RD No. 18053 (April, 1979), British Pat. No. 1,425,020, West German Patent Application (OLS) Nos. 2,219,917, 2,261,361, 2,329,587, and 2,433,812. α-pivaloyl-acetanilide type couplers have good fastness, especially against light, in the formed dyes. On the other hand, α-benzoylacetanilide type couplers can obtain dyes of high color density.
As magneta couplers which may be used in the present invention, ballast group-containing hydrophobic indazolone-type or cyanoacetyl-type, preferably 5-pyrazolone-type and pyrazolo-azole-type, couplers are typical. Regarding the 5-pyrazolone-type couplers, those which are substituted by an arylamino or acylamino group in the 3-position are preferred from the viewpoints of the hue of the formed dyes or the color density thereof, and typical examples of said couplers are described, for example, in U.S. Pat. Nos. 2,311,082, 2,343,703, 2,600,788, 2,908,573, 3,062,653, 3,152,896, and 3,936,015. As the releasing groups in the di-equivalent 5-pyrazolone-type couplers, nitrogen atom-releasing groups as described in U.S. Pat. No. 4,310,619 or arylthio groups as described in U.S. Pat. No. 4,351,897 are especially preferred. Ballast group-containing 5-pyrazolone-type couplers as described in European Pat. No. 73,636 can form dyes of high color density. As the pyrazolo-azole type couplers, pyrazolobenzimidazoles as described in U.S. Pat. No. 3,369,879, preferably pyrazolo[5,1-c][1,2,4]triazoles as described in U.S. Pat. No. 3,725,067, pyrazolo-tetrazoles as described in Research Disclosure, RD No. 24220 (June, 1984), and Japanese Patent Application (OPI) No. 33552/85, and pyrazolo-pyrazoles as described in Research Disclosure, RD No. 24230 (June, 1984) and Japanese Patent Application (OPI) No. 43659/85 are mentioned. From the viewpoint of the light-fastness of the formed dyes with low yellow-subabsorption, imidazo[1,2-b]pyrazoles as described in U.S. Pat. No. 4,500,630 are preferred, and pyrazolo[1,5-b][1,2,4]triazoles as described in European Pat. No. 119,860A are especially preferred.
As cyan couplers which may be used in the present invention, hydrophobic and non-diffusible naphthol-type or phenol-type couplers are mentioned; and typical couplers are naphthol-type couplers as described in U.S. Pat. No. 2,474,293 and especially preferably oxygen atom-releasing type di-equivalent naphthol-type couplers as described in U.S. Pat. Nos. 4,052,212, 4,146,396, 4,228,233, and 4,296,200. Examples of phenol-type couplers are described in U.S. Pat. Nos. 2,369,929, 2,801,171, 2,772,162, and 2,895,826.
Cyan couplers that are resistant to moisture and high temperature are preferably used in the present invention, and typical examples thereof are phenol-type cyan couplers having a higher alkyl group than ethyl group in the meta-position of the phenol nucleus thereof, as described in U.S. Pat. No. 3,772,002; 2,5-diacylamino-substituted phenol-type couplers as described in U.S. Pat. Nos. 2,772,162, 3,758,308, 4,126,396, 4,334,011, and 4,327,173, West German Patent Application (OLS) No. 3,329,729 and European Pat. No. 121,365; and phenol-type couplers having a phenylureido group in the 2-position and an acylamino group in the 5-position, as described in U.S. Pat. Nos. 3,446,622, 4,333,999, 4,451,559, and 4,427,767.
In order to compensate any unnecessary absorption of the formed dyes, masking is preferably applied to color photographic materials for camera by incorporating colored couplers therein. Typical examples of the colored couplers to be used therefor are yellow-colored magenta couplers as described in U.S. Pat. No. 4,163,670 and Japanese Patent Publication No. 39413/82 and magenta-colored cyan couplers as described in U.S. Pat. Nos. 4,004,929 and 4,138,258 and British Pat. No. 1,146,368. Other colored couplers which may be used in the present invention are described in the aforesaid Research Disclosure, RD No. 17643, Item VII-G (December, 1978).
A coupler which may form a color-dye having a proper diffusibility can be used together with the above-mentioned coupler in the present invention, whereby the graininess of the emulsion can be improved. Various couplers of said kind are known, including magenta couplers as described in U.S. Pat. No. 4,366,237 and British Pat. No. 2,125,570; and yellow, magenta, and cyan couplers as described in European Pat. No. 96,570 and West German Patent Application (OLS) No. 3,234,533.
The dye-forming couplers and the above-described special couplers may be in the form of a dimer or more polymers. Typical examples of dye-forming coupler polymers are described in U.S. Pat. Nos. 3,451,820 and 4,080,211. Examples of magenta coupler polymers are described in British Pat. No. 2,102,173 and U.S. Pat. No. 4,367,282.
Couplers which may release photographically useful groups in coupling can preferably be used in the present invention. DIR-couplers which release a development-inhibitor are described in various patent publications as referred to in the aforesaid Research Disclosure, RD No. 17643, Item VII-F (December, 1978), and these are advantageously used in the present invention.
Examples of said couplers which may preferably be used in the present invention are developer-inactivating couplers as described, for example, in Japanese Patent Application (OPI) No. 151,944/82; timing-type couplers as described, for example, in U.S. Pat. No. 4,248,962 and Japanese Patent Application (OPI) No. 154,234/82; and reactive-type couplers as described in Japanese Patent Application No. 39653/84; and in particular, developer-inactivating type DIR couplers as described in Japanese Patent Application (OPI) Nos. 151,944/82 and 217,932/83, and Japanese Patent Application Nos. 75474/84, 82214/84, and 90438/84, and reactive type-DIR couplers as described in Japanese Patent Application No. 39653/84 are especially preferred.
The emulsions to be used in the present invention are preferably physically-ripened, chemically-ripened, and spectrally-sensitized. Additives to be used in the steps for said ripening or sensitization are described in Research Disclosure, RD No. 17643 (December, 1978) and RD No. 18716 (November, 1979), particularly in the portions of said literature set forth below.
In addition, conventional photographic additives which may be used in the present invention are also described in said two Research Disclosure publications, and the relevant portions thereof are also set forth in the following Table.
______________________________________No. Kinds of Additives RD No. 17643 RD No. 18716______________________________________1 Chemical sensitizer p.23 P.648, right column2 Sensitivity accelerator P.648, right column3 Spectral sensitizer, pp.23-24 p.648, right Super-sensitizer column-p.649, right column4 Brightening agent p.24 --5 Antifoggants, pp.24-25 p.649, stabilizer right column6 Light-absorbent, pp.25-26 p.649, right filter dye, UV- column-p.650, absorbent left column7 Stain-inhibitor p.25, p.650, right right column to left column8 Color image stabilizer p.25 --9 Hardener p.26 p.651, left column10 Binder p.26 p.651, left column11 Plasticizer, p.27 p.650, lubricant right column12 Coating aid, p.26-27 p.650, surfactant right column13 Anti-static agent p.27 p.650, right column______________________________________
The photographic materials of the present invention may be any of black-and-white photographic materials and multi-layer multi-color photographic materials, and in particular, the present photographic materials are preferably used as color light-sensitive materials for high-speed photography.
In the case of applying the present invention to color light-sensitive materials, the layer in which the emulsion according to the present invention is present is not particularly restricted, but it is preferred to be used in a blue-sensitive layer, particularly a high-speed blue-sensitive layer. Further, it is preferred that fine silver halide grains having a grain size of 0.2 μm or less are allowed to exist so as to be adjacent to said emulsion layer.
Conventional methods and processing solutions can be applied to photographic processing of the light-sensitive materials according to the present invention. Processing temperatures are generally selected from the range of from 18° to 50° C. However, temperatures lower than 18° C. or higher than 50° C. may also be employed. Any photographic processing, including monochromatic photographic processing involving formation of a silver image, and color photographic processing involving formation of a dye image, can be used, depending on the desired end use of the light-sensitive material.
In particular, when the photographic materials of the present invention are developed by a so-called parallel development, which is a typical color development, extremely favorable results may be obtained in terms of sensitivity and graininess. For said development, the photographic materials of the present invention may be processed in a conventional manner as described in detail in the aforesaid Research Disclosure, RD No. 17643 (December, 1978), pp. 28-29 and ibid., RD No. 18716 (November, 1979), p. 651, left to right column.
The present invention is explained in greater detail by reference to the following examples, which, however, are not intended to be interpreted as limiting the scope of the present invention.
EXAMPLE 1
In the manner of Example 1 of Japanese Patent Application (OPI) No. 143,331/85, twinned-crystal emulsion Nos. 1 through 3 were prepared, whereupon the addition time and other conditions were varied. Referring to Example 2 of said Patent Application, octadehral crystal emulsion Nos. 4 through 7 were prepared analogously. The characteristics of the emulsions formed are shown in Table 1.
TABLE 1__________________________________________________________________________ I-content Average (mole %) in Core/Shell Existence of grain composition Ratio Average definite strat-EmulsionShape of size prescribed (volume I-content ified structureNo. grains (μm) Core Shell ratio) (mole %) in grains__________________________________________________________________________1 twinned 1.7 30 0 1/2 10 Acrystals2 twinned 2.1 42 0 1/2 14 Bcrystals3 twinned 1.6 2 2 -- 2 Acrystals4 octahedron 2.0 0 0 -- 0 A5 octahedron* 2.0 5 0 1/1 2.5 A6 octahedron* 2.0 20 0 1/1 10 B7 octahedron* 2.0 40 0 1/1 20 B__________________________________________________________________________ (Notes) 1. A: No distinct stratiform structure exists. B: A distinct stratiform structure exists. 2. *: This could also be considered as a tetradecahedron which is extremely near to an octahedron, containing about 5% of the face (100) an the balance of the face (111).
Each of the above seven emulsions was chemically-sensitized with sodium thiosulfate and chloroauric acid under optimum conditions, to obtain samples of coating solutions. On a triacetyl-cellulose film support having a subbing layer were coated an emulsion layer and a protective layer, and the composition of the coated layer is given in Table 2.
Poly(N-vinylpyrrolidone) (hereinafter, referred to as "PVP") was added to each emulsion in an amount of from 0 to 10 g per mole of silver contained therein.
TABLE 2______________________________________(1) Emulsion layer:Emulsion: one of Emulsion Nos. 1-8 shown in Table 1(silver content: 2.1 × 10.sup.-2 mole/m.sup.2)Coupler (1.5 × 10.sup.-3 mole/m.sup.2) ##STR25##Tricresyl phosphate (1.10 g/m.sup.2)Gelatin (2.30 g/m.sup.2)(2) Protective layer:2,4-dichlorotriazine-6-hydroxy-s-triazine-sodiumsalt (0.08 g/m.sup.2)Gelatin (1.80 g/m.sup.2)______________________________________
The above-formed samples were allowed to stand under a condition of 40° C. and relative humidity of 70%, for 14 hours, and then exposed to light for sensitometry and then developed according to the following color development.
The color development was carried out at 38° C. under the following conditions:
______________________________________1. Color development 2 min. 45 sec.2. Bleaching 6 min. 30 sec.3. Water-washing 3 min. 15 sec.4. Fixing 6 min. 30 sec.5. Water-washing 3 min. 15 sec.6. Stabilization 3 min. 15 sec.______________________________________
The composition of the treating solution used in each of the above treatment steps was as follows:
______________________________________Color developer:Sodium nitrilo-triacetate 1.0 gSodium sulfite 4.0 gSodium carbonate 30.0 gPotassium bromide 1.4 gHydroxylamine sulfate 2.4 g4-(N-ethyl-N-β-hydroxyethylamino)-2- 4.5 gmethyl-aniline.sulfateWater to make 1 literBleaching solution:Ammonium bromide 160.0 gAqueous ammonia (28 wt %) 25.0 mlEthylenediamine-sodium tetraacetate- 130 giron complexGlacial acetic acid 14 mlWater to make 1 literFixer:Sodium tetrapoly-phosphate 2.0 gSodium sulfite 4.0 gAmmonium thiosulfate (70 wt %) 175.0 mlSodium bisulfite 4.6 gWater to make 1 literStabilizer:Formalin (37 wt % formaldehyde solution) 8.0 mlWater to make 1 liter______________________________________
The color density of each of thus-treated samples was measured with a green filter. The results of the obtained photographic characteristics for the samples are set forth in the following Table 3.
TABLE 3______________________________________Emulsion Amount of added RelativeNo. PVP (q/mole-Ag) sensitivity Fog______________________________________1 0 430 0.141 0.4 380 0.122 0 720 0.152 0.4 650 0.123 0 280 0.183 0.4 240 0.154 0 100 0.284 0.4 120 0.30(Invention)5 0 140 0.195 0.4 170 0.19(Invention)6 0 800 0.106 0.4 1270 0.10(Invention)7 0 780 0.087 0.4 1200 0.08(Invention)______________________________________
In the above sample Nos. 4 through 7, the sensitivity extremely increased due to the addition of PVP. In the other samples containing emulsions of twinned grains, however, the sensitivity did not increase at all even after the addition of said PVP. The results of the Table 3 therefore prove that the sensitivity of the emulsions containing normal crystalline grains of the present invention noticeably increases due to the addition of PVP, and further, the increment of the sensitivity is more remarkable in the emulsions containing grains having a distinct stratiform structure.
While the invention has been described in detail and with reference to specific embodiments thereof, it will be apparent to one skilled in the art that various changes and modifications can be made therein without departing from the spirit and scope thereof. | A negative-tupe silver halide photographic material is provided, having high sensitivity and good graininess with low fog. The material has at least one silver halide emulsion layer on a support, wherein chemically-sensitized silver halide grains contained in the emulsion of said emulsion layer comprise normal crystalline grains, and said emulsion layer containing said normal crystalline silver halide grains contains a polymer having a repeating unit represented by formula (I): ##STR1## wherein R 1 represents a hydrogen atom or an alkyl group; Q represents one group selected from formulae (i), (ii), (iii), and (iv); ##STR2## wherein q is an integer of from 2 to 4; ##STR3## wherein R 2 and R 3 each represents a hydrogen atom or an alkyl group; ##STR4## wherein Z 1 represents an atomic group forming a lactam ring, an oxazolidone ring, or a pyridone ring;
A represents a single bond, ##STR5## B represents --O-- or ##STR6## wherein R 4 represents a hydrogen atom or an alkyl group; and l is an integer of from 1 to 6; and ##STR7## wherein a has the same meaning as defined for formula (iii);
D represents a single bond, --O-- or ##STR8## wherein R 5 represents a hydrogen atom, an alkyl group, or ##STR9## wherein R 6 represents an alkyl group; and
m and n each represents an integer of from 1 to 6, provided that the sum of m and n is an integer of from 4 to 7. | 6 |
RELATED APPLICATIONS
This application claims the benefit of priority under 35 U.S.C. §119(e) from U.S. Provisional Application Ser. No. 60/429,130 filed Nov. 26, 2002, entitled “Fatigue Relieving Support for Steering Wheels and the Like”, which is incorporated herein by reference.
FIELD OF THE INVENTION
The present invention relates to systems and methods that may be used by vehicle and vessel operators to relieve and/or prevent fatigue in the arms and hands when operating directional controls.
BACKGROUND OF THE INVENTION
In learning to drive, a person is taught that the preferable placement of the hands with respect to a steering wheel is at the ten and two o'clock (i.e., 10:00 and 2:00) positions. These hand locations are said to give the driver the best control of the operation of the vehicle, which includes automobiles, trucks, tractors, or other types of vehicles with steering wheels, as well as nautical vessels and aircraft.
If the arms and hands are held on the steering wheel at these locations for extended periods of time, they become fatigued. To relieve this fatigue, often they are removed from the steering wheel and rotated, shaken, or exercised in some way to reenergize them.
In the fatigued state, the arms and hands feel very stiff and less mobile. Further, in the fatigued condition, the ability of the arms and hands to rapidly react to emergency situations and properly control the vehicle is greatly reduced and accidents are more likely to occur. This problem arises in any vehicle or vessel and is not restricted to automobiles nor automobile-type steering controls.
There needs to be a system that will prevent and/or relieve this fatigue, yet not interfere with the operator's ability to control the vehicle or vessel.
SUMMARY OF THE INVENTION
The present invention is a system and method that is associated with a steering wheel or vehicular directional control that relieves or prevents fatigue, for example, when operator drives for extended periods of time. The system of the present invention may be formed integral with, or attached to, the wheel or control. Each embodiment of the system will provide support to at least a portion of the vehicle or vessel operator's body so as to relieve or prevent fatigue.
The system of the present invention will include at least one part that extends outward at an angle from a plane across the face of the steering wheel or vehicular control. This part is at least partially deformable in at least one direction, so that the system will not interfere with the operation of the wheel or control. This deformability, however, will not impede the support function of the system on the invention. Furthermore, the deformable material has memory, so that after a deforming force is removed, it resumes its original predeformation configuration and shape, which is, extending outward at an angle from a plane across the face of the steering wheel or vehicular control.
It is an object of the present invention to have a system and method that may be implemented with the steering control of a vehicle or vessel to prevent or lessen the amount of fatigue that occurs in the arms and hands from driving or steering over extended periods of time.
The features and advantages of the present invention will be more readily apparent and understood from the following detailed description of the invention, which should be understood in conjunction with the accompanying drawings and claims that are appended to the end of the detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a steering wheel with an embodiment of the system of the present invention associated with it.
FIG. 2 is a perspective view of a steering wheel with multiple systems of an embodiment of the present invention associated with the steering wheel.
FIG. 3 is a cross-section of the steering wheel shown on FIG. 1 , with an operator's hand resting on an embodiment of the system of the present invention.
FIG. 4 is a cross-section of the steering wheel of FIG. 1 , with an operator's hand firmly grasping the steering wheel as in an emergency situation that deforms the system of the present invention.
FIG. 5 is a cross-section of another embodiment of the system of the present invention, in which the system snaps or clips onto the steering wheel.
FIG. 6 is a perspective view of another embodiment of the system of the present invention, in which the system envelops the steering wheel rim and is fastened in place.
DETAILED DESCRIPTION
For purposes of illustration only, and not to limit the scope of the present invention, the invention will be explained with reference to the specific steering wheel examples indicated in the drawings. One skilled in the art would understand that the present invention is not limited to the specific examples disclosed and can be more generally applied to other transport means having different steering controls than those disclosed.
Referring to FIG. 1 , generally at 100 , an embodiment of system 101 of the present invention is shown attached to steering control 105 . System 101 includes first section 103 that connects to steering control 105 and deformable second section 102 . First section 103 may be formed from a rigid, semi-rigid, or deformable material. If it is deformable, it may have memory. Second section 102 that connects to first section 103 may be formed from a deformable material that has memory.
Deformable material 102 extends outward from the steering control 105 over a predetermined section of the steering control which is shown in FIG. 1 to be an arc. Deformable second section 102 may extend outwardly from the steering control at or below the inside circumference of the control over the predetermined arc. This arc will typically include at least the ten 104 and two 106 o'clock positions, or may include the entire circumference. As shown in FIG. 1 , the arc that covers the ten 104 and two 106 o'clock positions is disposed on the upper one-half (½) of steering control 105 .
Steering control 105 may be a normal steering wheel, with a rim 108 and spokes 110 . Alternatively, the steering control 105 may take on other forms as is known to those in the art, i.e., an aircraft yoke.
In FIG. 2 , generally at 200 , steering control 211 has two systems of the present invention associated with it. The first is shown at 202 and the second at 203 . The first and second systems in FIG. 2 , extend over a smaller arc of the steering control compared to the single system shown in FIG. 1 .
The first system of the present invention at 202 includes first section 204 that connects to steering control 211 and second section 205 that extends outward from first section 204 . Further, a second section such as 205 extends outward at an angle from a plane across the face of a steering control such as 211 (see FIG. 3 ). First section 204 may be rigid, semi-rigid, or deformable, while second section 205 is deformable. If the first section is deformable, it may have memory.
Similarly, the second system of the present invention at 203 includes first section 207 that connects to steering control 211 and second section 209 that extends outward from first section 207 . Further, a second section such as 209 extends outward at an angle from a plane across the face of a steering control such as 211 (see FIG. 3 ). First section 207 may be rigid, semi-rigid, or deformable, while second section 209 is deformable. Again, if the first section is deformable, it may have memory.
In FIG. 2 , system 202 is at or near the ten o'clock position and system 203 is shown at or near the two o'clock position. As shown in FIG. 2 , system 202 that is at or near the ten o'clock position and system 203 that is at or near the two o'clock position are disposed on the upper one-half (½) of steering control 211 . Although, the two systems have been described as being positioned at the ten and two o'clock locations, it is understood that they may be placed at other locations around the rim and there may be more than two systems and still be within the scope of the present invention.
Referring to FIGS. 1 and 2 , first section 103 in FIG. 1 , and first sections 204 and 207 in FIG. 2 , may be formed integral with steering control 105 and 211 , respectively. Given that the system is disposed at or below the inside circumference of the steering wheel, in this configuration, the operator can securely grip the steering wheel over the system when the wrists or portions of the hands are resting on the deformable second section. Further, the first section may be constituted as an interface to which the second section attaches.
Referring to FIG. 3 , generally at 300 , steering control 305 is shown that includes rim 308 , spokes 310 , and steering column 312 . First section 301 is formed integral with rim 308 and deformable second section 302 extends outward from the first section. As is shown, second section 302 extends outward at angle 316 from plane 318 across the face of steering control 305 . The material of second section 302 has sufficient strength that when driving, the driver may rest his/her wrists or portions of the hands 322 on the material and they will be supported. The structure is such that the weight of the arms and hands through the wrists or portions of the hands are supported without the material deforming.
When the wrists or portions of the hands are supported, as shown in FIG. 3 , the driver can firmly grip the steering control rim 308 over first section 301 in a manner that he or she has full control of the vehicle. Deformable second section 302 is easily deformable in a direction opposite to which it provides support or any other direction if a sufficient deforming force is applied to second section 302 . Therefore, if the driver should grip the steering control by pushing the material upwardly, it will readily deform to permit such a grip. Also, as shown in FIG. 4 , generally at 400 , if the driver should grip the steering wheel control rim 308 by grasping it such that deformable second section 302 is compressed toward, or below the interior circumference of, the steering control, it will readily compress and be deformed in such a manner that the driver can grip the steering wheel. Arrows 402 represent the force applied by the driver to the steering wheel control rim 308 , resulting in the deformation of second section 302 . Second section 302 is deformed in this manner so that it will not affect the driver's ability to grasp the steering control in any emergency situation.
Deformable section 302 has memory such that after deforming pressure is removed, it will return to its original position. When this is done, the system of the present invention will appear as shown in FIG. 1 , 2 , or 3 . Once the deformable second section has returned to its original position, it will again be in condition to support the arms and hands through the wrists or portions of the hands resting on the deformable second section.
Referring to FIG. 5 , generally at 500 , a second embodiment of the present invention is shown. System 501 of the present invention shown in FIG. 5 includes a first section 502 that detachably connects to steering control rim. Deformable second section 503 connects to, and extends outwardly from, first section 502 . As is shown, deformable second section 503 extends outward at angle 516 from plane 518 across the face of steering control rim 508 . First section 502 may snap-on or otherwise attach to the steering control such that it may appear integral with the steering control. One of many possible known means for accomplishing this is by first section 502 being mostly rigid, and leaving a space 507 so the attachment can be forced over rim 508 and leave room for the steering control spokes 510 . Regardless of the means for attachment, once first section 502 is attached to the steering control, it will provide all of the benefits that have been described for the first section being integrally formed with the rim. Additionally, the second embodiment may be a single structure with a single resting material support, a single structure with multiple resting supports, or multiple structures each with its own resting support.
By way of example, FIG. 6 , generally at 600 , shows another alternate method to attach the system of the present invention to steering control rim 608 . The system in this figure has first section 602 that will envelop rim 608 . First section 602 may be made from a flexible material. First section 602 may have a slit 611 , which after this section envelops the rim, may be stitched shut by stitches 613 . As in the other embodiments of the present invention, deformable second section 603 connects to, and extends outwardly from, first section 602 . Further, a deformable second section such as 603 extends outward at an angle from a plane across the face of a steering control rim such as 608 (see FIGS. 3 and 5 ).
It is understood by those skilled in the arts that the system can be adjusted in terms of size and orientation to adapt to different operator sizes and preferences.
Having described the embodiments of the invention, it should be apparent that various combinations of the embodiments may be made or modifications added thereto as is known to those skilled in the art without departing from the spirit and scope of the invention, which is defined in the claims below. | A system and method for relieving and preventing fatigue caused by extended gripping of a vehicle/vessel steering wheel. The system includes a first section that attaches to the rim of the steering wheel at a predetermined location and a deformable second section that connects to, and extends outwardly from, the first section. The deformable second section supports a portion of the body such as wrists, hands, and forearms. | 8 |
BACKGROUND OF THE INVENTION
In the past, steam injection elements have been employed to heat water in a heating chamber by injecting steam into the water. A typical prior art steam injection water heater is disclosed in U.S. Pat. No. 2,455,498 to C. T. Kern. These heaters worked satisfactorily at relatively low steam pressures, e.g., below 300 psi. At high steam pressures, water hammer develops in the system, presumably due to sudden collapse of relatively large steam bubbles which are created by the high pressure steam, as the steam condenses in the water. The orifices in the foraminous steam injection element were made smaller in an attempt to eliminate the water hammer, but it persisted, notwithstanding substantial reduction in orifice size. Moreover, there is a limit to reduction in the size of the orifices, since they must inject a sufficient volume of steam into the water to heat it to the desired temperature.
SUMMARY OF THE INVENTION
In accordance with the present invention, water hammer is eliminated in high pressure steam injection water heaters by surrounding the foraminous steam injection tube thereof with a foraminous diffusion screen spaced from the injection tube for diffusing the steam jets issuing from the steam injection element before they condense. The diffusion screen suppresses bubble size and eliminates water hammer.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is an axial sectional view of a steam injection heater utilizing the foraminous diffusion screen of this invention.
FIG. 2 is an enlarged view of the steam injection tube and diffusion screen of FIG. 1, partly in side elevation and partly in axial section.
FIG. 3 is an enlarged side elevational view of a modified steam injection tube and diffusion screen with the steam injection tube and diffusion screen partially cut away.
FIG. 4 is a cross-sectional view taken on the line 4--4 of FIG. 3.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Although the disclosure hereof is detailed and exact to enable those skilled in the art to practice the invention, the physical embodiments herein disclosed merely exemplify the invention which may be embodied in other specific structure. The scope of the invention is defined in the claims appended hereto.
One embodiment of the steam injection heater of this invention includes a heating chamber 10 (FIG. 1) which consists of a cylindrical casing 12 and a base portion 14. These are flanged at 16 and 18 respectively and are held together by bolts 20 and nuts 22. Bolts 20 extend through matching openings in flanges 16 and 18. A gasket 24 seals the joint between flanges 16 and 18. Base portion 14 has a liquid inlet 24 at its bottom and has a steam inlet 26 at its side. A steam inlet elbow 28 extends inwardly within base portion 14 from inlet 26 and is supported by being attached at its side margin 30 to base portion 14. Steam inlet elbow 28 is preferably integrally cast with base portion 14.
A foraminous steam injection tube 32 is connected by screw threads 33 at its base portion 34 to matching screw threads in the top of steam inlet elbow 28. Steam injection tube 32 is in the shape of a hollow cylinder and has a plurality of circular orifices 36 therein. Orifices 36 are enlarged in FIG. 2 for clarity of illustration. For example, they may have a diameter in the neighborhood of 0.055 inches, for a tube 32 1 inch in diameter.
A piston 38 is slidably mounted within tube 32 and is normally urged downward toward a piston stop ring 40 in the bottom of tube 32 by a compression coil spring 42 which is held in place at its upper end by spring stop ring 44 in the top of tube 32. When steam under pressure is introduced into steam inlet 26, the steam pressure forces piston 38 upwardly and exposes some of the orifices 36. The steam then discharges as small jets through orifices 36 and is absorbed into and heats the surrounding water, which is introduced into water inlet 24 and is guided in a helical path around steam injection tube 32 by helical vanes 46, which extend inwardly from the interior of casing 12. The heated water and condensed steam leaves the heating chamber 10 through water outlet 48 at the top of casing 12.
The higher the pressure of the steam, the higher will piston 38 be raised, and the more orifices 36 will be exposed to discharge steam jets into the surrounding water. In the device as thus far described, and as described in U.S. Pat. No. 2,455,498, the steam enters the water in the form of bubbles. As steam pressure increases, the bubbles grow larger. The increasing use of high pressure steam has created a water hammer problem in devices of this type, as the large bubbles will collapse violently as the steam condenses, with resultant water hammer noise.
In accordance with the present invention, water hammer at high steam pressures is avoided by a mounting a foraminous diffusion screen 50 concentrically about steam injection tube 32 and surrounding the perforated portions thereof. Diffusion screen 50 is cylindrical in shape and is coaxial with tube 32. Diffusion screen 50 has a plurality of orifices 56 therein which intercept and diffuse the jets of steam coming from steam injection tube orifices 36. Orifices 56 can assume various shapes. In the embodiment of FIG. 2, they are circular. Screen 50 has an upper flange 52 welded or brazed to steam injection tube 32 at the portion thereof immediately above the orificed area therein.
Orifices 56 in diffusion screen 50 are enlarged in FIG. 2 for clarity of illustration. In practice, their diameter will depend on the steam pressure. A typical diameter for orifice is 0.020 inches. In an injection heater having a diffusion screen diameter one and one-half inches in diameter, diffusion screen 50 is spaced from steam injection tube 32 by approximately five thirty-seconds of an inch. It should be noted, however, that the above-mentioned dimensions are exemplary and can be varied in practice over a reasonable range, depending on the steam pressure, water flow rate, desired temperature, and other design factors involved in any given application of the heater.
FIGS. 3 and 4 show another embodiment of the steam injection element of this invention which includes a foraminous steam injection tube 58 having circular orifices 60 therein. Tube 58 is threaded at its bottom end 62 and has a piston 64 slidably mounted therein. A compression spring 66 normally urges piston 64 downwardly toward a piston stop ring 68 attached within tube 58. A removable spring stop ring 70 is attached within the top of tube 58 to anchor the top of spring 66. As in the previously described embodiment, none of orifices 60 are exposed at zero steam pressure. As piston 64 is moved upwardly because of increase in the steam pressure, an increasing number of orifices 60 are uncovered. Steam escapes through the exposed orifices 60 and forms outwardly directed steam jets therethrough.
A foraminous diffusion screen 72 is mounted over the perforated portion of tube 58 and serves to intercept and diffuse the steam jets issuing from orifices 60. Screen 72 comprises a helical coil 76 whose adjacent turns are spaced apart to form slots 78. Screen 72 is spaced and supported from screen 58 by a series of axially extending spacer ribs 74. These are arranged in a squirrel cage pattern around steam injection tube 58 and are welded or brazed at their top end to a ring 80, which is also welded or brazed to tube 58 and to the top of helical coil 76. The slot space 78 between adjacent turns of helical coil 76 varies, depending on the steam pressure employed. For example, a spacing of 0.010 inches may be used for steam in the range of 300-600 psi and a narrower spacing of 0.003 inches may be used for higher pressures. Helical coil 76 is preferably rectangular in cross-sectional shape although other shapes can be employed, if desired. Circular orifices 60 in injection tube 58 typically have a diameter in the neighborhood of 0.055 inches, and the interior of helical coil 76 is spaced approximately five thirty-seconds inches from the exterior of tube 58. However, it should be understood that the above-noted dimensions are exemplary and can be varied in practice over a reasonable range, depending on the steam pressure, water flow rate, desired temperature, and other design factors involved in any given application of the heater.
As best shown in FIG. 4, the slots 78 between adjacent turns of helical coil 76 are broken up by ribs 74 into circumferentially elongated orifice slots 82 which are approximately one-eighth inch long. Each slot segment 82 forms a narrow slot orifice which intercepts the steam jets escaping from circular orifices 60 to reduce the size of bubbles formed in the heating chamber and eliminate water hammer in the system.
In all embodiments the steam must pass through two tandem related screens before admixture thereof with the water. The outer screen has much smaller orifices than the inner screen. The outer screen intercepts the steam jets issuing from the orifices in the first screen and squeezes the jet into a smaller compass or envelope. Accordingly, the jet emerging from diffusion screens 50, 72 contains steam bubbles of a reduced size as compared with bubble sizes in the absence of the diffusion screen. Reduction of bubble size reduces the violence of bubble collapse as the steam condenses and eliminates water hammer noise.
Apparatus embodying the invention can vary in size and capacity. In practice, steam injection tubes 32, 58 are made in different sizes, from three-fourths inch diameter to 5 inch diameter.
The method of the present invention has been disclosed in connection with the description of the apparatus. In summary, it comprises reducing bubble size by intercepting the steam jets and diffusing or squeezing the jets into a smaller compass or envelope as they enter the water. Hence the bubbles will be smaller and their collapse will be less violent than would otherwise be the case. Water hammer noise is thus eliminated. | A foraminous steam injection tube is mounted within a heating chamber to inject steam into water flowing through the heating chamber to heat the water. A foraminous diffusion screen is mounted around the steam injection tube and in spaced tandem relation, to diffuse the steam jets issuing therefrom, suppress the formation of large bubbles and to eliminate water hammer in the system. | 8 |
RELATED APPLICATIONS
This application claims priority from U.S. Provisional Application Ser. No. 62/068,820, filed 27 Oct. 2014, the contents of which are here incorporated by reference.
GOVERNMENT INTEREST
None
BACKGROUND
To construct a building, it is known in the art to build a wall as a frame having a horizontal sill plate on the bottom and a horizontal top plate on the top, connected by a series of vertical studs. These components had for decades been made of wood. More recently, light weight steel has been adopted for this.
Such wall panels may be cost-effectively pre-assembled in a manufacturing facility and shipped to a building site for a comparatively rapid final assembly. Pre-fabricated wall frames, however, must be moved, and moving may torque the wall frame and distort its shape. Thus, pre-fabricated wall frames should be stabilized against torsional and other stress to maintain the wall panel shape. This is typically done by welding to the wall panel at least one tensioned steel strap running diagonally across a face of the wall frame. This is shown in FIG. 1 , which shows the bottom portion of a wall panel having a base plate [ 2 ], a plurality of vertical steel studs [ 6 ] and/or shearwall posts [ 1 ] placed in a baseplate notch [ 3 ]. A diagonal strap(s) [ 4 ] is tack-welded [ 5 ] to the base of the shearwall post [ 1 ]. The diagonal strap is installed under tension using a standard steel strap tensioning tool and welded in place.
This prior art construct stabilizes the pre-fabricated wall panel during transit and installation. After installation, however, when load is placed on the wall panel, the load may be greater than the tension on the strap, causing the strap to lack tension; when this happens, the steel strap may buckle outward from the wall panel, damaging the gypsum or other wall panel covering.
To remedy such strap buckling, the skilled artisan currently cuts the welded strap from the installed wall panel, re-sets the strap and re-welds it to the wall panel in situ at the building construction site. This process, however, is time-consuming, and thus is both expensive and frustrates one of the advantages of pre-fabricated construction: the ability to construct a building quickly. There is thus a need in the art for a way to stabilize pre-fabricated wall panels for shipping, while avoiding the need to remove and re-weld stabilizing straps. We have found a way.
BRIEF DESCRIPTION
Our invention entails an improved stabilizing strap having an integral tensioning means, whereby a strap installed on a wall panel may be tensioned as needed without disconnecting the strap from the wall panel.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a typical prior art configuration.
FIG. 2 shows an example of our adjustable shearwall assembly, elevation and plan views.
FIG. 3 shows a detailed view of an exemplary adjustment mechanism, side, top, section and isometric views.
FIG. 4 shows another example of our adjustable shearwall assemply, elevation and plan views.
DETAILED DESCRIPTION
Our invention may be easily understood by looking at FIG. 2 , which shows one example of our system.
FIG. 2 shows an elevation view of the bottom portion of a prefabricated steel stud wall panel. The panel has a base plate [ 2 ] bearing a vertical shearwall post [ 1 ] and a plurality of vertical studs [ 6 ].
Attached to one of the vertical members is a first diagonal member [ 4 b ]. We prefer the first diagonal member [ 4 b ] be a flat steel strap. One could alternatively use a strap made of other material (e.g., nylon), but this may complicate fire code compliance testing etc. One could also use a steel cable, rod or other member with a significant depth. Doing so, however, would require cutting notches or holes in each of the vertical studs [ 6 ] to accommodate the diagonal member, complicating the fabrication process and reducing the theoretical load bearing capacity of each vertical stud [ 6 ].
We prefer to attach the first diagonal member [ 4 b ] to a shearwall post [ 1 ] because a post [ 1 ] provides greater structural strength than does a stud [ 6 ]. We prefer to attach [ 5 ] the first diagonal member [ 4 b ] by a weld. One could alternatively use fasteners (e.g., sheet metal screws) or an adhesive.
Attached to the upper portion of another vertical member (not shown) is a second diagonal member [ 4 a].
The second diagonal member [ 4 a ] and first diagonal member [ 4 b ] are adjustably joined by a joint [ 7 ]. The joint [ 7 ] is adjustable and thus allows an installation mechanic to increase tension on the diagonal members [ 4 a , 4 b ] after the wall panel has been installed.
An example of an adjustable joint is shown in FIG. 3 . The joint may be readily made from two pieces of conventional C channel steel [ 7 a , 7 b ] connected by at least one bolt [ 7 c ]. The exemplary joint illustrated in FIG. 3 uses four bolts [ 7 c ] (and appurtenant washers and nuts). One may use more or less bolts as appropriate; it may be least expensive to fabricate and install this kind of joint using only one bolt sited at or near the center of the face of the C channel. The steel C channel [ 7 a , 7 b ] may be reinforced with a block [ 7 d ] to prevent the bolts from pulling through the face of the C channel. The steel C channel may, alternatively or in addition, be reinforced with a flange [ 7 e ] to maintain the C channel in its proper intended conformation. One may (as illustrated) use a nut to anchor the bolt [ 7 c ]. Alternatively, one may thread a hole(s) in the reinforcing block [ 7 d ] and screw the bolt directly into the block, eliminating the need for a nut. Similarly, if the C channel stock has appropriate strength, one may thread a hole in the C channel and screw the bolt directly into the C channel. The two halves of the join [ 7 a , 7 b ] are separated by a gap [ 9 ] for adjustment; we have found a gap of roughly 1″ works well.
One may alternatively use another type of adjustable joint. For example, if one fashions the diagonal members [ 4 a , 4 b ] from cable rather than strap, then one may use a turnbuckle as the joint [ 7 ]. Similarly, if one fashions the diagonal members [ 4 a , 4 b ] from nylon webbing, then one may use a conventional ratchet-type strap tightening clasp, e.g., a Kiln Case Tightener, commercially available from Paragon industries, Inc., Mesquite Tex. The critical requirement is that the joint must be sufficiently adjustable to take up any undesirable slack in the diagonal members [ 4 a , 4 b ] after installation.
One may alternatively dispense with the second diagonal member [ 4 a ]. To do so, one can attach one end [ 7 a ] of the adjustable joint [ 7 ] directly to the baseplate [ 2 ], a shearwall post [ 1 ] or a stud [ 6 ]. If this approach is taken, we prefer to attach to a post [ 1 ], and further prefer the attachment incorporate a gusset plate [ 8 ] as shown in FIG. 4 . We prefer the gusset plate [ 8 ] be attached to both the baseplate [ 2 ] and post [ 1 ] (as exemplified in FIG. 4 ).
Given our disclosure, the artisan will readily arrive at alternatives. We thus intend the legal coverage of our invention to be defined by the appended legal claims and their permissible equivalents, rather than by the specific example illustrated here. | An improved steel stud wall panel which includes a diagonal member able to be placed under tension during installation. The diagonal tension imparts rigidity to the wall panel, preventing warp. | 4 |
BACKGROUND OF THE INVENTION
(1) Field of the Invention
The present invention pertains to a hanger and screen assembly for use with rain gutters. In particular, the present invention pertains to a hanger and screen assembly that is assembled with a conventional rain gutter to protect the gutter from clogging with leaves and/or other debris. The hanger is specifically configured to facilitate the installation of the screen over the top opening of the gutter and the screen is specifically configured to overlap like screens at its opposite ends to provide a continuous screen cover over the gutter opening with no gaps between adjacent screens.
(2) Description of the Related Art
It is a well known practice to place lengths of screen over the top openings of gutters to protect the gutters from becoming clogged with leaves and/or other debris. Various different types of gutters, gutter hangers, and screens have been developed in the prior art for the purpose of preventing leaves and other debris washed off of roof surfaces from collecting inside gutters bordering the roof surfaces, and for the purpose of facilitating the assembly of the gutters, gutter hangers, and screens to the eaves of the roof.
An example of a prior art gutter and gutter hanger is disclosed in U.S. Pat. No. 3,416,760. The gutter hanger disclosed in this patent is typical of prior art hangers. A disadvantage associated with prior art hangers is that, when the gutter and hanger are assembled to the roof eave from the roof, it is difficult for the workman to lean over the edge of the roof to locate the gutter and gutter hanger in their proper positions against the eave and secure the gutter and gutter hangers to the eave. Very often the workman will only reach over the edge of the roof to locate the gutter and gutter hanger against the eave and then attempt to fasten the gutter hanger to the eave with a fastener such as a nail or wood screw without actually being able to see the end of the gutter hanger being attached to the eave. Often this will result in the gutter and gutter hanger being attached to the eave in improper positions relative to each other, and at times this will result in the workman completely missing the gutter hanger with the fastener as the fastener is driven into the eave.
What is needed to overcome this disadvantage of prior art gutters and gutter hangers is an improved gutter hanger with a means of positively locating a fastener such as a nail or wood screw in a hole of the gutter hanger to attach the hanger to the eave without requiring that the workman view the gutter hanger hole to locate the fastener in the hole.
Examples of typical prior art gutter screens are disclosed in U.S. Pat. Nos. 2,209,741 and 4,907,381. Many prior art gutter screens have a forward edge specifically configured to be attached to a forward edge of a particular gutter. These screens are disadvantaged in that they likely are not capable of being used with other gutters not having the specific forward edge configuration for the screen. Moreover, many prior art gutter screens of this type are disadvantaged in that it is difficult to attach the forward edge configuration of the gutter screen to the forward edge of the gutter along the entire length of the screen section.
Many prior art gutter screens are also disadvantaged in that they do not comprise any means of retaining the rearward edge of the screen over the top opening of the gutter. These types of prior art gutter screens have rearward edges that are free to move up away from the top opening of the gutter and often become separated from the gutter after a period of use. Still further, many prior art gutter screens are disadvantaged in that they are designed to be assembled over the top opening of a gutter in an end-to-end relationship. After a period of time, the sections of screen tend to separate from each other forming gaps between adjacent lengths of screen that enable leaves and other debris washed from the roof surface to pass through the gaps and possibly clog the gutter.
What is needed to overcome the above set forth disadvantages of prior art gutter leaf screens is a leaf screen that is specifically designed to be used with a particular gutter hanger, where the forward edge of the leaf screen is configured to be engaged against and retained by a front section of the gutter hanger specifically configured to receive the forward edge of the leaf screen, and the rearward section of the hanger is provided with tabs that project upward and forward from the hanger and engage the rearward edge of the screen to retain the screen rearward edge on the hanger.
SUMMARY OF THE INVENTION
The present invention overcomes the disadvantages associated with prior art gutter hanger and screen assemblies by providing an improved hanger and screen assembly with gutter hangers having specific configurations designed to facilitate the installation of the screens on the hangers and retain the screens on the hangers as well as facilitating the assembly of the hangers on a roof eave, and screen lengths having specific configurations to facilitate the attachment of the screens on the hangers and to overlap adjacent screen lengths to prevent gaps from forming between adjacent screens.
The gutter hanger of the present invention includes a middle section dimensioned to span across the top opening of a conventional gutter between the back wall and front wall of the gutter. A front section of the hanger is connected to the forward end of the hanger middle section and has a specific configuration designed to engage inside the top edge of the front wall of a conventional gutter. The front section has a general C-shaped configuration with the opening of the C-shaped configuration facing rearwardly toward the hanger middle section. The opening is provided to receive a forward edge of the screen and to retain the screen forward edge.
One or more tabs are provided on the middle section of the hanger toward the rearward end of the hanger. The tabs extend upwardly and forwardly from the middle section and are provided to engage the rearward edge of the screen. The rearward edge of the screen is wedged between the tabs and the hanger middle section and is secured in this position over the gutter top opening by the tabs.
The sections of screen are easily inserted on the hanger and over the top gutter opening by first inserting the forward edge of the screen inside the C-shaped front section of the hanger, and then inserting the rearward edge of the screen between the tabs and the middle section of the hanger. The screen is slightly bent across its lateral width as it is assembled on the hangers and the resiliency of the screen causes the screen front edge and rear edge to engage between the front section and the tabs of the hanger thereby securely attaching the screen on the hanger.
A rearward section of the hanger is configured to engage over the top of a conventional gutter backwall. The rearward section extends upwardly from the rear end of the hanger middle section, over the gutter backwall, and then downward behind the gutter backwall. A hole is provided completely through the rearward section of the hanger to accommodate a fastener such as a nail or wood screw. The nail or wood screw is passed through the hole in attaching the hanger to the eave of a roof. A substantially horizontal transverse groove is formed in the rear section of the hanger. The groove intersects the hole at the center of the hanger rear section and facilitates the locating of a fastener in the hole by guiding a tip of the fastener along the groove until it is inserted through the hanger hole.
The front middle and rear sections of the hanger are formed unitarily and are preferably formed of metal.
BRIEF DESCRIPTION OF THE DRAWINGS
Further objects and features of the present invention are revealed in the following detailed description of the preferred embodiment of the invention and in the drawing figures wherein:
FIG. 1 is a side elevation view, in section, of the gutter hanger and leaf screen assembly of the present invention assembled with a conventional gutter to the eave of a roof;
FIG. 2 is a perspective view of the gutter hanger of the present invention;
FIG. 3 is an end view, in section, of the gutter hanger taken along the line 3--3 of FIG. 2;
FIG. 4 is an end view, in section, of the hanger of the present invention taken along the line 4--4 of FIG. 2; and
FIG. 5 is a partial view showing the right hand of the leaf screen of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 shows the gutter hanger and leaf screen assembly 10 of the present invention assembled to a conventional gutter 12 and supporting the gutter on the eave 14 of a roof. The hanger and screen assembly of the invention is basically comprised of a plurality of screen lengths 16 (only one of which is shown in FIG. 1) and a plurality of hangers 18 (only one of which is shown in FIG. 1). For simplicity, only one screen length 16 and one hanger 18 will be described. Preferably, both the screen length and hanger are constructed from metal However, other types of materials may be employed in constructing the screen and hanger of the present invention.
The hanger 18 of the assembly is shown in FIG. 2. The hanger is basically comprised of a middle section 22 having opposite forward and rearward ends, a forward section 24 connected at the forward end of the middle section, and a rearward section 26 connected at the rearward end of the middle section.
The middle section 22 is an elongated member having a predetermined length sufficient to span laterally across the top opening of a gutter 12 between the forward wall 28 and rearward wall 32 of the gutter. A center ridge 34 is formed in the middle section 22 to provide reinforcement to the middle section. A pair of tabs 36 are formed in the middle section on opposite sides of the ridge 34 and adjacent the rearward end of the middle section. The tabs 36 are substantially identical and are formed by a pair of U-shaped cuts made through the middle section with the portions of the middle section defined by the cuts being bent upward from the middle section. As is best seen in FIG. 1, the tabs 36 extend upwardly and forwardly of the middle section 22. As is best seen in FIGS. 3 and 4, the opposite longitudinal sides 38, 42 of the middle section 22 are bent downwardly to form reinforcing flanges extending along the lateral length of the middle section.
The forward or front section 46 of the hanger 18 is formed unitarily with the front end of the hanger middle section 22. As seen in FIGS. 1 and 2, the front section 46 has a general C-shaped configuration with the opening 48 of the C-shaped configuration facing rearwardly toward the hanger middle section 22. The dimensions of the hanger front section 46 are determined to enable the front section to be easily inserted into an edge channel 52 formed along the top edge of the front wall of many conventional gutters. The dimensions of the front section 46 are also determined to facilitate the engagement of the front edge of the screen 16 of the present invention inside the C-shaped opening 48 of the front section as will be explained. As is best seen in FIGS. 2 and 3, the bends formed in the hanger front section 46 to produce the C-shaped configuration are provided with gussets 56 at their opposite ends. The gussets 56 formed at the opposite ends of the bends reinforce the bends and the front section 46 of the hanger.
The rearward or rear section 62 of the hanger 18 is formed unitarily with the rearward end of the hanger middle section 22 and extends upwardly from the middle section rearward end. The rear section 62 of the hanger is specifically configured to engage over the top edge of a backwall 32 of a conventional gutter. The rear section 62 is formed with an upwardly extending front portion 64, a bend portion 66 at the top most end of the front portion 64, and a rear portion 68 extending downwardly from the bend 66 behind the front portion 64. The front and rear portions 64, 68 and the connecting bend 66 of the hanger rear section 62 give the rear section a general inverted U-shaped configuration that enables the rear section 62 to be easily fastened over the top edge of a gutter backwall 32.
A pair of coaxial holes 72 extend through both the front and rear portions 64, 68 of the hanger rear section 62. As seen in FIGS. 2 and 4, the holes 72 are centered in the rear section 62. A groove 74 is formed in the front portion 64 of the rear section 62. The groove 74 extends transversely across the rear section front portion 64 and intersects the forward most of the holes 72 at a midpoint of the groove. The groove is provided to facilitate the insertion of a fastener such as a nail or wood screw in the hole 72 as will be explained.
The screen 16 of the present invention has a general rectangular configuration defined by a front edge 82 formed by a forward most fold in the screen and a rear edge 84 formed by a rearward most fold in the screen. A front screen flange 86 is formed between the front edge fold 82 and the front end 88 of the screen. The front flange 86 formed by the front edge fold 82 extends beneath the screen along the entire longitudinal length of the screen 16 between a left side edge (not shown) and an opposite right side edge 92 of the screen.
A rearward flange 94 is formed between the rearward most fold at the rear edge 84 of the screen and the rear end 100 of the screen. As seen in FIG. 5, the screen rear flange 94 is formed from a first section 96 of the screen that is folded under the screen at the rear edge 84 fold line, and a second section 98 of the screen that is folded underneath the first section 96 along a second fold line 102. The first section 96 of the flange extends beneath the screen 16 in a forward direction and the second section 98 of the flange extends beneath both the screen and the flange first section in a rearward direction. The general Z-shaped cross section of the screen rear flange 94 gives the rear flange a resiliency that biases the rear edge 84 of the screen in an upward direction.
Left and right flaps or tabs 104 (only the right tab is visible in FIG. 5) are provided at the opposite left and right side edges 92 of the screen. As is best seen in FIG. 5, the flaps 104 are formed only on that portion of the screen left and right side edges between the front edge 82 and the rear edge 84 of the screen. Preferably, the flaps 104 extend completely across the lateral width of the screen between the front edge 82 and rear edge 84. The flap shown in FIG. 5 does not extend to the front and rear edges 82, 84 of the screen to provide a better view of the forward and rearward most folds and the front and rear flanges formed in the screen by the folds. It should be understood that in the preferred embodiment of the screen 16, the left and right flaps 104 extend from the front edge 82 of the screen to the back edge 84 of the screen. The left and right flaps 104 are provided at the left and right side edges 92 of the screen to overlap between adjacent screen lengths as will be explained.
In assembling the gutter hanger and screen assembly 10 of the present invention to a conventional gutter, and in mounting the assembly and the gutter to the eave 14 of a roof, the hanger 18 is first assembled to the gutter 12. As seen in FIG. 1, in assembling the hanger 18 to the gutter the front section 46 of the hanger is first inserted inside the edge channel 52 of the gutter. The front section 46 is easily inserted into the edge channel 52 of the gutter by first positioning the hanger 18 in a general vertical orientation relative to the gutter front channel 52 as viewed in FIG. 1. In this orientation of the hanger 18, the forward most end 106 of the hanger is engaged beneath the underside of the gutter channel 52. The hanger is then rotated in a clockwise direction as viewed in FIG. 1, causing the forward most end 106 of the hanger front section 46 to engage inside the lip 108 formed at the top end of the gutter channel 52. As the hanger is rotated clockwise, the C-shaped configuration of the front section 46 wedges, inside the channel 52 at the top edge of the gutter front wall 28.
Simultaneously with the attachment of the hanger front section 46 inside the gutter channel 52, as the hanger 18 is rotated clockwise the rear section 62 of the hanger is engaged over the top edge of the gutter backwall 32 with the bend 66 of the rear section engaging over the top edge of the gutter back wall and the front and rear portions 64, 68 engaging over front and rear surfaces of the back wall. With the hanger 18 assembled to the gutter 12 in the relative positions of the hanger and gutter shown in FIG. 1, the hanger and gutter are ready to be secured to the eave 14 of the roof.
In assembling the hanger and gutter to the eave, the back wall 32 of the gutter and the rear portion 68 of the hanger rear section are placed in their desired position against the eave 14. Most gutters, including that of the present invention, are hung from the roof. The workman on the roof cannot see the hanger because the roof shingles hang over the gutter hanger and obstruct the workman's view. The workman assembling the hanger and gutter to the eave inserts a fastener, such as the nail 112 shown in FIG. 1, into the holes 72 through the hanger rear section and drives the nail into the eave 14 thereby securing the hanger and the gutter to the eave. The groove 74 provided in the hanger rear section assists the workman when the hanger and gutter are assembled to the eave by a workman on the roof 114. The workman need only reach over the edge of the roof and feel for the groove 74 provided in the hanger rear section 62 without actually seeing the groove 72. The workman then places the tip of the fastener 112 in the groove 74 and slides the fastener tip along the groove until it falls into the holes 72 provided through the hanger rear section 62. In this manner, the groove 74 provided in the rear section of the hanger assists the workman in locating the fastener in the hanger hole 72 without requiring that the workman actually see the hole, thus greatly facilitating attachment of the hanger and gutter to the eave from the roof.
Once the hanger 18 and gutter 12 have been attached to the eave 14, the lengths of screen 16 are assembled on the hanger. In assembling the screen 16 on the hanger 18, the front flange 86 is first inserted inside the opening 48 of the C-shaped hanger front section 46. The resiliency of the screen at the front edge 82 formed by the forward most fold enables the front flange 86 to be resiliently bent toward the underside of the screen along the front edge 82 to wedge the screen front edge 82 securely in the opening 48 of the hanger front section 46 and inside the channel 52 of the gutter.
With the front edge 82 of the screen secured in the hanger front section 46 and the gutter channel 52, the screen is then bent slightly across its lateral width to position the rearward end 100 of the screen in a position just forward of the pair of tabs 46 of the hanger 18. The rearward end 100 of the screen is then inserted between the hanger middle section 22 and the tabs 36 to securely wedge the rearward end 100 between the middle section and tabs. The engagement of the screen rearward end 100 between the hanger middle section 22 and the tabs 36 securely holds the rear of the screen on the hanger.
The resiliency of the screen across its lateral width maintains the engagement of the screen front edge 82 inside the hanger front section 46 and the gutter channel 82 and also maintains the engagement of the screen rear end 100 between the hanger middle section 22 and the tabs 36. The general Z-shaped configuration of the rear of the screen 16 biases the rear screen edge 84 upward toward the end of the roof 14 to position the screen 16 as a continuation of the roof surface. The Z-shaped configuration of the rear end of the screen also enables the screen to extend rearwardly covering the entire gutter top opening while still providing the positive engagement between the rear end 100 of the screen and the hanger middle section 22 and tabs 36.
In the preferred embodiment of the invention, each screen length 16 extends longitudinally along the gutter for about four feet. Larger or smaller longitudinal lengths of screen 16 may be employed if so desired. When assembling screen lengths side by side on the hangers 18 of the present invention, the left side edge of one screen will abut up against the right side edge of an adjacent screen with the flaps or tabs 104 overlapping. This ensures that no gaps are provided between adjacent lengths of screen for leaves or other debris to fall between.
While the present invention has been described by reference to a specific embodiment, it should be understood that modifications and variations of the invention may be constructed without departing from the scope of the invention defined in the following claims. | An improved gutter hanger and leaf screen assembly is comprised of hangers formed with holes and grooves at their rearward ends for attachment of the hangers to the eave of a roof. The holes in the hangers are provided for the insertion of fasteners such as nails or wood screws therethrough, and the grooves are provided to position the fasteners in the holes by first inserting a tip of the fastener in the groove and sliding the fastener tip along the groove until it falls into the hole. The hangers are also provided with forwardly projecting tabs which facilitate the attachment of the leaf screen of the assembly onto the hangers and secure the rearward ends of the leaf screen on the hangers. The leaf screen of the assembly is formed with folds at its forward and rearward edges that are provided to securely hold the leaf screen on the hangers. Opposite left and right side edges of the leaf screen are also provided with flaps that overlap adjacent leaf screens when several screens are assembled side by side over the top openings of gutters. The overlapping flaps prevent gaps from forming between adjacent leaf screens and prevent leaves or other debris from falling through gaps between adjacent leaf screens. | 4 |
RELATED APPLICATIONS
[0001] This application claims priority to U.S. Provisional Patent Application No. 62/007,411, filed Jun. 4, 2014, and entitled “Airway Bell” by Catherine Bell, MD and Chris Moore, CRNA, JD, which is incorporated herein by reference.
BACKGROUND
[0002] Laryngoscopes and laryngoscope handles are essential tools for the practice of anesthesia. Laryngoscope handles are either rechargeable-battery or battery powered. The laryngoscope blades are attached to laryngoscope handles and are utilized for intubating patients. The blade, which is illuminated by power source contained in the handle, is inserted into the oropharynx, commonly known as the portion of the throat connected to the mouth. As such, the blade is exposed to potential contaminants such as bacteria and viruses. Since the blade and laryngoscope handle are used as a unit, they are both considered contaminated after use. Therefore, before re-use the laryngoscope handles and blades must be sterilized and this is done according to the manufacturers' recommendations.
[0003] Prior processes allowed for the laryngoscope handles and blades to be assembled and placed in a recharging dock, see FIG. 1 . The re-charging station allows for a constant state of readiness as the laryngoscope handles are fully charged and the blade is attached. In the event of an anesthetic crisis, the required airway equipment is immediately available and ready for use, possibly saving time and lives as the anesthesia provider may establish a patent airway and breathe for the patient.
[0004] Recent changes to the standards for Operating Room sterile requirements have established a concern for the maintained sterility of the laryngoscope handles and blades. It is possible that the laryngoscope handles left exposed to the atmosphere of the operating room could become exposed to particulate matter from surgery. As the laryngoscope handles are not cleaned unless used in a case, those left in the charging station become vulnerable to OR environment contamination. The recommendation has been to keep laryngoscope handles and blades in sealed sterile packaging and only open them for a case. This process eliminates the state of readiness, which is essential for the practice of safe anesthesia care.
[0005] The foregoing examples of the related art and limitations related therewith are intended to be illustrative and not exclusive. Other limitations of the related art will become apparent upon a reading of the specification and a study of the drawings.
SUMMARY
[0006] The following examples and aspects thereof are described and illustrated in conjunction with systems, tools, and methods that are meant to be exemplary and illustrative, not limiting in scope. In various examples, one or more of the above-described problems have been reduced or eliminated, while other examples are directed to other improvements.
[0007] According to these teachings, sterilization of laryngoscope handles involves a housing as illustrated, with a light source. The function of the light source may vary. Multiple light sources can be used. A light source can provide a germicidal environment, and another can provide sterilization. An exemplary embodiment is provided which includes a protective housing equipped with doors, a light source based sterilization technology and a laryngoscope handle re-charging station.
[0008] Advantageously, the combination of sterilization technology and a re-charging station within a single enclosed housing allow laryngoscope handles and blades can be kept in an easily accessible yet sterile environment without compromising the readiness of the equipment.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] FIG. 1 depicts a front view of an example of protective housing for a laryngoscope handle charger.
[0010] FIG. 2 depicts a rear view of an example of protective housing for a laryngoscope handle charger.
[0011] FIG. 3 depicts an exploded front view of an example of protective housing for a laryngoscope handle charger.
DETAILED DESCRIPTION
[0012] in the following description, several specific details are presented to provide a thorough understanding. One skilled in the relevant art will recognize, however, that the concepts and techniques disclosed herein can be practiced without one or more of the specific details, or in combination with other components, etc. In other instances, well-known implementations or operations are not shown or described in detail to avoid obscuring aspects of various examples disclosed herein.
[0013] FIG. 1 depicts an example of a front view of a protective housing for a laryngoscope handle charger 100 . In the example of FIG. 1 , the device 100 includes a housing 102 , two doors 104 in the front of the housing, two door handles 106 , one affixed to each door, and a ready light 108 which illuminates when the device has completed the UV irradiation cycle.
[0014] In the example of FIG. 1 , the housing 102 is a box that can be constructed of stainless steel, plastic or any other known or convenient material; it is sealed at all joints and can fit over an existing re-charging station for recharging the laryngoscope handles. Interior insulation can be included to minimize transmission of heat to the exterior of the housing. The dimensions of the housing can be increased to allow for the storage of additional laryngoscope blades of various sizes to be suspended from the interior panel adjacent to the recharging station. The additional blades would have full exposure to the UV light thus allowing them to remain in a bacteriostatic condition and immediately available for use.
[0015] In the example of FIG. 1 , the two doors 104 in the front of the housing can be constructed of the same material as the housing, which allow for a laryngoscope handle (which has been sterilized according to manufacturers' recommendation) to be placed into the housing, and the doors closed, thus preventing further exposure to the atmosphere of the operating room. The blade may also be attached to the laryngoscope handle and kept in the housing as it will also be in a state of continued sterilization and readiness. In addition to preventing contamination from the atmosphere, the housing contains a sterilization technology which ensures continued sterile equipment ready to use at any time.
[0016] In the example of FIG. 1 , a door handle 106 is affixed to each door to allow the doors to be easily opened and closed.
[0017] In the example of FIG. 1 , the ready light 108 illuminates when the device has completed the sterilization cycle so that the provider is assured that the laryngoscope is sterile and ready for use.
[0018] FIG. 2 depicts an example of a back view of a protective housing for a laryngoscope handle charger 200 . In the example of FIG. 2 , the protective housing for a laryngoscope charger 200 includes a housing 202 , a trap door for outlets 204 , a possible outlet for a power cord to the UV light 206 , and a possible outlet for a power cord to the charger or outlet for a single, unified power cord 208 .
[0019] In the example of FIG. 2 , the housing 202 can be as described above.
[0020] In the example of FIG. 2 , the trap door for outlets 204 can be constructed of the same material as the housing; which allows for outlet cables to run from the charging station and UV light source inside the housing to an electric power source external to the housing.
[0021] In the example of FIG. 2 , the possible outlet for a power cord to the UV light 206 can be composed of a variety of materials, including but not limited to plastic, glass, acrylic, rubber, resin, or another known or convenient material, and which can provide an outlet for a power cord for a UV light source while also minimizing the unnecessary leakage of UV light from the housing.
[0022] In the example of FIG. 2 , the possible outlet for a power cord to the charger or outlet for a single unified power cord 208 can be composed of a variety of materials, including but not limited to plastic, glass, acrylic, rubber, resin, or another known or convenient material, and which can provide an outlet for a power cord for a laryngoscope re-charging station while also minimizing the unnecessary leakage of UV light from the housing. Future models would contain designs for a built-in recharging station or a plug external to the housing for the existing electrical attachment so that the unit would only require a single electrical outlet in the operating room or procedure room.
[0023] FIG. 3 depicts an example of an exploded view of a protective housing for a laryngoscope handle charger 300 . In the example of FIG. 3 , the protective housing for a laryngoscope charger 300 includes a UV light source 302 , a re-charging station 304 , laryngoscope handle slots 306 in the re-charging station, a ready light 308 , a sterilization sensor 310 , and internal control mechanics for a light source trigger 312 .
[0024] Ultraviolet germicidal irradiation (UVGI) is a disinfection method that uses ultraviolet (UV) light at sufficiently short wavelength to kill microorganisms. UVGI utilizes short-wavelength ultraviolet radiation that is harmful to microorganisms. It is effective in destroying the nucleic acids in these organisms so that their DNA is disrupted by the UV radiation, leaving them unable to perform vital cellular functions.
[0025] In the example of FIG. 3 , the UV light source 302 emits pulse UV light at a sufficiently short wavelength to cause UVGI. This UVGI light source is obtained under separate patent and is separately manufactured and then mounted in the housing. When the housing is opened, a laryngoscope handle is inserted into the charger and the door closed, housing the UVGI process is initiated, germicidal inactivation and/or sterilization occurs and any contamination from the atmosphere is prevented.
[0026] In the example of FIG. 3 , the re-charging station 304 is a standard laryngoscope re-charging station.
[0027] In the example of FIG. 3 , the laryngoscope handle slots 306 , as per the specifications of the laryngoscope re-charging station, are designed appropriately for the laryngoscope(s) to be charged.
[0028] In the example of FIG. 3 , the external ready light 308 can be as described in above.
[0029] In the example of FIG. 3 , the sterilization sensor 310 , can be a timing device measuring the duration of time the laryngoscope handles have been exposed to UV light to determine when the laryngoscope handles are sterilized. Sterilization sensor 310 is connected to the ready light so that when the handles are sterilized, the ready light illuminates.
[0030] In the example of FIG. 3 , the internal control mechanics for a light source trigger 312 , cause the UV light source to be triggered to emit pulse UVGI when the housing door is opened, a handle is inserted into the re-charging station and the housing door is closed. Conversely, when the doors to the housing are opened, the trigger 310 can automatically switch off the ultraviolet light source so that the health care providers near the unit will not be exposed to the ultraviolet light and the operating room or procedure will not be unnecessarily illuminated when doctors and other practitioners are accessing the laryngoscope handles. Once a laryngoscope handle is placed into the housing the UVGI process is initiated, germicidal inactivation and/or sterilization occurs and any contamination from the atmosphere is prevented.
[0031] It will be appreciated to those skilled in the art that the preceding examples and embodiments are exemplary and not limiting to the scope of the present invention. It is intended that all permutations, enhancements, equivalents, and improvements thereto that are apparent to those skilled in the art upon a reading of the specification and a study of the drawings are included within the true spirit and scope of the present invention. It is therefore intended that the following appended claims include all such modifications, permutations and equivalents as fall within the true spirit and scope of the present invention. | In accordance with the teachings provided herein, a Protective Laryngoscope Housing With Light Source Sterilization can emit pulse UV light at a sufficiently short wavelength to cause Ultraviolet germicidal irradiation (UVGI) to maintain an easily accessible, yet sterile or germicidal environment for laryngoscope handles. | 0 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to divisional application Ser. No. 14/426,794, filed on Mar. 9, 2015, which claims priority to PCT Application No. PCT/EP2012/067666, having a filing date of Sep. 10, 2012, the entire contents of which are hereby incorporated by reference.
FIELD OF TECHNOLOGY
[0002] The following relates to a method and a blasting material for producing a satinized finish or also called “satinized surface” on an aluminium substrate.
BACKGROUND
[0003] Anodized aluminium components are nowadays used in many fields in which, on the one hand, the decorative “aluminium look” is to be preserved and, on the other hand, corrosion protection of the sensitive aluminium surfaces are required. Fields which may be mentioned are the window and structural facings sector, or also the automotive field and domestic appliances.
[0004] Before the anodization, the aluminium parts are in most cases pickled in order to free the aluminium surfaces of impurities and remove the oxide layer (passive layer) that is naturally present. Depending on the type of treatment, semi-matt to matt-glossy surfaces are produced which, owing to their appearance, are referred to as so-called “satinized” surfaces.
[0005] In order to achieve improved corrosion protection, and also for design reasons, the aluminium components are anodized, that is to say an oxide layer is initiated by means of electrolysis. This method is also referred to as anodization, wherein aluminium is oxidized electrolytically. The aluminium surfaces so treated can also be dyed before final sealing.
[0006] The oxide layers produced by the anodization of aluminium and aluminium alloys are far superior to the oxide layers that occur naturally on the aluminium surfaces in terms of mechanical properties, corrosion resistance and decorative appearance. Good corrosion resistance to industrial and marine atmospheres is achieved with oxide layers of 20 μm. The oxide layer that is produced is not electrically conductive.
[0007] In order to be able to form homogeneous oxide layers, the anodization is preceded by mechanical or chemical pretreatment methods. These are specified, for example, in DIN 17611. Table 1 shows the designation system for the pretreatment of aluminium surfaces according to the mentioned DIN 17611.
[0000]
TABLE 1
Type of
Symbol
pretreatment
Notes
E0
Degreasing
Surface treatment before anodization, in which the surface is
and
degreased and deoxidized without further pretreatment.
deoxidation
Mechanical surface flaws, e.g. pits and scratches, remain
visible. Areas of corrosion which were scarcely noticeable
before the treatment can be visible after the treatment.
E1
Grinding
Grinding leads to a comparatively uniform but slightly dull-
matt appearance. All surface flaws present are largely removed,
but grinding marks can remain visible.
E2
Brushing
Mechanical brushing produces a uniform glossy surface with
visible brush strokes. Surface flaws are only partly removed.
E3
Polishing
Mechanical polishing leads to a glossy, bright surface, while
surface flaws are only partly removed.
E4
Grinding and
By means of grinding and brushing, a uniformly glossy surface
brushing
is achieved; mechanical surface flaws are removed. Areas of
corrosion which can become visible with treatments E0 or E6
are removed.
E5
Grinding and
By means of grinding and polishing, a smooth, glossy
polishing
appearance is achieved; mechanical surface flaws are
removed. The effects of corrosion, which can become visible
with treatments E0 or E6, are removed.
E6
Pickling
After degreasing, the surface acquires a semi-matt or matt
sheen by being treated with special alkaline pickling
solutions. Mechanical surface flaws are evened out but not
removed completely. The effects of corrosion on the metal
surface can become visible upon pickling. A mechanical
pretreatment prior to pickling can remove these effects;
however, it is more beneficial to treat and store the metal in
such a manner that corrosion is avoided.
E7
Chemical or
After degreasing of the surface in a vapor degreasing agent or
electrochemical
in a non-etching cleaning agent, a high-gloss surface is
polishing
obtained by treatment in special chemical or electrochemical
bright plating baths. Surface flaws are removed to only a
limited degree, and effects of corrosion can become visible.
E8
Polishing and
Grinding and polishing with subsequent chemical or
chemical or
electrochemical polishing. This treatment leads to a high-gloss
electrochemical
appearance; mechanical surface flaws and the beginnings of
polishing
corrosion are generally removed.
[0008] The mechanical, chemical and/or electrochemical pretreatments serve to prepare the surface of the aluminium substrates for the anodic oxidation. Specific surface effects can be achieved thereby. They serve to clean the surfaces of the components, to remove oxide layers (passive layer or incorrectly anodized surfaces) and surface defects. A uniform appearance of the surface is thereby achieved, and the resulting bright aluminium surface permits a brisk ion exchange during electrolysis. In addition, specific desired and also undesired structures are created, such as, for example, grinding and brush marks.
[0009] One of the chemical treatment methods that is frequently used is pickling of the aluminium substrate surfaces, which is also known as E6 treatment. Uniformly matt and decorative surfaces are thereby created; the so-called E6 finish. The irregularities on the surface that are produced by the extrusion of profiles and the rolling of metal sheets are to be covered or removed. Structural irregularities, such as web marks and welding seams, caused by the technology are also to be mattified as far as possible so that they are not troublesome from a decorative point of view.
[0010] Owing to the amphoteric properties of the aluminium surfaces, the component surface can be pickled both using bases and using acids. The oxide layer that is naturally present on the aluminium surface is thereby removed and any defects in the surface resulting from the production process are lessened. Consequently, a bright aluminium surface is obtained. This permits the very good ion exchange that is necessary for the subsequent electrolytic treatment.
[0011] In most cases, the aluminium substrates to be treated are introduced into an immersion bath containing an aqueous solution of sodium hydroxide (NaOH). Owing to its chemical properties, the sodium hydroxide solution serves both to remove impurities such as fats and oils and to pickle the aluminium surfaces. In many cases, however, cleaning and pickling take place separately, because a significantly lower NaOH concentration is sufficient for cleaning and thus, for example, less NaOH is carried into the subsequent rinsing tank. The cleaning process is referred to according to DIN17611 as E0. However, depending on the content of any alloying constituents of the substrate or on the effect to be achieved, further sodium compounds such as silicates, carbonates or phosphates can also be used.
[0012] Sodium oxide carries out a very strong attack on the oxides, oxide hydrates and the base metal of the aluminium substrate, which is about 20 times greater than at comparable acid concentrations. For an optimum reaction procedure, the dipping bath must be maintained in a defined temperature range. The temperature inside the pickling bath is dependent on the utilization over time. That is to say, the pickling bath must be heated if the supply of aluminium is low or, in the case of a very high aluminium supply, must also be cooled on account of the increased exothermic reaction in order to be kept in the optimum temperature range.
[0013] By the use of sodium hydroxide solution, the oxides and oxide hydrates are reacted as follows:
[0000] AlO(OH)+NaOH NaAlO 2 +H 2 O
[0000] AlO(OH)+NaOH+H 2 O Na[Al(OH) 4 ]
[0000] Al(OH) 3 +NaOH Na[Al(OH) 4 ]
[0000] Al 2 O 3 +2NaOH+3H 2 O 2Na[Al(OH) 4 ]
[0014] In addition, the lye also attacks the base metal:
[0000] 2Al+2H 2 O+2NaOH→2NaAlO 2 +3H 2 ↑
[0000] 2Al+6H 2 O+2NaOH→2NaAl(OH) 4 +3H 2 ↑
[0015] That is to say, sodium aluminate (NaAl(OH) 4 ) and hydrogen (H 2 ) form as reaction products. By adding additives such as, for example, nitrates or nitrites to the pickling medium, the evolution of hydrogen can be inhibited and the pickling operation accelerated, as a result of which the base metal is attacked to a lesser degree. However, these additives can lead to the formation of further critical waste products, such as, for example, ammonia, which pollute the waste water.
[0016] Furthermore, aluminium hydroxide can be deposited in the tank on the walls and the heating elements, so-called scale formation, which can hinder operation and in particular significantly impair the efficiency of the heating elements. Scale formation can be counteracted by adding complexing agents such as gluconates or phosphonates. However, such complexing agents are also environmentally relevant and can pollute the waste water.
[0017] Accordingly, depending on the particular process technique, the pickling process produces various types of waste, which are disposed of or treated in different ways. The consumed pickle and the resulting sludge must be disposed of as waste, which gives rise to disposal costs. The sludge produced from the pickle is usually deposited, which is associated with further disposal costs. Together, these disposal costs represent a considerable cost factor in the surface treatment of aluminium substrates.
[0018] In addition, the attack of the pickle on the aluminium surface to produce a so-called E6 finish also brings about the removal of an amount of material of up to 100 g/m 2 or 30 The attack and the removal of material thereby take place not only on the outside faces with a decorative requirement, but also on the inside faces, which remain invisible. In total, the amount of material removed is therefore up to 200 g/m 2 or 60 μm of the total profile. The consumption of pickling agent is thereby linearly dependent on the amount removed. The loss of pickling agent by the removal of material that is caused can be compensated for relatively easily by adding fresh pickle. However, the sodium aluminate complex that forms also causes an increase in the viscosity of the pickle, as a result of which the pickling process becomes less effective over time. As the aluminium concentration increases, aluminium hydroxide also precipitates from the pickling medium and settles as a sludge-like deposit in the pickling tank. The pickling bath must therefore be renewed or replaced at regular intervals. Methods according to the current prior art are accordingly associated with a high occurrence of environmentally critical substances and a high energy consumption.
SUMMARY
[0019] An aspect relates to a method for producing satinized surfaces on aluminium substrates which is capable of overcoming the mentioned disadvantages. In particular, it is an aspect of embodiments of the present invention to provide a method for producing satinized aluminium surfaces whose appearance is substantially identical to the aluminium surfaces produced by treatment according to DIN 17611 E6.
[0020] There is accordingly proposed a method for producing a satinized surface on an aluminium substrate, comprising the method steps:
[0021] providing an aluminium substrate;
[0022] treating by blasting with a blasting material the surface regions of the aluminium substrate provided that are to be satinized; wherein there is used as the blasting material a mixture of angular and spherical particles having a grain diameter D 90 of ≦0.3 mm.
[0023] According to one embodiment there is proposed a method for producing a satinized surface on an aluminium substrate, comprising the method steps:
[0024] providing an aluminium substrate;
[0025] treating by blasting with a blasting material the surface regions of the aluminium substrate provided that are to be satinized;
[0026] anodizing the surface regions treated by blasting; and
[0027] sealing the anodized surface regions,
[0000] wherein there is used as the blasting material a mixture of angular and spherical particles having a grain diameter D 90 of ≦0.3 mm.
[0028] According to one embodiment there is proposed a method for producing a satinized surface on an aluminium substrate, comprising the method steps:
[0029] providing an aluminium substrate;
[0030] treating by blasting with a blasting material the surface regions of the aluminium substrate provided that are to be satinized;
[0031] anodizing the surface regions treated by blasting; and
[0032] sealing the anodized surface regions, wherein as the blasting material a mixture of angular and spherical particles having a grain diameter D 90 of ≦0.3 mm and ≧0.01 mm. is used.
[0033] According to one embodiment, the blasting material can be so chosen that the mixture comprises angular and spherical particles having a grain diameter D 90 of ≦0.3 mm and ≧0.01 mm, preferably from ≦0.2 mm to ≧0.01 mm, more preferably from ≦0.1 mm to ≧0.01 mm, additionally preferably from ≦0.05 mm to ≧0.01 mm and further preferably from ≦0.02 mm to ≧0.01 mm.
[0034] Unless indicated otherwise, the expression “particle diameter” and “grain diameter” as used in the present description refers to a particle diameter and grain diameter D 90 , that is to say at least 90% of the total particle composition or of the total grain composition have the indicated particle or grain diameter.
[0035] The respective contents of the angular and round particles, indicated in % by weight, are so chosen that the total composition of angular and round particles does not exceed 100% by weight.
[0036] According to one embodiment, the blasting material can be so chosen that the mixture comprises angular and spherical particles as new grain with the following particle diameter distribution:
[0000] >0.315 mm=<0.1%;
≦0.315 to ≧0.200 mm=≦5%;
<0.200 mm and ≧0.050 mm=≧95%
<0.050 mm=<0.1%, based on the total blasting material mixture.
[0037] According to embodiments of the invention, it can be provided in one embodiment of the method that the blasting material particle mixture is sieved and/or screened before being applied to the substrate surface, in order to ensure that no particles above and/or below the particle diameter provided according to embodiments of the invention are present.
[0038] Surprisingly, it has been shown that, with mechanical treatment of the aluminium surface and subsequent anodization and sealing, it is possible to achieve a finish, preferably an E6 finish, which has a substantially or even an identical appearance to aluminium surfaces correspondingly treated by pickling. By dispensing with pickling, the environmentally critical waste products are advantageously avoided. In addition, tempering of the pickling baths is not necessary, as a result of which a substantial portion of the energy to be used in the aluminium surface treatment can be saved. Ultimately, in the mechanical surface treatment according to embodiments of the invention, only the surface regions of the aluminium substrate that are ultimately visible are treated. Regions that are not visible, such as, for example, the inside of hollow profiles, are not treated, unlike in the pickling treatment according to the prior art, as a result of which the amount of material removed, based on the profile as a whole, is substantially reduced. As a result, material savings on the aluminium substrate are possible. In particular, it has been shown that structural faults in the aluminium substrate, such as, for example, web marks or welding seams, can be removed substantially better by means of the blasting treatment according to embodiments of the invention than was hitherto possible with a chemical method, such as a pickling treatment. This is also true of more pronounced surface defects such as pressing marks or scratches.
[0039] In addition, the blast treatment according to embodiments of the invention is significantly more environmentally friendly compared with chemical surface treatment methods.
[0040] The term particle and grain or grains are used synonymously in the description.
[0041] Within the meaning of the embodiment of the invention, the term “spherical” in connection with particles and grains means that the particles and grains are substantially round, that is to say their length is smaller than twice their diameter.
[0042] Within the meaning of the embodiment of the invention, the term “angular” in connection with particles and grains mean that the particles and grains are not spherical, have edges and broken edges have sharp edges.
[0043] All physical data relating to the particles according to embodiments of the invention refer to a so-called “new grain”, unless indicated otherwise.
[0044] The expression “new grain” in connection with embodiments of the present invention refers to grains or particles before use as blasting material.
[0045] The expression “operating state” in connection with embodiments of the present invention relates to particles when used as blasting material, which have been delivered to a blasting material machine for blasting onto an aluminium component and circulate therein.
[0046] Requirements of blasting materials in general are set down in standards DIN 8201; DIN ISO 11124 and SAE J 444, to which reference is made here in their entirety.
[0047] Blasting materials of angular and spherical grain which can be used according to embodiments of the invention can, however, also have sieve analyses which lie outside the above standards.
[0048] Application of the blasting material particle mixture to the aluminium substrate surface can be carried out according to embodiments of the invention both by means of compressed air and by means of centrifugal wheel technology. While in the case of the application of the blasting material particle mixture to the aluminium substrate surface by means of compressed air, the blasting material particles are carried by a compressed air jet and accelerated onto the substrate surface, in the case of centrifugal wheel technology, the blasting material particles are accelerated to the desired speed by a rapidly rotating centrifugal wheel. It is also possible to use the blasting material particle mixture in conjunction with, for example, aqueous suspensions. Such application of the blasting material particle mixture by means of a wet-jet method using water pressure and a nozzle or by means of a centrifugal wheel is rarely used for such profile machining. Possible dust formation during blast treatment can thereby be reduced, for example.
[0049] The use of angular particles in the blast treatment of aluminium surfaces does not lead to the desired E6 surface quality. In fact, the surface obtained by the use of angular particles tends to be rough. The surface tends to remain rough as a result of the pretreatment with angular particles. The quality of the resulting aluminium surface is nowhere near the desired E6 surface quality. The use of spherical particles does not lead to the removal of pressing marks or to the desired E6 surface quality of aluminium. Nor does the use of spherical particles in the first treatment step and the use of angular particles in a subsequent second step lead to an aluminium surface having anything like the desired E6 surface quality. On the contrary, a significantly rougher surface than with the above-mentioned treatment sequence is achieved. On the other hand, a specific mixture of angular and spherical particles surprisingly, and without chemical treatment, leads to the desired aluminium E6 surface quality.
[0050] Without wishing to be bound to this theory, it is assumed that the angular particles contained in the blasting material particle mixture exert an abrasive action on the substrate surface, by means of which the natural oxide layer on the substrate as well as any impurities are removed, while the spherical particles exert a surface-sealing action.
[0051] By the use of the blasting material particle mixture according to embodiments of the invention, a “sanitization”, as it were, of the surface of aluminium is achieved.
[0052] According to one embodiment, it is possible by means of the blasting material particle mixture according to embodiments of the invention to achieve a surface structure and appearance which are similar to the highest degree to the chemical E6 pickling action. In other words, it is possible by means of the use of the blasting material particle mixture according to embodiments of the invention to achieve an aluminium surface quality which corresponds to E6 surface quality.
[0053] Application of the blasting material particle mixture can take place, surprisingly, not only by means of blasting units, which ensure very uniform application, but also by hand, without the immediate formation of isotropic, direction-dependent surface structures. The surface structures produced according to embodiments of the invention, on the other hand, can be anisotropic.
[0054] According to one embodiment, the new grain blasting material particle mixture has a content of angular new grain particles of between ≦80% by weight and ≧20% by weight, preferably between ≦70% by weight and ≧30% by weight, more preferably ≦60% by weight and ≧40% by weight, in particular 50% by weight±2% by weight, based on the total weight of the new grain blasting material particle mixture.
[0055] According to one embodiment, the new grain blasting material particle mixture has a content of round new grain particles of between ≧20% by weight and ≦80% by weight, preferably between ≧30% by weight and ≦70% by weight, more preferably ≧40% by weight and ≦60% by weight, in particular 50% by weight±2% by weight, based on the total weight of the new grain blasting material particle mixture.
[0056] According to one embodiment, the new grain blasting material particle mixture has a content of angular new grain particles of between ≦80% by weight and ≧20% by weight, preferably between ≦70% by weight and ≧30% by weight, more preferably ≦60% by weight and ≧40% by weight, in particular 50% by weight±2% by weight, and round particles, wherein the total amount by weight of the blasting material particle mixture of angular and spherical new grain particles is 100% by weight.
[0057] According to one embodiment, the new grain blasting material particle mixture has:
a) a content of angular new grain particles of between ≦80% by weight and ≧20% by weight, preferably between ≦70% by weight and ≧30% by weight, more preferably ≦60% by weight and ≧40% by weight, in particular 50% by weight±2% by weight; and/or b) a content of round new grain particles of between ≧20% by weight and ≦80% by weight, preferably between ≧30% by weight and ≦70% by weight, more preferably ≧40% by weight and ≦60% by weight, in particular 50% by weight±2% by weight;
based on the total weight of the new grain blasting material particle mixture, wherein the total composition of angular and round new grain particles is 100% by weight.
[0060] According to a further embodiment, the new grain blasting material particle mixture has a content of angular new grain particles and spherical new grain particles of in each case 50% by weight, based on the total weight of the blasting material particle mixture, wherein the amount of angular new grain particles and spherical new grain particles can each be present with a deviation of ±2% by weight.
[0061] According to a preferred embodiment of the invention, the blasting material particle mixture in the operating state has an average content of angular particles of between ≦80% by weight and ≧20% by weight, preferably between ≦70% by weight and ≧30% by weight, more preferably ≦60% by weight and ≧40% by weight, in particular 50% by weight±2% by weight.
[0062] The expression “operating state” is to be understood as meaning that it is the average composition of the blasting material during the blasting operation.
[0063] According to a further embodiment, the blasting material particle mixture in the operating state has an average content of angular particles of between ≦75% by weight and ≧35% by weight, preferably between ≦70% by weight and ≧45% by weight, based on the total composition of the blasting material particle mixture.
[0064] The blasting material particle mixture used in the method according to embodiments of the invention is subject to a certain amount of wear. In particular, the angular blasting material particles present become worn during use. It can therefore be provided according to embodiments of the invention that the blasting material particle mixture is supplemented during use in order to maintain its efficiency. It can in particular be provided that the blasting material particle mixture is supplemented continuously or discontinuously with a blasting material particle mixture which has a content of angular particles of between ≦80% by weight and ≧50% by weight, in particular 75% by weight±2% by weight, and a content of spherical particles, wherein the total amount by weight of the blasting material particle mixture of angular and spherical particles is 100% by weight.
[0065] According to a further embodiment, the blasting material particle mixture in the operating state has an average content of angular particles of between ≦80% by weight and ≧35% by weight, preferably between ≦70% by weight and ≧45% by weight, in particular 50% by weight±2% by weight, and round particles, wherein the total amount by weight of the blasting material particle mixture of angular and spherical particles is 100% by weight.
[0066] According to a further embodiment, the blasting material particle mixture in the operating state has an average content of angular particles and spherical particles of in each case 50% by weight, based on the total weight of the blasting material particle mixture, wherein the amount of angular new grain particles and spherical new grain particles can each optionally be present with a deviation of ±2% by weight.
[0067] According to one embodiment, the blasting material particle mixture in the operating state has an average content of spherical particles of between ≧20% by weight and ≦80% by weight, preferably between ≧30% by weight and ≦70% by weight, more preferably ≧40% by weight and ≦60% by weight, in particular 50% by weight±2% by weight, based on the total weight of the new grain blasting material particle mixture.
[0068] According to one embodiment, the blasting material particle mixture in the operating state can have an average content:
a) of angular particles of ≦80% by weight and ≧20% by weight, preferably between ≦70% by weight and ≧30% by weight, more preferably ≦60% by weight and ≧40% by weight, in particular 50% by weight±2% by weight; and/or b) of spherical particles of between ≧20% by weight and ≦80% by weight, preferably between ≧30% by weight and ≦70% by weight, more preferably ≧40% by weight and ≦60% by weight, in particular 50% by weight±2% by weight,
based on the total weight of the blasting material particle mixture in the operating state.
[0071] By corresponding continuous or discontinuous addition, the average blasting material particle mixture can be maintained during the operating state.
[0072] According to a further embodiment, there can be added to the blasting material mixture during the operating state new grain blasting material having a content of angular particles and spherical particles of in each case 50% by weight with a deviation of ±2% by weight, based on the total weight of the blasting material particle mixture, wherein the total weight of angular and spherical particles is 100% by weight.
[0073] According to a further embodiment, there can be added to the blasting material mixture during the operating state new grain blasting material having a content of angular particles of 70% by weight±2% by weight and spherical particles of 30% by weight±2% by weight, based on the total weight of the blasting material particle mixture, wherein the total weight of angular and spherical particles is 100% by weight.
[0074] Spherical particles generally have a longer lifetime than angular particles. Angular particles have a tendency to break during the operating state; the spherical particles, on the other hand, are made of a far more ductile material and consequently have a significantly lower tendency to break.
[0075] It is accordingly possible to add larger amounts of angular particles as compared with spherical particles during the operating state, in order to maintain the average blasting material particle mixture during the operating state.
[0076] It is pointed out in this connection that particles having a diameter of <0.01 mm, also referred to as dust, are not to be understood as being blasting material particles within the meaning of this invention, so that all the % by weight data do not include particles having a diameter of <0.01 mm.
[0077] According to a further embodiment of the method according to embodiments of the invention, the angular particles have an average hardness of ≧600 HV, in particular ≧640 HV, preferably ≧750 HV and preferably ≧600 HV and ≦800 HV.
[0078] Angular particles having a hardness in the range of ≧600 HV and ≦800 HV are commercially available, for example, from Vulkan-Inox under the mark Grittal®.
[0079] It has been shown that angular blasting material particles in this hardness range, in combination with the spherical particles, achieve optimum removal of the surface for producing the desired satin effect on the aluminium surface. In particular, the angular blasting material particles can be iron-based metal alloys, preferably iron-based metal alloys which have a martensitic matrix with chromium carbides, and preferably stainless steel particles, in particular stainless special steels. Preferably, the stainless steel comprises chromium carbides. More preferably, the stainless steel has a chromium content of 30% by weight±2% by weight and a carbon content of 2% by weight±0.5% by weight. Particularly preferably, the angular particles can consist of a chromium carbide-containing stainless steel.
[0080] According to a further embodiment of the method according to embodiments of the invention, the spherical particles have an average hardness of ≧250 HV, preferably ≧280 HV, preferably ≧300 HV, more preferably ≧350 HV, yet more preferably of ≧400 HV and additionally preferably of ≧450 HV. According to a further embodiment, the spherical particles have an average hardness of ≧250 HV and ≦500 HV.
[0081] Spherical particles having a hardness in the range of ≧250 HV and ≦500 HV are commercially available, for example, from Vulkan-Inox under the mark Chronital®.
[0082] It is, however, also possible to use spherical particles having a hardness of >500 HV, for example ≦550 HV.
[0083] It has been shown that spherical blasting material particles in this hardness range produce optimised sealing of the surface for producing the desired satin effect in combination with the angular particles on the aluminium surface. In particular, the spherical blasting material particles can be iron-based metal alloys, preferably stainless steel particles. Preferably, the stainless steel has an austenitic microstructure. More preferably, the stainless steel has a chromium content of 18% by weight±2% by weight and a nickel content of 10% by weight±2% by weight.
[0084] According to a further embodiment of the present invention, the stainless steel particles are particularly preferably stainless special steel.
[0085] A further advantage of the method according to embodiments of the invention is that used blasting material, because of its composition, can simply be conveyed to industrial processing, for example steel production. Accordingly, it does not represent a waste material but a commodity, which can be supplied to steel-producing companies as an additive.
[0086] The blasting speed in the blasting process, also called “the delivery speed”, can be on average from ≧30 m/s to ≦100 m/s, preferably from ≧35 m/s to ≦90 m/s, more preferably from ≧40 m/s to ≦80 m/s, more preferably from ≧45 m/s to ≦70 m/s, and most preferably from ≧50 m/s to ≦60 m/s.
[0087] The pressure of the jet at the outlet nozzle can be from ≧2 bar to ≦10 bar, preferably from ≧3 bar to ≦8 bar, and more preferably from ≧4 bar to ≦6 bar. However, it is also possible to carry out blasting with higher pressures.
[0088] According to a further embodiment of the method according to the invention, the substrate surface to be satinized is deoxidized and/or pickled after the blast treatment and before anodization. An acidic deoxidizing or pickling bath can hereby be used.
[0089] According to a further embodiment of the method according to the invention, the substrate surface to be satinized is subjected to a polishing treatment after the blast treatment and before anodization. The satin effect can thereby advantageously be enhanced. A polishing treatment can be carried out, for example, by means of a hot acidic, preferably phosphoric acid-containing treatment solution, with which the aluminium surface treated by blasting is brought into contact. Alternatively, a polishing treatment can be carried out electrolytically in a mixture of phosphoric acid and sulfuric acid by applying a voltage. In addition, all other known polishing methods for aluminium surfaces can be used.
[0090] The anodization and sealing of the aluminium substrate surface provided according to embodiments of the invention can be carried out in the conventional manner known from the prior art, as is also described, for example, in DIN 17611.
[0091] According to a further embodiment of the method according to embodiments of the invention, it can be provided that rinsing steps are provided between the individual treatment steps in order to remove any method residues adhering to the substrate surface.
[0092] Embodiments of the present invention relates additionally to a blasting material for the blast treatment of aluminium surfaces, wherein the blasting material has a grain diameter of ≦0.3 mm, preferably ≦0.2 mm, more preferably ≦0.1 mm, which is characterized in that the blasting material in the operating state has an average content of angular particles of between ≦90% by weight and ≧30% by weight, preferably between ≦75% by weight and ≧40% by weight, in particular 50% by weight.
[0093] According to a preferred embodiment of the blasting material, the spherical particles have an average hardness≧300 HV, preferably ≧450 HV, and the angular particles have an average hardness≧640 HV, preferably ≧750 HV.
[0094] Particularly preferably, the angular particles comprise a chromium carbide-containing stainless steel having a martensite structure or a microstructure of 6-ferrite; or the angular particles consist of a chromium carbide-containing stainless steel having a martensite structure or of a microstructure of 6-ferrite.
BRIEF DESCRIPTION
[0095] Some of the embodiments will be described in detail, with reference to the following figures, wherein like designations denote like members, wherein:
[0096] FIG. 1 shows a comparison of the surface structures produced by pickling according to the prior techniques and blast treatment according to the invention.
DETAILED DESCRIPTION
[0097] FIG. 1 shows a comparison of the surface structures produced by pickling according to the prior techniques and blast treatment according to embodiments of the invention. As the comparison shows, the aluminium surfaces treated by blasting according to embodiments of the invention differ only insubstantially from the aluminium surfaces treated by pickling according to DIN 17611 E6, both in the normal view and in the microscopic enlargement. In fact, it is shown that the substrate surface treated according to embodiments of the invention no longer shows any web marks in the normal view. Substrate surfaces treated by blasting according to embodiments of the invention can readily be assembled with surfaces treated by means of the known pickling treatment without any visually perceptible difference between their surfaces.
Example 1
[0098] Profile sections of extruded aluminium profiles of the alloy AlMgSiO 5 were removed from a pressing plant for comparative tests. Sieve fractions of sieve sizes D 90 of from 0.1 mm to 0.2 mm mesh size of both angular material and spherical material were produced from blasting materials of a German manufacturer. The round blasting material was stainless steel having a chromium content of 18% by weight±1% by weight and a nickel content of 10% by weight±2% by weight. The angular blasting material was stainless steel having a chromium content of 30% by weight±1% by weight and a carbon content of 2% by weight±0.1. The prepared profile sections were then blasted in a manual cabinet with variable compressed air pressure, mixtures of the spherical and angular sieve fractions also being used.
[0099] After blasting, the profile sections were first cleaned in a cleaner for aluminium surfaces from ALUFINISH, product ALFICLEAN, then pickled gently for one minute in a dilute sodium hydroxide solution (50 g/l at 60° C.), and then deoxidized in an acidic solution of 150 g/l of sulfuric acid and a peroxidic additive (ALFIDEOX from ALUFINISH; 1 g/l) and then anodized in a bath containing 180 g/l of sulfuric acid. A current density of 1.5 A/dm was used; the anodization time was 40 minutes until a layer thickness of 20 μm was achieved. Between each of the above-mentioned treatment steps, the profile sections were rinsed, and a rinsing operation of at least one minute in tap water was also carried out after the anodization. The oxide layers produced were then sealed for one hour in hot water at 96° C. to 98° C., a so-called sealing aid from ALUFINISH, product ALFISEAL, being added to the water in a concentration of 2 g/l. The profile sections were then subjected to a comparative assessment.
[0100] In addition, after the above-mentioned cleaning and pickling, some blasted profile sections, instead of being deoxidized as mentioned above, were polished in a solution of 75% sulfuric acid, 15% phosphoric acid and 10% water at a temperature of >100° C. for one minute and then likewise anodized as described. The results of the evaluations are described briefly below:
Example 1a
[0101] In the case of the profile sections treated with the spherical blasting material particles, the web marks and welding seams on the surfaces were still wholly visible and not covered.
Example 1b
[0102] In the case of the profile sections treated with angular blasting material particles, a decoratively troublesome whitish coating was observed throughout after anodization; the surface finish of surfaces later treated with the same blasting material particles was significantly different from the first tests with fresh blasting material particles. The coverage of web marks and welding seams was significantly reduced.
Example 2
[0103] Mixtures of the angular and spherical blasting agent particles in the range of 30% spherical material and 70% angular material and 30% angular and 70% spherical blasting material particles gave a significantly more decorative surface finish, and both the web marks and the welding seams were covered to the greatest possible extent. In addition, the surface finish was reproducible in a plurality of repeat tests.
Example 3
[0104] In the case of the profile sections subjected to a polishing treatment instead of deoxidization, the surfaces treated with the mixture of spherical and angular blasting material showed an attractive, glossy, satin-like finish.
Example 4
[0105] The tests were repeated in a so-called centrifugal wheel system with some different blasting material particle mixtures. The same surface finish as had been achieved in the manual cabinet with compressed air was found, even when the pressure was varied.
Example 5
[0106] Angular new grain particles, for example of the mark Grittal® obtainable from Vulkan Inox GmbH, having a grain diameter D 90 in the range of from 0.1 mm to 0.2 mm and an average hardness of 750 HV were used as blasting material. As spherical new grain particles, particles having a grain diameter D 90 in the range of from 0.1 mm to 0.2 mm and an average hardness of 450 HV were used as the blasting material. Spherical new grain particles having an average hardness of 450 HV can be obtained, for example, using particles of the mark Chronital® obtainable from Vulkan Inox GmbH, by pre-rounding or compacting the spherical grains beforehand in a machine so that the spherical test material has a hardness of 450 HV. The angular and spherical new grain particles were mixed as indicated in Table 2.
[0107] The blasting material mixture in question, see Table 2, was delivered in a blast cabinet of type Normfinish, manufacturer Leering Hengelo BV, of series DP 14, with continuous blasting material cleaning for the treatment of an extruded standard aluminium window frame profile, for example ALMG SI 0.5, under the following conditions:
[0108] The results are shown in Table 2.
[0000] Sieve fraction D 90 : <0.2 mm and >0.1 mm
Nozzle diameter: 10 mm/
Blasting pressure: 2 bar
Distance nozzle to blasting material: 300 mm
Blasting angle: 80°
Amount of Blasting Material
[0109] delivered: 7.2 kg/min.=432 kg/h
Blasting speed 1 m/min
[0000]
TABLE 2
Blasting
Blasting
material in
material in
each case
each case
sieve
sieve
fraction D 90
fraction D 90
Finish assessment
<0.2 mm
<0.2 mm
of extruded standard aluminium window
and >0.1 mm
and >0.1 mm
frame profiles
Test
angular
spherical
ALMG SI 0.5
Evaluation
1
0
100
Some pressing marks not covered;
− −
welding seams more glossy than the finish
of the aluminium surface;
web marks visible;
2
20
80
Some pressing marks not covered;
−/+
welding seams and web marks almost no
longer visible;
3
30
70
Pressing marks largely covered;
+
welding seams and web marks no longer
visible;
4
40
60
Pressing marks completely covered;
++
welding seams and web marks not visible;
very uniform finish; smooth aluminium
surface; virtually E6 finish;
5
50
50
Pressing marks completely covered;
+++
welding seams and web marks not visible;
E6 finish;
6
60
40
Pressing marks completely covered;
++
welding seams and web marks not visible;
very uniform finish similar to point 4;
smooth aluminium surface; virtually E6
finish;
7
70
30
Pressing marks completely covered;
+
welding seams and web marks not visible;
finish is more matt compared to point 4
and 6;
8
80
20
Pressing marks, welding seams and web
−/+
marks not visible, but matt and rough
surface; when viewed obliquely there is a
whitish finish;
9
100
0
Pressing marks, welding seams and web
− −
marks not visible, surface is more matt
and more rough than in point 8; when
viewed obliquely there is a whitish finish
Evaluation:
+++ = very good corresponds to E6 finish
++ = good corresponds almost to E6 finish
+ = satisfactory, better than E5 finish
−/+ = slightly better than E5 finish
− = acceptable, E5 finish and poorer
− − = unsatisfactory
[0110] Although the present invention has been disclosed in the form of preferred embodiments and variations thereon, it will be understood that numerous additional modifications and variations could be made thereto without departing from the scope of the invention.
[0111] For the sake of clarity, it is to be understood that the use of “a” or “an” throughout this application does not exclude a plurality, and “comprising” does not exclude other steps or elements. The mention of a “unit” or a “module” does not preclude the use of more than one unit or module. | A method and a blasting material for producing a satinized surface on an aluminium substrate is provided. There is proposed a method for producing a satinized surface on an aluminium substrate, including the steps of: providing an aluminium substrate and treating by blasting with a blasting material the surface regions of the aluminium substrate provided that are to be satinized; wherein there is used as the blasting material a mixture of angular and spherical particles having a grain diameter D 90 of 0.3 mm. | 2 |
FIELD OF INVENTION
The present invention relates to the handling of parts and notably of cylindrical tubular parts. In practice, the object of the handling operation can be the removal of said parts from containers in order to feed metal working machines, and the loading of said cylindrical or tubular parts in containers with a view to their storage, their transportation to another machining stage, or their conditioning for being dispatched.
In the usual technique, the parts are loaded most often in bulk in a container, and when it is necessary to place them generating line against generating line in the feeding chute of a machine, they are poured onto an inclined feeding plate which in subjected to vibrations in order to distribute them in a single layer, with the parts being placed parallel to each other. In this type of apparatus, the parts are subjected to impacts, hence the risk of marks imprinted on them when they are metallic parts, or even of breakages when the parts are made of a fragile material.
Attempts have also been made to handle them with robots, the robot providing a positioning of the part perferably defined during loading as well as unloading. The robot solution is much more costly than that previously known, which consisted in feeding and discharge chutes in which the cylindrical or tubular parts can roll; and the handling part by part by means of a robot is a relatively slow operation.
OBJECTS AND SUMMARY OF INVENTION
The loading in a container and unloading from said container cylindrical or tubular parts is characterized in that a container is provided, a vertical wall of which is removable, in that said container is placed in front of and adjacent a table the width of which at the end is slightly less than the inner width of the side of the container removable wall, on which table are fed or have to be placed the cylindrical parts, which bear against each other side by side on their generating lines, with the face of the container the removable wall of which has been removed facing said table, the length of the container perpendicularly to said removable wall corresponding substantially to a multiple of the length of a cylindrical part, the height of the container being such as to bring slightly above the level of the table plane the lower level of the upper layer or upper bed of cylindrical parts to be discharged, or slightly below said level, which is the upper level of the upper bed of the cylindrical parts already loaded in the container, the parts of a bed which are in the container bearing against the side faces of said container, or the parts of a layer which is on the table. The table has substantially the width of a bed of parts in the container, the table bearing via the parts at the ends of the layer against abutment elements coacting with said table, said table is being advanced in the container for bringing its end adjacent the end of the bed of parts which has to be unloaded, or adjacent the end of the bed of parts already loaded and on which has to be loaded a bed of parts which is on the table and transports in a single block the cylindrical parts forming a bed from the table in order to lay them on the upper surface of the bed of parts which is in the container, or from the upper bed of the parts which is in the container for depositing them on the table, by a displacement in the direction of the parts length.
For the unloading operation, the table is displaced at the beginning of the unloading cycle of a bed in the direction of the container and introduced in said container substantially until a contact is established with the nearest vertical face of the stack of beds of parts, then, once the bed of parts has been brought by traction on the table, said table is moved rearwardly up to the unloading station situated outside the container where the parts are discharged from the table by rolling transversely to the direction of the table displacement.
For the loading operation, the table on which the parts are fed by having them roll transversely so as to form a bed is displaced in the direction of the container and introduced into said container in order to come slightly above the location where the parts have to be deposited and the table is progressively moved rearwardly while the parts are pushed or maintained in place for providing the relative displacement of the parts relative to said table.
An object of the present invention is also an installation for practicing the hereabove method, said installation comprising a frame, a table mobile horizontally according to one direction of said frame, means for displacing in a controlled manner said table along said direction so that its free end protrudes with respect to the frame free end, at least one container formed of at least one bottom and three fixed vertical side walls, the face without a vertical wall having a width slightly greater than the width of the table free end. An elevator means placed opposite the frame in the direction of mobility of the table is adapted to move vertically in a controlled manner a container with its face without side wall in register with the table so that the end of said table can be introduced in said container, and means for displacing parts substantially horizontally between the inside of said container and the end surface of the table.
According to another feature, the end of the table on which are deposited the parts, during their unloading or with a view to their loading, is formed of a shelf articulated to the table about one of its side edges, said shelf coming when the table is in a retracted position into register with the feeding chute or the discharge chute of known types joining the device to the machine serviced, and vice versa. Means are provided which allow varying the inclination of said shelf between the horizontal position and a predetermined inclined position.
According to another feature and for loading the container, the frame carrying the table is formed with an opening on its side edge which comes into resiger with the discharge chute of known type, which joins the machine serviced to the device, said opening being at the level of the shelf edge which is opposite the articulation in the upward position of the shelf and liftable dogs are provided at the end of said discharge chute and in register with said opening for retaining the parts on said chute when the table opening is not in alignment with the chute outlet.
According to other feature and when the parts to be handled are of a magnetic material, the means for displacing substantially horizontally the parts between the inside of said container and the table end surface is preferably an electromagnet occupying the whole width of the table and mobile to the front and to the rear with respect to said table. The electromagnet has indeed the advantage to possess a planar active surface which can be engaged against the upper portion of the frontal faces of the parts, independently of their length and section, and the power of the electromagnet can be easily modified as a function of the weight of the parts for avoiding entraining adjacent parts other than those of the handled bed. During operation, the electromagnet which retains the parts by a magnetic attraction also moves them from the container onto the table and from the table onto the upper bed of the forwardmost part stack.
When fragile tubular parts or parts made of a nonmagnetic material are involved, the electromagnet can be replaced by a comb the tines of which come into engagement within the bores of the tubular parts or in the channels remaining in the stacks between the cylindrical parts. This picking device allows lifting and depositing the parts, but the comb has to be adapted at least to the section of the parts to be handled and has to possibly include a positioning corrector when the side position of the bed in the container varies beyond a certain tolerance.
According to another feature and when the unloading of the parts is involved, the table front edge carriers a detection crosspiece for the frontal face of the stack of parts forming the bed situated below the bed of parts to be unloaded, said detection crosspiece controlling by the depth of its position the stoppage of a motor device which controls the advance of the table and its reverse motion over a small distance.
According to another feature and when a loading of the parts is involved, the table front edge includes a sensor of the surface of the upper layer of parts on which the parts have to be deposited, such a sensor controlling the upward motion of the elevator carrying the container.
According to another feature, the container removable wall is engaged, by its side ends, into two vertical slots facing each other and formed in the two side walls of the container perpendicular to the removable wall, a plurality of slots being provided in each of said side walls. This arrangement allows setting the position of the removable side wall after having loaded a container as a function of the length of the parts and of the number of piles of parts placed end to end.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be described hereinafter in more detail with reference to the accompanying drawings wherein:
FIG. 1 is a longitudinal sectional view of the installation according to the invention,
FIG. 2 is a schematic plan view thereof,
FIG. 3 is a sectional view on a larger scale and along line III--III of FIG. 2,
FIG. 4 is detailed sectional view of the front portion of the table and gripping arm,
FIG. 5 is a view similar to FIG. 4 of another embodiment,
FIG. 6 is a side elevation view of an installation according to another embodiment,
FIG. 7 is a transverse sectional view along line VII--VII of FIG. 6, and
FIG. 8 is a perspective view of a container for practicing the invention.
DETAILED DESCRIPTION OF THE INVENTION
The machine which is part of the installation of FIGS. 1 through 3 includes a frame 1 of rectangular shape, on the two sides of which are fixed two horizontal and parallel slides 2. In said slides 2 slide the edges of a table 3. On the front portion of said table 3 bears a shelf 4 which is articulated about a hinge 5. The frame side wall 6 and the slide upper wing 2' which are on the side of hinge 5 are interrupted over a length 7 corresponding to the width of plate 4 so that the upper edge 7 of said wall 6 will be at the level of the shelf side wall. On the other side, only the upper portion of wall 6 is suppressed over the same length in order to form an upper edge 8 of side wall 6 which is slightly above the level of table 3.
The sliding of table 3 on slides 2 is controlled by a jack 9 the end of the U-shaped stem 10 of the piston of which is rigidly connected to the table rear edge. A jack 11 carried by the frame is placed in such manner as to be, in the retracted position of table 3, below an opening 12 formed in table 3 on the opposite side with respect to hinge 5. Consequently, the stem of said jack 11 can lift shelf 4 in order to discharge, above the edge 7 adjacent which is a discharge channel 44, the cylindrical parts which have been brought onto the shelf or for bringing the edge of the shelf opposite hinge 5 to the same level as edge 8 which can form the end of a feed chute 45. In the latter case, the parts move downwardly along shelf 4 which is inclined for forming a bed on said shelf, the bed bearing via its first part against dogs 46 extending above edge 7. Said dogs 46 are for example L-shaped levers articulated at 47 to the frame and the other arm of which engages a cam 48, the dogs being retracted through the action of springs 49 when said dogs 46 are opposite a scallop of cam 48 corresponding to the alignment of shelf 4 with edge 7. When jack 11 moves shelf 4 downwardly, it closes simultaneously a door 50 above edge 8 for stopping the cylindrical parts which move downwardly in the feed chute 45. Door 50 is connected by a rod assembly 51 which could also be a transmission of another type to the stem of jack 11.
Facing the front end of the frame is mounted a horizontal elevating plate 13 the vertical displacements of which are controlled by a jack 14 or any other known motive device. On elevator plate 13 can be mounted, while being perfectly centered by dogs 15, containers 16 adapted for receiving parts p, which are preferably cylindrical and tubular, which are disposed in layers l, the layers forming stacks e. In FIG. 1 is shown a container comprising two piles of eight layers. Wall 17 of the container is removable so that the frontal faces of the parts forming the stacks which are against said wall are exposed. Said wall 17 can be formed for example of two opening half-doors articulated along their vertical edges to the vertical edges of the side faces of the container and swingable on said side faces. Said wall 17 can be formed, in containers used for parts of variable lengths, by a double wall the thickness of which is settable so that wall 17 forms, after being put in position, a bearing surface for the front face of the frontal stack. Preferably however, the container is made as described hereafter with reference to FIG. 8.
In the case of an installation used for discharging articles, a sensor 18 mounted at the end of the stem of jack 19 can be moved above the elevator plate 13 for detecting the position of the upper layer of parts and controlling jack 14 so that the upper layer l of the frontal stack e is at the required level with respect to the table level. When the machine involved is a machine used for loading articles, an equivalent sensor is mounted underneath the table front edge for controlling jack 14 so that the table be, prior to the beginning of the loading process, at a small height above the upper layer of parts on which a new layer of parts is going to be placed.
The installation includes moreover a handling arm 20 adapted for being displaced along the displacement direction of table 3 via a jack 21 or other equivalent motive device.
As shown in FIG. 2, the end of table 3 which is below shelf 4 extends, when driven by jack 9, between the two side walls of container 16. In the front face of said table is slidably mounted a comb 24 with a number of fingers 22 sliding in longitudinal bores 23 of the table. Said comb is biased toward the outward position by springs 26 and its stroke is limited by a dog 27 carried by a finger 22 which moves in a recess 28. In its rearmost position, dog 27 closes the microcontact of a circuit 29 controlling the stoppage of the feeding of jack 9 and a slight motion rearwardly of the table. During the advance of the table, comb 24 comes into abutment against the end face of layer l 2 of the frontmost stack of parts in container 16. Said layer is, as explained above, at the level set by sensor 18 controlling jack 14 and is the second layer in the case where layer l 1 (FIG. 4) has to be loaded. when a new layer has to be loaded, comb 24 comes to bear against layer l 1 already loaded in a pile which is nearer the bottom wall than the new pile in formation, or against said bottom wall, the table being above the layer on which has to be loaded said new layer.
The parts gripping and handling member is, for example for an unloading of parts, made of a crosspiece 30 mounted at the end of the stem of jack 21. Frontwardly of said crosspiece 30 is mounted a flat electromagnetic spool 31 which is articulated at its lower portion 32 at the end of fingers 33 sliding in longitudinal bores of crosspiece 30 and maintained resiliently at its upper portion by springs 34. Fingers 33 are urged by springs 35 and their stroke is limited by dogs 36 moving in a recess 37. At the end of the rearward stroke, one of dogs 36 closes the microcontact of a circuit 38.
When spool 31 is pushed back rearwardly due to its coming into abutment against the frontal face of layer l 1 , when being advanced by jack 21, dog 36 establishes a contact in circuit 38. Spool 31 is then energized and attracts the parts forming layer l 1 . The feeding of jack 21 is simultaneously cut. Jack 14 is then released so that container 16 moves downwardly along a settable distance, the parts of layer l 1 being thus lifted above parts of layer l 2 . Jack 21 then moves back rearwardly and brings the layer of parts above shelf 4. At the moment when the parts are above shelf 4, such as position being detected by any known means, the feeding of spool 31 is reduced and then cut. Due to the weight of the parts fixed on the front face of spool 31, the latter tilts about axis 32, the motion being damped by springs 34, until the parts come to bear by one end on shelf 4, then their other end slides on the spool front face until the bed is supported on shelf 4. The feeding of the spool is then completely cut and jack 21 moves the gripping arm rearwardly. Then, jack 9 brings rearwardly table 3 and shelf 4 which carries the layer of parts l 1 . When jack 11 is below opening 12, it extends, which tilts shelf 4 by rotating about hinge 5 and the parts p forming layer l 1 are discharged by passing above the edge 7 of the side wall 6 of frame 1. When the last tube is discharged from shelf 4, a sensor controls the release of jack 11 and shelf 4 moves back downwardly and comes to bear on table 3.
The hereabove described parts gripping and handling device can also be used for loading parts in the container, but it can be simplified since its only function is to maintain the parts in position during the backward motion of the table in order that said parts fall by tilting on the lower layer of parts.
In the embodiment of FIG. 5, spool 31 is replaced by a second crosspiece 40 which can slide vertically inside slides of a block forming a gripping head 41 under the action of microjacks 42 having vertical axis. In crosspiece 40 are mounted, with a spacing corresponding to the spacing of the tubes p in the layer, tines 43 forming a horizontal comb. The gripping block 41 is mounted on crosspiece 30 in the same manner as the electromagnetic spool 31. When jack 21 moves forward the gripping head 20 thus formed with crosspiece 40 up to the mid-height, the tines 43 engage one inside each tube. When the coming into abutment of crosspiece 40 on the end face of the tubes of layer l 1 closes contact 38, the feeding of jack 21 is stopped and microjacks 42 are fed in order to lift crosspiece 40 which entrains with it the tubes of upper layer l 1 . Jack 21 is then reversed for bringing the tubes hanging on tines 43 above shelf 5. The feeding of microjacks 42 is reversed, which places the tubes on said shelf and jack 21 is then retracted to the maximum and leaves layer l 1 on shelf 4, after which the operation goes on as hereabove described with reference to FIG. 4.
Instead of penetrating the tubes of layer l 1 , tines 43, with adequate width and section, could penetrate the voids between the peripheral surfaces of stacked cylindrical parts.
When elevator plate 13 is in the completely raised position, the return of jack 9 controls the return of jack 14 to its starting position, the stopping of the cycle and the energizing of an acoustic or luminous warning device.
In the hereabove description, the motive members providing the various displacements have been shown and described as hydraulic jacks, but they could be replaced by screw jacks controlled by electrical motors, by racks associated with the output pinions of electrical motors, or by chain or cable elevators.
Such a variant is shown in FIGS. 6 and 7 in which the same reference numerals with index a designate the same parts or equivalent parts. Reference 1a designates the frame, reference 2a the slides which are made of threaded shafts the rotation of which under the action of an electrical motor 9a moves table 3a frontwardly or rearwardly with respect to the frame. Reference 4a designates the shelf articulated at 5a about an axis situated on one of the sides of the table. Reference 6a designates the lateral sides of the frame and reference 11a the pneumatic jack which tilts shelf 4a by a rotation about axis 5a, the head of the stem of said jack extending through an opening 12a formed in table 3a, an opening which is in register with the jack head in the fully retracted position of table 3a. In this position, shelf 4a is in alignment with a chute 45a down which roll the cylindrical parts to be loaded on shelf 4a, or with a chute 44a through which are discharged the cylindrical parts which have been brought onto shelf 4a.
Opposite the front end of the frame is mounted a horizontal elevator plate 13a the vertical displacements of which are controlled by an electrical motor 14a. On the elevator plate 13a can be mounted, by being centered by fittings 15a, a container 16a. The parts gripping and handling member is made of a crosspiece 30a the displacements of which with respect to table 3a are controlled by an electrical motor 21a, references 46a and 50a designate dogs, shown schematically by arrows, which are lifted or moved downwardly, as dogs 46 or door 50, by pneumatic jacks for respectively stopping the parts which roll down onto shelf 4a or in chute 45a.
In the side wall 55a and the bottom of container 16a are provided grooves 56a, 56b in which fit the edges of the removable wall 17, as will be described in more detail hereafter with reference to FIG. 8.
In FIG. 8 is shown a preferential embodiment of the container which allows setting in a simple manner the position of the removable wall 17 as a function of the length of the parts and of the number of piles set in place in the container.
Container 52 comprises a base 53 which allows the stacking, with fixed to said base ring bows forming a loop 54 provided for catching the hooks of elevating means and aligning the containers during stacking. The side walls 55 are formed with vertical grooves 56 in which can engage the side walls of the plate forming the removable wall 17. A plate 57 which occupies only a portion of the length of the container is welded as a bridge on the upper edges of the side walls 52 and bottom 58 for increasing the container rigidity. | An installation for handling parts between a container in which they are placed in layers and piles and a table which cooperates with a chute joining the installation to a service machine. The installation comprises a table mobile horizontally relative to the frame, structure for displacing in a controlled manner the table so that its free end protrudes with respect to the frame free end, and at least one container formed of at least one bottom and three fixed vertical side walls. The face of the container without a vertical wall has a width slightly greater than the width of the table free end. An elevator is placed opposite the frame in the direction of mobility of the table and is adapted to move vertically in a controlled manner. A container with its face without a vertical wall is in register with the table so that the end of said table can be introduced in the container. Structure is provided for displacing parts substantially horizontally between the inside of the container and the end surfrace of the table. | 1 |
PRIORITY STATEMENT
[0001] This application is the national phase under 35 U.S.C. §371 of PCT International Application No. PCT/CN2013/088240 which has an International filing date of Nov. 29, 2013, which designated the United States of America, the entire contents of which are hereby incorporated herein by reference.
TECHNICAL FIELD
[0002] An embodiment of the present invention generally relates to a method for detecting sensors, and in particular to a method for detecting the measurement accuracies of the angle sensors used for measuring the rotation angle of guide vanes and the pressure sensor used for measuring the thrust of the push rod in a gas turbine.
BACKGROUND ART
[0003] In order for a compressor to adapt to different operation statuses of a gas turbine, guide vanes need to be set in the compressor. The flowage of air in the compressor is changed by changing the angle of attack of the guide vanes.
[0004] FIG. 1 shows the structure of the guide vane driving mechanism in a prior art gas turbine, where only a part of the guide vanes ( 80 ) are depicted for an example purpose. As shown in FIG. 1 , the guide vane driving mechanism comprises a driving ring ( 81 ), a push rod ( 82 ), a plurality of connecting rods ( 83 ) corresponding to guide vanes ( 80 ), and a plurality of adjusting rods ( 84 ) corresponding to guide vanes ( 80 ). The push rod ( 82 ) is connected to the driving ring ( 81 ) and the push rod ( 82 ) can push the driving ring ( 81 ) to rotate relative to a cylinder ( 85 ).
[0005] One end of a connecting rod ( 83 ) is connected to a guide vane ( 80 ) and the other end is connected to one end of an adjusting rod ( 84 ). The other end of an adjusting rod ( 84 ) is connected to the driving ring ( 81 ). When the driving ring ( 81 ) rotates relative to the cylinder ( 85 ), it drives the adjusting rods ( 84 ) and the connecting rods ( 83 ) to move so that the guide vanes ( 80 ) rotate to change their rotation angles. In addition, the guide vane driving mechanism is equipped with a plurality of elastic bases ( 86 ) and the driving ring ( 81 ) is connected to the cylinder ( 85 ) through these elastic bases ( 86 ).
[0006] When the push rod ( 82 ) exerts a thrust on the driving ring ( 81 ), on the one hand, the driving ring ( 81 ) will rotate relative to the cylinder ( 85 ), and on the other hand, the center of the circle of the driving ring ( 81 ) deviates from the center of the circular cross section of the cylinder ( 85 ). For the guide vanes ( 80 ) which are driven by the driving ring ( 81 ) to rotate, the rotation angle of the guide vanes ( 80 ) corresponding to the connection between the push rod ( 82 ) and the driving ring ( 81 ) on the driving ring ( 81 ) is maximum, and the rotation angle of the guide vanes ( 80 ) far away from the connection between the push rod ( 82 ) and the driving ring ( 81 ) on the driving ring ( 81 ) is minimum.
[0007] To measure the thrust of the push rod, it is necessary to install a pressure sensor ( 88 ). Two angle sensors ( 87 ) (only one is given for an example purpose in FIG. 1 ) are provided for the gas turbine and are each connected to one guide vane to measure the rotation angles of the connected guide vanes in real time. The mean rotation angle and the difference between the maximum rotation angle and the minimum rotation angle, namely, the maximum rotation angle offset, of all guide vanes are calculated from the rotation angles measured by the two angle sensors.
[0008] To keep the calculated vales of the mean rotation angle and the maximum rotation angle offset close to the actual values, the included angle between the connection line from the installation position of one angle sensor to the center of the circular cross section of the cylinder and the connection line from the connection point between the push rod and the driving ring to the center of the circular cross section of the cylinder should be 0°, and the included angle between the connection line from the installation position of the other angle sensor to the center of the circular cross section of the cylinder and the connection line from the connection point between the push rod and the driving ring to the center of the circular cross section of the cylinder should be 180°.
[0009] That is to say, one angle sensor can measure the maximum rotation angle of the guide vanes, and the other angle sensor can measure the minimum rotation angle of the guide vanes. The difference between the guide vane rotation angles measured by the angle sensors in these two positions is the maximum rotation angle offset, and the mean guide vane rotation angle measured in these two positions is the mean rotation angle of all guide vanes.
[0010] A zero shift will happen to the angle sensors and the pressure sensor during use and thus their measurement accuracies will be affected.
SUMMARY
[0011] An embodiment provides a method for detecting sensors in a gas turbine so as to detect the measurement accuracies of the angle sensors and the pressure sensor.
[0012] An embodiment of the present invention is directed to a method for detecting sensors in a gas turbine, wherein the gas turbine comprises a cylinder, a plurality of guide vanes, a first angle sensor with an installation angle of 0°, a second angle sensor with an installation angle of 180°, and a guide vane driving mechanism which can drive the guide vanes to rotate. The guide vane driving mechanism comprises a driving ring, a push rod which can push the driving ring to rotate relative to the cylinder, a plurality of connecting rods and adjusting rods connecting the guide vanes and the driving ring, and a plurality of elastic support bases connecting the cylinder and the driving ring.
[0013] The method for detecting angle sensors includes: measuring the thrust of the push rod; measuring the first rotation angle of the guide vanes in the installation position of the first angle sensor; measuring the second rotation angle of the guide vanes in the installation position of the second angle sensor; obtaining a measured maximum rotation angle offset according to the absolute value of the difference between the first rotation angle and the second rotation angle; obtaining a calculated maximum rotation angle offset according to the thrust of the push rod, that is, maxΔα=F×K, where F is the thrust of the push rod and K is a geometric constant related to geometric parameters of the guide vane driving mechanism; calculating the absolute value of the difference between the measured maximum rotation angle offset and the calculated maximum rotation angle offset, if the absolute value is less than or equal to a standard value, determining that the angle sensors and the pressure sensor have a suitable sensing accuracy, and if the absolute value is greater than the standard value, determining that the angle sensors and/or the pressure sensor need/needs to be calibrated.
[0014] In another example embodiment of the method for detecting sensors in a gas turbine, the calculation formula of the geometric constant is
[0000]
K
=
R
a
+
R
t
R
a
×
l
×
K
G
,
[0000] where l is the length of the connecting rod of a guide vane, R t is the distance from the connection between an adjusting rod and the driving ring to the center of the circular cross section of the cylinder, R a is the distance from the connection between the pushing rod and the driving ring to the center of the circular cross section of the cylinder, and K G is the overall elasticity coefficient of the elastic support bases.
[0015] In a third example embodiment of the method for detecting sensors in a gas turbine, the standard value is 0.5°.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] The following drawings are used to give an example description and explanation of the present invention, but do not limit the scope of the present invention.
[0017] FIG. 1 shows the structure of a prior art compressor.
[0018] FIG. 2 shows the exploded structure of the guide vane driving mechanism in a gas turbine.
[0019] FIG. 3 shows the structure of the guide vane driving mechanism in FIG. 2 after assembly.
[0020] FIG. 4 shows the enlarged structure of Part IV in FIG. 2 .
[0021] FIG. 5 is used to describe the overall elasticity coefficient of the elastic support bases.
[0022] FIG. 6 is used to describe the flowchart of the method for detecting sensors in a gas turbine.
DETAILED DESCRIPTION OF THE INVENTION
[0023] To help to understand the technical characteristics, objective, and effect of the present invention more clearly, the following describes an embodiment of the present invention with reference to the drawings in which the same reference number represents the same component.
[0024] In this document, “example” means “acting as an instance, example, or illustration”, and any illustration or embodiment described in this document should not be interpreted as a more preferred or advantageous technical solution.
[0025] For the simplicity of the drawings, only the parts related to the present invention are shown for an example purpose and they do not represent the actual structure of a product. In addition, only one of the components which have the same structure or function is depicted or marked for an example purpose in some drawings so that the drawings are simplified to help you to understand.
[0026] In this document, “one” not only represents “only one”, but also may represent “more than one”. In this document, “first” and “second” are used only to distinguish components from each other, but do not represent their importance or sequence. In this document, the value of an angle is not a limitation in a strict mathematic and/or geometric sense, but also includes an error which those skilled in the art can understand and is allowable for a measurement or a calculation.
[0027] FIG. 2 shows the exploded structure of the guide vane driving mechanism in a gas turbine. FIG. 3 shows the structure of the guide vane driving mechanism in FIG. 2 after assembly. To clearly show the structure of the guide vane driving mechanism, FIG. 2 and FIG. 3 depict only a part of the guide vanes for an example purpose. See FIG. 2 and FIG. 3 . The guide vane driving mechanism comprises a push rod ( 10 ), a driving ring ( 20 ), a cylinder ( 30 ), and eight elastic support bases ( 40 ), six adjusting rods ( 50 ), and six connecting rods ( 60 ).
[0028] The pushing rod ( 10 ) is connected to the driving ring ( 20 ). The thrust (F) exerted by the push rod ( 10 ) can push the driving ring ( 20 ) to rotate relative to the cylinder ( 30 ). The driving ring ( 20 ) has a center of circle ◯ s and the cylinder ( 30 ) has a center of circular cross section ◯ H , namely, a center of the circular cross section vertical to the central axis of the cylinder ( 30 ) around the cylinder ( 30 ). When the push rod does not exert a thrust (F) on the driving ring ( 20 ), the center of circle ◯ s overlaps the center of circle ◯ H ; when the push rod exerts a thrust (F) on the driving ring ( 20 ), the center of circle ◯ s deviates from the center of the circular cross section ◯ H (see FIG. 5 ).
[0029] Eight elastic support bases ( 40 ) are set between the cylinder ( 30 ) and the driving ring ( 20 ). The elastic support bases ( 40 ) can provide elastic support for the driving ring ( 20 ). The elastic support provided by the elastic support bases ( 40 ) can reduce the stress level caused by thermal expansion of the cylinder ( 30 ), and when the center of circle ◯ s deviates from the center of the circular cross section ◯ H , the elastic support bases ( 40 ) can always touch against the driving ring ( 20 ). Each elastic support base ( 40 ) has a distribution angle θ and the distribution angle is an included angle between the connection line from the elastic support base ( 40 ) to the center of the circular cross section ◯ H and the horizontal line passing through the center of the circular cross section ◯ H .
[0030] FIG. 4 shows the enlarged structure of Part IV in FIG. 2 . As shown in FIG. 2 , FIG. 3 , and FIG. 4 , one end of an adjusting rod ( 50 ) is connected to the driving ring ( 20 ), and the other end of the adjusting rod ( 50 ) is connected to one end of a connecting rod ( 60 ). The other end, which is not connected to the adjusting rod ( 50 ), of the connecting rod ( 60 ) is connected to the journal ( 72 ) of a guide vane ( 70 ). When the driving ring ( 20 ) rotates relative to the cylinder ( 30 ), through the adjusting rods ( 50 ) and the connecting rods ( 60 ), the driving ring ( 20 ) drives guide vanes ( 70 ) to rotate to change their rotation angles a. The length of a connection rod ( 60 ) is l. The distance from the connection between the push rod ( 10 ) and the driving ring ( 20 ) to the center of the circular cross section ◯ H is R a . The distance from the connection between an adjusting rod ( 50 ) and the driving ring ( 20 ) to the center of the circular cross section ◯ H is R t .
[0031] To distinguish between the two angle sensors ( 74 ) (only one is shown in FIG. 2 ), the two angle sensors are named the first angle sensor and the second angle sensor, respectively. The two angle sensors are respectively connected to the journal of a guide vane. The included angle between the connection line from the guide vane in the installation position of an angle sensor to the center of the circular cross section ◯ H and the connection line from the connection between the push rod ( 10 ) and the driving ring ( 20 ) to the center of the circular cross section ◯ H is called installation angle for short below. For the first angle sensor, the installation angle is 0° and the measured rotation angle of a guide vane is the first rotation angle α 1 ; for the second angle sensor, the installation angle is 180° and the measured rotation angle of a guide vane is the second rotation angle α 2 .
[0032] Through the first rotation angle α 1 and the second rotation angle α 2 , the mean rotation angle α mean of all the guide vanes, and the difference between the maximum rotation angle and the minimum rotation angle among all the guide vanes, namely, the maximum rotation angle offset maxΔα, can be reflected. The first rotation angle α 1 is the maximum rotation angle of all the guide vanes and the second rotation angle α 2 is the minimum rotation angle of all the guide vanes. In this case, the maximum rotation angle offset is the difference between the first rotation angle α 1 and the second rotation angle α 2 , and the mean rotation angle is the mean value of the first rotation angle α 1 and the second rotation angle α 2 . The thrust (F) of the push rod is measured by the sensor ( 12 ) set on the push rod.
[0033] FIG. 5 is used to describe the overall elasticity coefficient of the elastic support bases and the imaginary circle represents the displaced driving ring. See FIG. 5 . The elastic support bases ( 40 ) set between the cylinder ( 30 ) and the driving ring ( 20 ) can respectively provide elastic support for the driving ring ( 20 ). The included angle between the direction of the elastic force exerted by an elastic support base ( 40 ) on the driving ring ( 20 ) and the horizontal line (in the X direction in FIG. 4 ) passing through the center of the circular cross section ◯ H is the distribution angle θ of the elastic support base ( 40 ) and the elasticity coefficient of each elastic support base ( 40 ) is K s . When the push rod ( 10 ) exerts a thrust (F) on the driving ring ( 20 ), the elastic force exerted by each elastic support base ( 40 ) on the driving ring ( 20 ) can balance the thrust (F), that is to say, the resultant force of the component forces of all the elastic support bases ( 40 ) in the Y direction in FIG. 4 is equal to the thrust (F). The sum of the components of the elasticity coefficient K s of all the elastic support bases ( 40 ) in the Y direction is defined as K G , namely, the overall elasticity coefficient of elastic support bases 40 , and
[0000]
K
G
=
K
s
∑
l
K
sin
2
(
θ
i
)
,
[0000] where i represents a different elastic support base. Hence, the thrust (F) exerted by the push rod ( 10 ) is equal to K G d, where d is the displacement of the driving ring ( 20 ) in the Y-axis direction.
[0034] FIG. 6 is used to describe the flowchart of the method for detecting sensors in a gas turbine. As shown in FIG. 6 , the method for detecting sensors in a gas turbine starts from Step S 10 . In Step S 10 , obtain two different guide vane rotation angles from the measurements of the first angle sensor and the second angle sensor. Obtain the first rotation angle α 1 from the measurement of the first angle sensor and the second rotation angle α 1 from the measurement of the second angle sensor. Obtain the thrust (F) of the push rod from the measurement. After completing the measurements of the first rotation angle α 1 , the second rotation angle α 2 , and the thrust (F) of the push rod in Step S 10 , go to Step S 20 .
[0035] In Step S 20 , obtain the measured maximum rotation angle offset according to the difference between the first rotation angle α 1 and the second rotation angle α 2 , namely, α 1 −α 2 . Obtain the calculated maximum rotation angle offset maxΔα according to the thrust F measured by the pressure sensor and the calculation formula maxΔα=F×K, where K2 is a constant related to the guide vane driving mechanism.
[0036] In an example embodiment of the method for detecting sensors in a gas turbine, the calculation formula of K is:
[0000]
K
=
R
a
+
R
t
R
a
×
l
×
K
G
,
[0000] where L is the length of a connecting rod, R t is the distance from the connection between an adjusting rod and a connecting rod to the center of the circular cross section ◯ H , R a is the distance from the connection between the push rod and the driving ring to the center of the circular cross section, and K G is the overall elasticity coefficient of the elastic support bases.
[0037] In Step S 30 , compare the measured maximum rotation angle offset α 1 −α 2 with the calculated maximum rotation angle offset maxΔα, if the absolute value of the difference between the measured maximum rotation angle offset α 1 −α 2 and the calculated maximum rotation angle offset maxΔα is greater than a standard value, go to Step S 40 ; if the absolute value of the difference between the measured maximum rotation angle offset α 1 −α 2 and the calculated maximum rotation angle offset maxΔα is less than or equal to a standard value, go to Step S 50 . In an example embodiment of the measurement method of the guide vane driving mechanism, the standard value is 0.5°.
[0038] In Step S 40 , determine that the sensing accuracy of the angle sensors and/or pressure sensor does not satisfy the requirement, further determine the conditions of the angle sensors and the pressure sensor, and calibrate the sensor(s) which has (have) a problem to complete the method for detecting sensors in the gas turbine.
[0039] In Step S 50 , determine that the sensing accuracy of the angle sensors and pressure sensor satisfies the requirement and complete the method for detecting sensors in the gas turbine.
[0040] It should be understood that although the Description gives a description by embodiment, it does not mean that each embodiment contains only one independent technical solution. The description method in the Description is only for the sake of clarity. Those skilled in the art should consider the Description as an integral body. The technical solutions in these embodiments can be combined properly to form other embodiments that those skilled in the art can understand.
[0041] The series of detailed descriptions above are only specific descriptions of feasible embodiments of the present invention and they are not intended to restrict the protection scope of the present invention. All equivalent embodiments or variants, for example, combination, division, or duplication of technical characteristics, without departure from the spirit of the present invention should fall within the protection scope of the present invention.
DESCRIPTION OF REFERENCE NUMBERS IN THE DRAWINGS
[0000]
10 : Push rod
12 : Pressure sensor
20 : Driving ring
30 : Cylinder
40 : Elastic support base
50 : Adjusting rod
60 : Connecting rod
70 : Guide vane
72 : Journal
74 : Angle sensor
80 : Guide vane
81 : Driving ring
82 : Push rod
83 : Connecting rod
84 : Adjusting rod
85 : Cylinder
86 : Elastic base
87 : Angle sensor
88 : Pressure sensor | A detection method of a sensor in a gas turbine includes adopting a pressure sensor to measure a pushing force of a push rod; measuring a first rotational angle of a guide vane where a first angle sensor is mounted; measuring a second rotational angle of the guide vane where a second angle sensor is mounted; obtaining a maximum measured rotational angle deviation from the absolute value of a difference value between the first and second rotational angles; calculating a maximum calculated deviation from the pushing force of the push rod; calculating the absolute value of a difference value between the maximum measured deviation and the maximum calculated deviation; and determining that the angle sensors and the pressure sensor have appropriate measurement accuracy; or, if the absolute value is greater than the standard value, determining that the angle and/or pressure sensors require calibration. | 5 |
This application claims the priority of provisional application Serial No. 60/078,155, filed Mar. 16, 1998. The invention relates generally to two-wheeled hand trucks, and more particularly to those adapted for transporting bottled water containers.
BACKGROUND OF THE INVENTION
Drinking water is commonly packaged and sold in large glass or plastic bottles having volume capacities of about five gallons. The containers are very bulky and heavy, weighing about 50 lbs. each.
Various two-wheeled hand trucks have been devised for carrying such bottled water containers. Co-pending U.S. patent application Ser. No. 08/812,935, which I incorporate herein by reference, discloses a two-wheeled hand truck having multiple, foldable bottle-carrying trays that are mounted to the side rails of the truck and extend forwardly over the nose plate in vertically spaced relation to one another for the accommodation of up to four such containers. When not in use, the trays are foldable flush with the rails so that the hand truck can be used in the usual manner to transport other types of cargo on the nose plate.
Other known hand truck constructions include single or multiple bottle-carrying racks carried off the frame that are either fixed or foldable, but not detachable from the frame of the truck.
SUMMARY OF THE INVENTION
One of the prime objects of the present invention is to provide a carrier for such bottled water containers that is mounted releasably to the frame of a two-wheeled hand truck to serve as the sole, or as an auxiliary, carrier for bottled water containers.
Another object of the invention is to construct the bottle carrier in such manner that it mounts on the frame of a two-wheeled hand truck without modification of the standard hand truck design. In particular, it is an object of the invention to construct such a carrier to include at least one, and preferably two, hangers that releasably engage the cross braces of the truck frame to support such a container outwardly of the frame.
It is a further object to construct a carrier that can be releasably selectively hung off either the front or back side of the frame. In an application employing a conventional hand truck, the carrier could be hung from the cross braces off the front side of the frame above the nose plate. In another application in which the carrier serves as an auxiliary support for an additional water bottle on a hand truck fitted with one or multiple bottle racks that project forwardly of the frame, such as in the case of the aforementioned hand truck with multiple, foldable bottle-carrying trays, the auxiliary carrier can be mounted detachably on the cross braces off the back of the hand truck frame to provide additional carrying capacity and counterbalance.
The mount hangers for the carrier uniquely cooperate with the vertically spaced cross braces in all instances to provide the results achieved.
THE DRAWINGS
A presently preferred embodiment of the invention is disclosed in the following description and in the accompanying drawings, wherein:
FIG. 1 is a perspective view of a detachably mountable water bottle carrier constructed according to the present invention;
FIG. 2 is a rear elevational view of the carrier of FIG. 1 mounted detachably on the frame of a hand truck;
FIG. 3 is a top view of the carrier of FIG. 2;
FIG. 4 is a side elevational view of the carrier of FIG. 2;
FIG. 5 is a side elevational view showing the carrier mounted detachably on a hand truck fitted with multiple, foldable bottle-accommodating trays;
FIG. 6 is a side elevational view of the carrier shown mounted detachably off the front of the frame of a conventional hand truck; and
FIG. 7 is a view like FIG. 5 but showing the carrier mounted off the back of the hand truck, and a load carried on the nose plate of the hand truck.
DETAILED DESCRIPTION
A detachable bottled water carrier 10 constructed according to the present invention for a two-wheeled hand truck 12 is shown in the drawing FIGS. 1-7 and includes a generally planar, and preferably rectangular back or base wall or frame 14 having an upper end 14 a and a lower end 14 b . A platform or bottom 16 projects outwardly from the lower end 14 b of the back wall 14 , preferably at a right angle thereto, presenting an upper surface 18 sized to typically receive and support a five-gallon bottled water container C in an upright orientation.
A retaining band 20 is secured to the back wall 14 above the platform 16 about midway between the upper and lower ends 14 a , 14 b of the back wall 14 . The band 20 encloses a space 22 that is no smaller across than the outer diameter of the bottled water container C, and preferably slightly larger than the diameter of the container C. The band 20 encircles the container C and supports the container C against tipping off the platform 16 . A typical 5-gallon water container has a nominal diameter of about 10⅜ inches, and thus the space 22 should have a minimum measurement across the space 22 of at least about 10⅜ inches, although a larger space could be provided so long as it provides the recurring support to the container C to retain the container C on the platform 16 . It will be understood that the space 22 is dependent on the size of the container C it is to support, and it may vary in size depending on the size of the container.
At least one, and preferably two, sets of load bearing vertically spaced hangers, parts, elements, or hooks, generally designated 24 , 26 , are provided on the opposite face of the back wall 14 for mounting the carrier 10 on the hand truck 12 , as will be described in greater detail below. The upper hangers 24 are preferably in the form of a pair of downwardly opening hooks 24 a , 24 b , mounted on the opposite upper corners of the back wall 14 and defining a generally rectangular, downwardly opening channel 28 near the upper end 14 a of the back wall 14 . The lower hangers 26 are preferably of the same construction and comprise a pair of downwardly opening hooks 26 a , 26 b fixed to the back wall 14 at the opposite lower corners thereof and presenting similar downwardly opening channels 29 that are spaced a predetermined distance from the upper channels 28 . The channels 28 , 30 facilitate the mounting of the carrier 10 on the cross braces of the hand truck frame, which will now be described.
The hand truck 12 is typically of the type generally disclosed in U.S. Pat. Nos. 3,997,182, 5,393,081, and co-pending application Ser. No. 08/812,935 now U.S. Pat. No. 5,913,527, all of which are commonly owned by the assignee of the present-invention, and their disclosures incorporated herein by reference.
The hand truck 12 includes a generally rectangular, load-carrying, primary or main frame 30 , preferably of the type having a pair of parallel vertical side rails 32 which are preferably channel-shaped extrusions that open laterally inwardly of the frame. A plurality of vertically spaced cross braces or rails 34 extend between the side rails 32 and are secured in position by means of suitable fasteners, such as bolts, rivets, weldments or the like such that the cross braces 34 and side rails 32 constitute a rigid, fixed framework for supporting the remaining components of the hand truck. Such a mainframe construction is generally uniform in design among numerous hand trucks on the market, and particularly those manufactured by the assignee of the present invention.
The hand trucks illustrated in FIGS. 5-7 are essentially of the same design except that the hand truck of FIG. 5 includes additional bottle-accommodating trays mounted to the frame 12 that are not included in the hand truck of FIGS. 6 and 7. For simplicity, the same reference numerals will be used to designate corresponding components in the two illustrated hand truck designs, as the hand truck of FIG. 5 is essentially a modification of the basic hand truck of FIGS. 6 and 7.
The hand trucks 12 of FIGS. 5-7 include a pair of laterally spaced wheels 36 mounted on opposite ends of an axle 38 which in turn is secured to the lower end of the frame 30 . A bale-shaped handle member 40 or other handle surface may be provided on the upper end of the side rails 32 according to conventional practice. Projecting forwardly from a front side 42 of the frame 30 is an angle-shaped nose piece, generally designated 44 , having a forwardly extending platform 46 with an upper load-supporting surface 48 , upon which a load to be transported may be supported in the usual manner.
The hand truck illustrated in FIG. 5 includes the addition of a plurality of bottle-carrying support trays 50 that are hinged to the side rails 32 and, when in use, project forwardly of the front of the frame 42 to support a corresponding plurality of the large five-gallon type bottled drinking water containers C, arranged one above the other crosswisely to the frame 12 . The trays 50 define trough-shaped platforms 52 including generally rectangular bottom wall portions 52 a that lie generally perpendicular to the side rails 32 when supporting the containers C, and forward and rearward product stabilizing wall portions or abutments 52 b , 52 c , respectively, that project upwardly and outwardly fore and aft of the bottom wall 52 a at an acute angle with respect to the plane of the bottom wall portion 52 a . The abutments 52 b , 52 c are of a restricted width and length so as to fit between the side rails 32 when the trays 50 are swung or folded to an inoperative stowed position flush with the front 42 of the frame 30 .
Turning now to the operation or use of the carrier 10 with the hand truck 12 of the present invention, the upper and lower hangers 24 , 26 are so located on the back wall of the carrier and their channels 28 , 29 so sized as to enable the carrier 10 to be hung on the cross braces 34 of the frame 30 . It will thus be appreciated that the configuration, size, and spacing of the upper and lower hangers 24 , 26 corresponds to the configuration, size and spacing of the cross braces 34 of the frame 30 to enable an operator of the hand truck to attach the carrier 10 to the frame 12 by simply locating the hangers 24 , 26 in position over the cross braces 34 and than lowering them into engagement with the cross braces 34 . When mounted, the offset weight of the carrier 10 and the engagement of the upper and lower hangers 24 , 26 with the cross braces 34 retains the carrier 10 securely but releasably in position on the frame 30 . It will be appreciated that the upper and lower brackets cooperate with one another to maintain the carrier 10 in attachment with the frame 30 during normal use of the hand truck 12 . For instance, when an operator rocks the hand truck rearwardly back onto its wheels, the lower hangers 26 support the carrier 10 and the container C in position against the frame 30 , restraining the lower end of the carrier and platform from swinging outwardly of the frame 30 under the forces of gravity. The operator may readily detach the carrier 10 by simply lifting the carrier vertically free of the cross braces 34 .
As illustrated in FIG. 5, the carrier 10 may serve as an auxiliary bottle carrier to be used in conjunction with a hand truck having the aforementioned multiple bottle-carrying trays 50 . In this application, the carrier 10 is hung off the back side 54 of the hand truck frame 30 so as not to interfere with the operation of the trays 50 .
FIG. 6 illustrates an arrangement wherein the carrier 10 is serving as the primary or sole bottle carrier for a conventional hand truck, and is shown hung off the front 42 of the frame 30 in position above the nose plate 44 .
FIG. 7 shows an alternative arrangement, wherein the carrier 10 is hung off the back side 54 of the same type of hand truck, leaving the platform 46 of the nosepiece 44 available to support a load L which may comprise, for example, cartons or boxes of smaller size beverage containers, or other products which are normally carried on the nosepiece 44 .
The bottle carrier 10 may be constructed from any of a number of materials, provided the carrier 10 is sufficiently strong to support the weight of a bottled water container C when mounted on the hand truck frame 30 . The presently preferred material for the carrier 10 is aluminum, wherein the back wall 14 and platform 16 may be formed of a single piece of aluminum sheet stock, cut and bent to the generally L-shaped configuration shown. The retaining band or girth retainer or element 20 may be made of the same or similar aluminum alloy sheet stock material, bent to a generally U-shaped configuration as shown in the top view of FIG. 3 and joined to the back wall 14 by weldments or suitable fasteners (i.e., rivets, bolts, etc.). The upper and lower hanger sets or hooks 24 , 26 may be fabricated from U-shaped channel stock cut to length and fixed such as by weldments or fasteners to the backside of the back wall 14 in the manner illustrated in the drawings. They uniquely will be fixed to the wall or base plate 14 at a vertically spaced distance correlating to the spacing of cross braces 34 .
Once mounted on the frame 30 , the carrier 10 may support a container C by simply loading the container C onto the platform 16 in an upright position from above, whereupon the bottom of the container C is supported on the platform 16 and the band 20 and back wall 14 together encircle the container C to retain the container C on the platform 16 during transport. To unload the bottle, the user simply lifts the container C off the platform 16 through the band 20 .
The disclosed embodiments are representative of presently preferred forms of the invention, but are intended to be illustrative rather than definitive thereof. The invention is defined in the claims. | A method of constructing a bottle carrier for a two-wheeled hand truck having a normally generally vertically disposed hand truck frame comprising transversely spaced side rails joined by at least a pair of vertically spaced cross rails between its upper and lower ends includes the steps of providing a generally upright carrier frame having a projecting platform of a size to support a bottle in upright position and which incorporates a bottle girth enveloping element of a size to closely embrace the diameter of an upright bottle on the platform; and providing vertically spaced load bearing parts on the carrier frame spaced apart vertically a distance corresponding to the vertical spacing of the pair of cross rails and configured to disengagably latch the carrier against the cross-rails. | 1 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present case is a continuation of copending application Ser. No. 11/286,811. Application Ser. No. 11/286,811 is a continuation of application Ser. No. 10/323,450, now U.S. Pat. No. 6,987,977, which is a continuation of application Ser. No. 09/452,768, filed Dec. 1, 1999, now U.S. Pat. No. 6,496,702. The entire disclosure of each of these applications is incorporated herein by reference, and priority is claimed to the filing date for the disclosure of each of these applications, including Dec. 1, 1999 of application Ser. No. 09/452,768.
[0002] The entire disclosure of copending application Ser. No. 11/456,796 is incorporated herein by reference. Application Ser. No. 11/456,796 is a continuation of application Ser. No. 10/899,528, now U.S. Pat. No. 7,079,641, which is a continuation of application Ser. No. 09/912,770, filed Jul. 24, 2001, now U.S. Pat. No. 6,788,779. The entire disclosure of each of these applications is incorporated herein by reference, and priority is claimed to the filing date for the first disclosure of each of these applications, including Jul. 24, 2001 of application Ser. No. 09/912,770.
[0003] The entire disclosure of copending application Ser. No. 11/388,089 is incorporated herein by reference. Application Ser. No. 11/388,089 is a continuation of application Ser. No. 09/661,181, now U.S. Pat. No. 7,020,264, which is a continuation of application Ser. No. 09/443,057, now U.S. Pat. No. 6,122,360, which is a continuation of application Ser. No. 08/968,825, now U.S. Pat. No. 6,005,931, which is a continuation-in-part of application Ser. No. 08/869,815, now U.S. Pat. No. 6,148,074, which is a continuation-in-part of application Ser. No. 08/802,667, now U.S. Pat. No. 6,201,863, which is a continuation-in-part of application Ser. No. 08/797,420, now U.S. Pat. No. 6,185,291, filed Feb. 10, 1997. The entire disclosure of each of these applications is incorporated herein by reference, and priority is claimed to the filing date for the first disclosure of each of these applications, including Feb. 10, 1997 of application Ser. No. 08/797,420.
[0004] The entire disclosure of copending application Ser. No. 10/406,347 is incorporated herein by reference, and priority is claimed to the filing date of Apr. 2, 2003 for the disclosure.
[0005] The entire disclosure of copending application Ser. No. 10/229,428 is incorporated herein by reference. Application Ser. No. 10/229,428 is a continuation of application Ser. No. 09/335,423, now U.S. Pat. No. 7,020,264. The entire disclosure of each of these applications is incorporated herein by reference, and priority is claimed to the filing date for the first disclosure of each of these applications, including Jun. 17, 1999 of application Ser. No. 09/335,423.
BACKGROUND OF THE INVENTION
[0006] 1. Field of the Invention
[0007] The present invention is in the field of telephony communication as it pertains to mobile devices or units operating on a private network and pertains more particularly to methods and apparatus for enhancing communication capability, data transfer capability, and increasing the number of mobile devices that can successfully operate on a communication-center facilitated virtual private network (VPN).
[0008] 2. Description of Related Art
[0009] The field of telephony communication has grown more diverse and flexible. Call-in centers that once were restricted to connection-oriented switched telephony (COST) are now employing computer-simulated telephony techniques generally referred to as data network telephony (DNT). Call-in centers that are enhanced with DNT and multimedia capability more appropriately termed communication centers in the art. This is due to the broad range of telephony and data transfer capabilities that are routinely practiced within or facilitated by such centers.
[0010] Communication centers are often used by enterprises to accomplish cellular communication links with fleets of vehicles having wireless communication devices installed therein for receiving instruction and responding back to personnel operating within the center, such as dispatchers, sales agents and so on. There are a variety of existing techniques used by communication centers today to track, control and support fleets of vehicles.
[0011] Services such as Omnitracs™ operated by Qualcomm and On-Star™ operated by General Motors Corp. (GM) use the well-known cellular telephone infrastructure and the global positioning system (GPS) to track and support vehicles in the field. Services offered include such as air bag deployment notification, remote door unlocking, road-side service, vehicle theft notification, and so on. In some cases device-equipped vehicles are owned and operated by a single entity that also provides the service. In some cases vehicles are owned individually, or in small groups and are subscribed to a service.
[0012] A commonality among all of these types of service communication systems is that users (i.e. drivers of subscribed vehicles) may need to be periodically tracked by the system to be given logistics support, help or advice at some point during a trip. In some cases tracking is employed for reporting purposes to customers of the service business, such as with some trucking companies and the like. The above-described systems target mostly high-end vehicles or commercial fleets as primary targets, due to the higher value and traffic they incur.
[0013] One problem with the infrastructure associated with the above-described services is that communication with the volume of serviced cars or commercial fleet of vehicles is typically implemented by a single communication center. As a result the systems are limited to a relatively small volume vehicles depending on the nature of the service. Such a communication center, as is known in the art, simply cannot handle a really large volume, such as perhaps a million vehicles or more.
[0014] The technologies (GPS and cellular services) that support the above-described services are continually being developed and made available over ever-increasing geographic regions. Therefore, it is desirable to provide similar services to a much larger customer base than the currently limited numbers serviced by today's largest system/infrastructures. As previously described, a single communications center cannot handle the desired volume. For example, a service base of a million users or more would logically encompass mostly “normal citizens” rather than professional drivers due to shear volume. In this regard, services offered would have to be more diversified among users instead of being standardized as with a fleet of company-owned service vehicles.
[0015] An unacceptable communication load would result in any single communication center. Moreover, other problems would arise from an overload of users interacting with a center such as increased costs of long-distance routing, and lack of “local knowledge” required to effect many desired and marketable services.
[0016] What is clearly needed is a method and apparatus that enables efficient data management and routing of service events to and from a large volume of tracked vehicles maintaining wireless communication devices, wherein specific interaction and routing does not have to be performed in or facilitated by one single communication center. Such a system would allow a single service to provide cost-effective, mainstream services to millions subscribers.
BRIEF SUMMARY OF THE INVENTION
[0017] In a preferred embodiment of the present invention a service communication system for mobile vehicles is provided, comprising a cellular telephony interface in individual ones of the mobile vehicles, for establishing telephony events over a cellular network with a base station; a global positioning system in individual ones of the mobile vehicles for determining global position from transmissions from GPS satellites; a network of base stations for receiving and broadcasting to the mobile vehicles, and for bridging events between cellular and public switched telephone service (PSTN) protocol; a network-level routing system connected by first telephony trunks to the base stations and enabled to retrieve GPS position from the telephony events; and a plurality of service centers connected to the network-level routing system by second telephony trunks. The network-level routing system determines a destination for individual ones of the telephony events among the plurality of service centers according to the retrieved GPS position.
[0018] In preferred embodiments the network-level routing system further comprises an interactive voice solution (IVS) system for providing synthesized voice responses to incoming events. Also in preferred embodiments individual ones of the service centers each comprise a telephone switching apparatus connected by a computer telephony integration (CTI) link to a CTI processor for monitoring a controlling the connected telephone switching apparatus, and the network routing center comprises a network-level CTI processor connected to a network-level switch, and wherein the CTI processors at network and service center level are interconnected by a data link separate from the second telephony trunks. In some embodiments data about a call event is stripped at the network-level routing system and transmitted by the data link separate from the second telephony trunks to a service center to which the call event is routed.
[0019] In various embodiments of the invention taught in enabling detail below, services for mobile vehicles may for the first time be provided in a specialized way by having local service centers attuned to the needs of certain areas and for special purposes, and by routing service call events to specialized centers based on mobile vehicle location at the time service is requested.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0020] FIG. 1 is an overview of a mobile device communication network as known to the inventor illustrating typical routing points for a call event from a mobile device to a contact center.
[0021] FIG. 2 is an overview of the mobile device communication network of FIG. 1 illustrating typical routing points for incoming voice calls into the contact center of FIG. 1 .
[0022] FIG. 3 is an overview of the mobile device communication network of FIG. 1 illustrating typical routing points for a call event to a car from a PSTN through the contact center of FIG. 1 .
[0023] FIG. 4 is an overview of a mobile device communication network enhanced with network data control and routing control according to an embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0024] FIG. 1 is an overview of a current-art mobile device communication-network 9 as known to the inventor illustrating typical routing points for a call-event from a mobile device to a contact center. Communication network 9 comprises a Cell network 13 , which is in an area that has by in large also GPS coverage, a connected PSTN network 11 , and a communication center 15 . Cell network 13 represents the well-known cellular communications networks in an area with the well-known GPS system. These two technologies including their respective infrastructures are utilized by service communication centers such as center 15 to track and provide support to fleets of vehicles having both GPS devices and wireless communication devices installed therein. One vehicle of such a fleet of vehicles is represented herein by a car 25 illustrated within Cell network 13 and presumably with the GPS coverage.
[0025] PSTN network 11 may be another type of telephony network such as a private telephone network as may be known in the art. Communication center 15 , also referred to as a contact center in the art, represents in this example a national service center that offers support and service to a fleet of vehicles as was defined in the background section. Center 15 utilizes PSTN network 11 and Cell networks 13 to facilitate communication and interaction between center 15 and an equipped vehicle such as car 25 .
[0026] A network bridging (base) station 17 is provided and adapted in this example to convert wireless cellular calls into PSTN calls and PSTN calls into cellular calls. This shall be a grossly simplified view of elements as are well known in the art of telephony. Further details would obfuscate discussing the present invention and have hence been left out. Station 17 is equipped with all of the necessary hardware and software to accomplish this task as is known in the art. Station 17 has a transceiver/receiver device 19 connected thereto and adapted to pick-up and transmit cellular transmissions. Cellular communication from car 25 to center 15 , or from center 15 to car 25 is routed, in this example, through the PSTN network 11 .
[0027] Communication center 15 has installed therein a central telephony switch 33 , which may be an ACD or PBX type switch. Switch 33 is adapted to function as a first destination for inbound call events originating from such as car 25 , or from other sources within PSTN 11 . Switch 33 is CTI (computer telephony integration) enhanced by a CTI processor 35 connected thereto by a CTI link 37 . Such enhancement provides status and event monitoring of the switch, and switch function control, such as intelligent routing control. For example, switch 33 functions in this embodiment as a private service control point (SCP) with agent/system level routing intelligence for routing to various points within center 15 .
[0028] A modem pool 41 is provided and adapted to strip data from inbound and outbound call events processed at center 15 . Modem pool 41 is connected to switch 33 by an internal telephony trunk 55 , and to an internal, interconnecting local area network (LAN) 49 , which interconnects several internal elements as described below, including the CTO processor 35 . Modem pool 41 represents a second “data” routing point within communication center 15 .
[0029] An interactive voice solution (IVS) machine 43 is provided and adapted to interact with customer's calls and contacts, and to process certain aspects of data in incoming calls to synthesized voice, which may go to an agent or back to a subscriber's vehicle. IVS 43 connects on LAN 49 . In this way IVS 43 is controlled to respond to call events according to event protocols.
[0030] A front-end communication-center server (CCS FE) 45 is provided and adapted to process workflow for incoming non-real-time events. Server 45 is connected to CTI processor on LAN 49 and is controlled by processor 35 . A back-end communication-center server (CCS BE) 47 is provided and adapted to process workflow for non-real-time outgoing events. Server 47 is connected to server 45 and also to IVS 43 on LAN 49 .
[0031] An agent's telephone 50 is provided at an agent station and adapted to enable live voice communication between such as car 25 and an agent operating within center 15 . Telephone 50 is connected to switch 35 by internal telephone wiring 51 . In other embodiments, an IP phone may be used connected to a LAN (e.g. LAN 49 ). A communication queue 39 is provided in switch 33 for incoming call events that are waiting for pickup by an available agent such as one operating telephone 50 . It will be apparent to one with skill in the art that in a service communication center such as center 15 , there will be many more agents' telephones than the one telephone 50 illustrated herein. Moreover, agents may also be operating local area network (LAN) connected terminals at the agent stations, such as terminal 52 shown, having graphical user interfaces (GUI) along with processing and data input capabilities. Such terminals may be personal computers (PCs) or other adapted machines.
[0032] It is noted here that the equipment and connections illustrated within communication center 15 in this embodiment represent such as apparatus connection and control schemes known to the inventor and is not yet widely available in the art to be termed prior art. It will be apparent to the skilled artisan that there are alternative architectures that might be used for the interconnection of operational elements in the communication center.
[0033] As described in the background section, large commercial fleets, such as trucking fleets, as well as private subscribers operating private vehicles are facilitated in terms of GPS tracking and cellular support by a single national communication center. Such is the case represented here. Because of this only a limited number of vehicles, perhaps up to a few thousands, may be adequately serviced without severely straining the resources of a national center such as center 15 . Moreover, routing within a center such as center 15 may be somewhat complicated depending on the nature of events and services offered.
[0034] In this example a typical routing path is illustrated for a call event arriving to center 15 from car 25 . Such a call event may be an automatically triggered data request, a voice/data request, or a voice call. It is important to note here that the modem communication between such as modem pool 41 and a modem installed in car 25 follows such as Analog Display Services Interface (ADSI) protocols or equivalents. Hence, the connection has two states; one being a voice connection and the other being a data connection using an A/B toggle switch at each modem with control afforded to communication center 15 .
[0035] An inbound event is broadcast from car 25 , received by receiver/transceiver 19 and transmitted to station 17 where it is converted to a PSTN call. Typically, because of the nature of the subscription service, being highly dependent in many instances on the location of the vehicle originating an event, data regarding global positioning is sent with the call event. This data is available to the system in the vehicle by GPS interface which operates, as is known in the art, by monitoring transmission from multiple satellites, represented here by satellites 23 and 24 , and triangulation calculations. In some cases, because, for example, a vehicle having initiated an event continues to move, the position has to be updated, which may be done periodically as a function of the vehicle system, or may be triggered from a remote station. In any event, the GPS position information is transmitted via the cell network.
[0036] Once on PSTN 11 , the event is routed to switch 29 . The event is then switched to central switch 33 at the communication center at a first agent-level routing point I over telephony trunk 31 . Routing point I is a private SCP equivalent implemented at center 15 . Once the event reaches routing point I, the nature of the event is determined (ANI/DNIS). In this example, we assume the event is a data call requiring a non-real-time or automated response, and the GPS arrives with the call event. Call nature determination and further routing is controlled by CTI processor 35 running CTI software adapted for the purpose. It is important to note here that every inbound event is routed to a routing point II (modem pool 41 ) over trunk 55 . Routing point II, which is at modem pool 41 , strips the data from the event, including the GPS location of car 25 at the time of event initiation.
[0037] Also, certain data about the call may be passed to Customer Client-Server workflow engine Front End (CCS FE) server 45 over LAN 49 for front-end processing. Data about the event passes from server 45 to Customer Client-Server workflow engine Back End(CCS BE) server 47 for back-end processing. Processed data, which reflects the command disposition of the event, passes from server 47 into IVS 43 for processing, if required, into synthesized voice instruction, which will become part of an outbound event. The Voice package necessitated is passed to modem pool 41 and an outbound event is created and forwarded to a routing point III. Hence, an outbound call event representing a synthesized voice response to the original request is routed back over trunk 31 into switch 29 in PSTN 11 . The response event is then routed to station 17 over line 27 where it is converted back to a cellular protocol and broadcast by transceiver/receiver 19 to car 25 where a motorist receives it.
[0038] Returning to routing point III, if the original event required or requested a live agent communication, the caller would either be connected to an available agent at, for example, telephone 50 , or, if none were available, be placed in queue 39 . An agent at telephone 50 will typically have access as well to a computer station 52 having a video display unit (PC/VDU), and the system may provide display for the agent related to telephony events. However, the voice aspect of a live event is not connected until all data is stripped and processed. Communication center 15 , through server 35 , controls the voice/data aspect of each event.
[0039] Because communication center 15 in this example is a national center handling all subscribing vehicles nation wide, events may have to be routed over long distances through PSTN 11 to a local cell network. Another issue is that one national center such as center 15 may not be up to date on recent local changes transpiring in the vicinity of car 25 . For example, if the original request was for a list of local motel vacancies in the immediate area of car 25 , center 15 may not have the recent listings or information on any new locations just opened for business. If, for example, the original request was for an emergency towing service, a national center may not know that car 25 is only a few miles from a recently opened service and may recommend a more distant provider causing added expense for the motorist.
[0040] It will be apparent to one with skill in the art that a communication network, wherein a single national center must facilitate communication with a nationally spread-out fleet of vehicles, will have substantial limitations with respect to providing accurate knowledge of local resources and with providing routing of events over long distance wired networks.
[0041] FIG. 2 is an overview of the mobile device communication network 9 of FIG. 1 as known to the inventor illustrating typical routing points for an incoming voice call into the contact center of FIG. 1 . As the elements involved in this embodiment are analogous to those described in FIG. 1 , reintroduction of such elements will not be made.
[0042] In this embodiment, we assume that car 25 places a live voice call for an agent at communication center 15 . A voice call is initiated from car 25 using the voice mode on the associated modem. Initial call routing is analogous to FIG. 1 . For example, transceiver/receiver 19 picks up the event and passes it into station 17 where it is converted to a PSTN call. The event is then routed over trunk 27 to switch 29 in network 11 . Techniques typically using ANI/DNIS cause routing of the event over trunk 31 to switch 33 (SCP). At this point the voice nature of the call is determined, and the call is routed first to an available agent as a PSTN-connected call. Notification is given by the agent to the vehicle operator that he or she requires data communications with the vehicle and will be placed on hold for reconnection. This may be accomplished by a voice-synthesized message.
[0043] The event is then routed to routing point II (modem pool 41 ) and the agent operating telephone 50 is placed on hold. This process must be performed so that any data associated with the live call request may be stripped by modem pool 41 and processed, including obtaining a read on car location per the GPS system if necessary. Once the data is processed by servers 45 and 47 as described above with reference to FIG. 1 , the agent at telephone 50 is reconnected to the caller in voice mode. If the agent becomes unavailable while data is being processed, then the inbound call event may be routed to queue 39 to wait for reconnection to a different agent.
[0044] It will be apparent to one with skill in the art that internal routing wherein the modem at communication center 15 must be re-linked back into the call flow in order to complete a voice call is rather complicated and uses significant resources. The modem at communication center 15 must issue a dual-tone-multiple-frequency (DTMF) or other suitable non-DTMF tone to switch the connection-state from voice to data and then back to voice as is known in the art with ADSI type modem-interfaces. Moreover, as communication network 9 is identical to the one described in FIG. 1 , the same limitations apply that were described in FIG. 1 .
[0045] FIG. 3 is an overview of the mobile device communication network 9 of FIG. 1 illustrating typical routing points for a call event to a car from a PSTN from the contact center of FIG. 1 . In this example as in the example of FIG. 2 , elements of communication network 9 remain the same as previous embodiments and therefore, will not be reintroduced. The example provided herein represents the routing path associated with a PSTN call to car 25 in Cell network 13 .
[0046] A call event represented by a vector 30 arrives at switch 29 in PSTN 11 . ANI and DNIS information indicates that the event is destined to communication center 15 . It is assumed that in this embodiment center 15 , which is a national center, must facilitate the call. This is typical of services of the type described in the background section.
[0047] Event 30 is routed from switch 29 over trunk 31 to switch 33 at communication center 15 . Because it is a conventional PSTN call, it may be routed directly to an agent (routing point II) such as one operating telephone 50 . The agent operating telephone 50 may further direct the call based on information supplied by the caller such as car identification number. In some cases a car identification number may be part of the call identification data. Based on the call data and agent input data, event 30 is routed back to switch 33 as an outbound call to car 25 . This employs the workflow process represented by servers 45 and 47 along with IVS 43 which instructs modem pool 41 to dial car 25 . Therefore, a third routing point is at switch 33 , which represents an outbound call in progress. The agent operating telephone 50 may or may not stay with the caller during this process. The outbound call is routed back through PSTN 11 , through bridging station 17 and onto car 25 through Cell network 13 . When the motorist operating car 25 picks up; he is connected to the waiting PSTN event.
[0048] It will be apparent to one with skill in the art that limitations exist with respect to communication network 9 described in FIGS. 1-3 including routing complexity, long distance costs, lack of local knowledge to aid motorists, and so on.
[0049] The above FIGS. 1-3 describe a current-art communication network that uses the GPS system and the cellular network along with the PSTN to enable national centers such as center 15 to communicate with motorists and on-board systems that may be associated with a subscribed car such as car 25 .
[0050] A communication network such as network 9 may utilize a virtual private network (VPN) comprising multiple wireless carriers and land networks as is known in the art. Therefore, networks 13 and 11 may be assumed to represent multiple wireless and land-line networks spread over large geographic areas. Even with VPN access, which limits some long distance charges, routing to one national center such as center 15 is still complicated.
[0051] FIG. 4 is an overview of a mobile device communication network 61 enhanced with network data control and routing control system 63 according to an embodiment of the present invention. New elements are introduced in this preferred embodiment. Such elements provide enhancement to overall performance and efficiency for the entire system.
[0052] In this example, instead of utilizing one single, national communication center to facilitate communication as is illustrated in current-art examples with reference to FIGS. 1-3 , the inventor illustrates a unique and novel network system 61 , which uses multiple, distributed communication-centers, illustrated herein as centers 71 and 73 , and places data control and voice/data switching capability at the network level, illustrated by a VID packet 63 . For clarity, not all the elements explained before are shown in the drawing but may or may not be present in each one of the centers.
[0053] Communication center 71 comprises a central switch 75 , a modem pool 77 , a CTI processor 81 , a representative telephone 83 , and a representative PC/VDU 84 . The separate elements are connected through a LAN 86 , and a trunk 79 connects switch 75 to modem pool 77 . IVS and CCS implementations as shown in communication center 15 of FIGS. 1-3 may be assumed to be present, but are not shown. Communication center 73 is in this embodiment is identical to center 71 , comprising a central switch 89 , a modem pool 91 , a CTI processor 95 , a representative telephone 97 , a representative PC/VDU 97 , a LAN 100 , and a trunk 93 . In center 71 , switch 75 is connected to CTI processor 81 by a CTI link 87 . Modem pool 77 is connected to switch 75 by internal telephone wiring 79 . Telephone 83 is connected to switch 75 by internal telephone wiring 85 . In center 73 , switch 89 is connected to CTI processor 95 by a CTI link 101 . Modem pool 91 is connected to switch 89 by internal telephone wiring 93 . Telephone 97 is connected to switch 89 by internal wiring 99 .
[0054] Centers 71 and 73 represent local distributed communication service centers provided by an enterprise hosting a mainstream service and therefore may be significantly smaller in size (number of agents, modems, workstations, etc.) than one large national center. An object of the present invention is to provide distributed centers such as centers 71 and 73 to allow for a much higher service capability (number of vehicles) than is possible with current art systems.
[0055] VID packet 63 is provided and operates at PSTN network level. Packet 63 is in this example is an equipment grouping that handles GPS, voice/data switching, and workflow processing activity, which was in previous examples provided within a national communication center such as center 15 of FIGS. 1-3 . Packet 63 comprises a modem pool 65 , an IVS machine 67 , and a CTI processor 69 . CTI processor 69 is connected to switch 29 by a CTI link 68 . This connection provides CTI monitoring and control over switch 29 such that it may be used in many enhanced ways, including as a private SCP. By placing VID packet 63 in the network, GPS location data may be utilized at the network level instead of from within a communication center. Voice and data switching and interactive voice/data control is also performed at network level by modem pool 65 and associated IVS 67 .
[0056] In a preferred embodiment of the present invention, an inbound call event from car 25 is received at a local bridging station such as station 17 by way of transceiver/receiver 19 and is converted to a PSTN call event as was described in previous examples. It is assumed for this example that the incoming call event includes data for GPS position. In some embodiments there may be a function for updating position by automatic pinging back through the system to the vehicle. The call event arrives at switch 29 over trunk 27 also as previously described. Here the similarity ends with respect to previously described routing means and data handling.
[0057] Data from such a call event is passed over data-network connection 68 to processor 69 in VID packet 63 . The call event is routed to modem pool 65 over trunk 66 . Modem pool 65 represents a routing point I, which is a pre-center routing point. GPS location data associated with car 25 is accessed by modem pool 65 . Data about the call event is stripped by modem pool 65 and processed by IVS 67 . By utilizing VID capability at the network level, now the inbound call event from car 25 may be routed to either center 71 or center 73 (or another call center) whichever is more appropriate. In many cases the appropriate center will be the closest center to car 25 , and the GPS data may be used to make the routing decision. An event such as an inbound event sourced from car 25 arrives at either center 71 or 73 by way of telephony trunk 72 out of modem pool 65 in the network. Other items may be used in considering the routing, as are well known in agent skill level routing, customer requirement routing etc.
[0058] Routing points II illustrated at switch 75 (center 71 ) and switch 89 (center 73 ) are optional routing points depending on which center will be designated to receive the inbound event. Data about the inbound event is passed to the appropriate communication center over a separate data network represented by path 70 connecting processors 69 , 81 and 95 . Processors 81 and 95 control further routing, at centers 71 and 73 , respectively.
[0059] Now GPS location is available as a determinant in routing to various call centers. This position information has other novel uses as well. Data processing and voice/data switching is performed at network level according to CTI routines for inbound events. Therefore, the ratio of modems to agents at each center may be significantly reduced. Call events arriving from anywhere in PSTN 11 may also be handled at network level. Modem pools 71 and 73 handle outbound traffic in normal fashion as well as providing voice/data switching.
[0060] The method and apparatus of the present invention may be integrated into existing VPN networks without departing from the spirit and scope of the present invention. In this way, multiple wireless carriers as well as land connections may be utilized in routing. Inbound events are routed intelligently by virtue of processors 69 (network), 81 (center 71 ), 95 (center 73 ), utilizing a separate data network illustrated by network connections 68 and 70 . As a result, inbound routing decisions may be based on a variety of criteria such as load balancing requirements, statistical routing, routing according to least expensive path, routing according to defined service, routing by agent skill, and so on.
[0061] In one embodiment of the present invention, a wide area network such as the Internet packet-data network may be utilized and integrated as a data/voice carrier. For example, an Internet-based service may be available for owners of subscribed vehicles to plan such as vacation trips or the like. Such data may be configured and uploaded to an Internet server and tagged to a particular vehicle. At the time of the trip the plans can be included in a series of inbound data calls to such as car 25 from the Internet. Of course, the appropriate DNT/PSTN bridge is required in order to interface switch 29 with the source data events.
[0062] GPS may also be used to trigger portions of a trip plan to be broadcast to car 25 . For example, car 25 reaches a certain point (GPS location, latitude or longitude as more broad lines along the planned trip route). Periodic pinging of the GPS system may be used to approximate the correct location of car 25 along a route. When such location data closely matches data included in the trip plan, an automated data call from the Internet carrying the appropriate data for the matching location would be processed as an inbound call event to the appropriate communication center. That center could then generate an outbound data call to car 25 that may include locations and directions for local motels, restaurants, banks, supermarkets, camp sites, and so on. There are many possibilities. Businesses and service providers such as auto towing, truck stops, rest areas, and the like may advertise to customers through local centers.
[0063] In some cases, the location of a requested service may effect network-level routing of an inbound call request. For example, if during travel, a subscriber such as one driving car 25 requests knowledge of a nearest hospital that provides emergency services, then a network-level SCP may, after pinging for GPS position, route the event to a local communication center known to have knowledge of a name, location and directions to a nearest hospital that matches the request. Such data would, of course, have to be known at network level such as by a connected data repository adapted for the purpose.
[0064] It will be apparent to one with skill in the art that a communication/service network such as network 61 can provide service to more vehicles by virtue of utilizing multiple communication centers than can be handled by a single communication center. It will also be apparent to one with skill in the art that such multiple centers as described above can provide more specific and updated information by virtue of being in close vicinity to the services requested, and local centers may be specialized to local services, and so on.
[0065] The methods and apparatus of the present invention may be practiced over standard Cell/PSTN networks or may be integrated into a VPN comprising multiple carriers. Likewise integration into such as the Internet or other WAN or G3-type digital networks is possible. Therefore, the method and apparatus of the present invention should be afforded the broadest scope. The method and apparatus of the present invention is limited only by the claims that follow. | A communication system has a cellular telephony interface in individual ones of two or more mobile vehicles, a position determination system in individual ones of the mobile vehicles, a network of cellular base stations coupled to the mobile vehicles, individual base stations coupled to one or both of a packet-switched or a line-switched telephony system, a router coupled to the base stations and enabled to retrieve GPS position from the telephony events, and a plurality of service centers coupled to one or both of the telephony systems. Telephony events from individual ones of the mobile vehicles are routed according to position reported by the position determination system. | 6 |
FIELD OF THE INVENTION
This invention relates to clear, impact-resistant thermoplastic based on a poly(methyl methacrylate) matrix and a process for improvement of their color.
BACKGROUND OF THE INVENTION
Poly(methyl methacrylate) has been known for many years as an useful material for a clear, weatherable thermoplastic. It can be prepared or formed into sheet or molded articles, it has excellent resistance to weathering, it has a high service temperature, preventing distortion on exposure to warm environments, it does not embrittle significantly on cooling, it has adequate toughness or impact resistance for many uses, surpassing glass in that respect, and it has excellent optical properties in its combination of light transmittance and avoidance of color. Such optical values are measured as % total white light transmittance, yellowness index, and haze.
Its major deficiency, as compared to materials like polycarbonate, has been lack of impact resistance. Many studies have been made to improve the impact resistance while maintaining the other desirable physical properties, including clarity. Most of these centered on the use of weatherable elastomeric materials, such as copolymers of alkyl acrylates, disperse in the poly(methyl methacrylate) matrix. The most commercially successful of these has been the use of a core/shell modifier structure, utilizing a butyl acrylate/styrene copolymer which has a refractive index matched to the poly(methyl methacrylate) matrix, and a grafted poly(methyl methacrylate) shell, the particle size being below 0.5 microns and the isolated particle dispersed in the poly(methyl methacrylate) matrix. A further improvement in the impact modifier has been the presence of a "hard core" of methyl methacrylate, chemically attached to the intermediate rubbery layer. The resulting polymer offers good optical properties, good resistance to crease-whitening on impact, and a five- to ten-fold increase in toughness over the unmodified matrix polymer.
The technology for such "core-shell" impact modifiers is described in Owens, U.S. Pat. No. 3,793,402, herein incorporated by reference. The technology for other core-shell modifiers is described in Owens, U.S. Pat. No. 3,808,130, also herein incorporated by reference. Many variants in the nature of such polymers may be utilized, including the order in which the various layers are created, the nature and extent of the grafting and/or crosslinking processes, the types of crosslinking monomers (defined in Owens as a monomer having two or more unsaturated sites of equal reactivity such as butylene glycol dimethacrylate, ethylene glycol diacrylate, and the like) and graftlinking monomers (a monomer having two or more sites of unequal reactivity, such as allyl methacrylate, diallyl maleate, and the like), the particle size, and the means of isolation. Also variations in the number and order of stages have been taught in several patent applications. It is anticipated that the present invention will be useful for all such variants.
The most convenient way to prepare such modifiers has been by sequential emulsion polymerization, as described in Owens, wherein the first stage or core of the multi-stage heterogeneous polymer is formed in emulsion, a second monomer or mixture of monomers is added under conditions which produce no new particles, so that the second monomer is polymerized on the surface or within the first polymer particle, the process being repeated until all the stages have been polymerized, the stages being attached to and intimately associated with the preceding stage. The additive is then usually isolated by spray-drying or coagulation and then blended with the poly(methyl methacrylate) matrix.
Because the matrix polymer is usually prepared by a bulk process in which few if any contaminants are present, whereas the emulsion process requires emulsifier, buffer salts, initiators which may be inorganic salts, and the like, the possibility exists that the isolation process, especially if it is spray-drying or coagulation under conditions where the emulsifier is not readily removed, will result in contaminants present in the impact modifier component which will affect the color or optical properties. Such contaminants may be insoluble precipitates which scatter light and cause haze, or they may be soluble components which contribute to color or which are sensitive to processing to form color.
A long-known and effective means for counteracting yellow color within a polymer sample has been to add very low levels of blue pigments or dyes, called toners. However, addition of toner will lower the amount of total white light transmittance, and, unless carefully controlled, will produce green or blue color.
Hung, U.S. Pat. No. 4,602,083, incorporated by reference, teaches that a variety of acrylic-based emulsions, including the impact modifier and the matrix polymer described herein, may be isolated from emulsion by the use of alkaline earth hypophosphites as coagulating agents, and that the resulting polymers have an improved combination of water resistance and optical properties, such as color, than similar materials isolated with conventional coagulants. Hung's process utilizes far larger quantities of the hypophosphite than are taught here, may also use other non-nucleophilic anions which are not reductants, and is not applicable to isolation of the impact modifier component by spray-drying. Hung does not suggest the utility in color reduction of the substantially lower amounts of reductant used in the present invention.
A means to lower the levels of both insoluble haze-producing and soluble color-producing contaminants has long been sought, and it is discovery of an method for improving the color without contributing to haze that is the present invention.
SUMMARY OF THE INVENTION
Thus, this invention relates to process for the improvement in color of poly(methyl methacrylate) modified to improve impact resistance with a core/shell polymer based on an poly(alkyl acrylate) copolymer rubbery stage and a poly(alkyl methacrylate) outer stage, when the core/shell polymer prepared by an emulsion process is treated with a small amount of a phosphorus-containing reducing agent, preferably sodium hypophosphite, prior to isolation from the emulsion and subsequent blending with the matrix poly(methyl methacrylate) in molten form. In one variant of the invention, the so-treated emulsion may be concurrently or sequentially co-isolated with the matrix polymer which has been separately prepared in emulsion form, the co-isolation being by spray-drying, kettle coagulation, or coagulation within an extruder. In another variant of the process, the core/shell polymer may be treated in emulsion by the reducing agent, isolated from the emulsion in solid form, and subsequently blended with the matrix poly(methyl methacrylate) while the latter is also in solid non-molten form, followed by melt-processing of the modifier/matrix blend. In another variant, the core/shell polymer is isolated from emulsion, the solid polymer then treated with the reducing agent, and thus-treated polymer then blended with the matrix poly(methyl methacrylate) in solid or molten form.
DETAILED DESCRIPTION
The matrix polymer may be a homopolymer of methyl methacrylate or a copolymer of up to about 30 weight percent of a monomer copolymerizable with methyl methacrylate, such as other methacrylates, styrene, alpha-methyl styrene, acrylate esters, and the like. Of such co-monomers, preferred are the lower alkyl esters of acrylic acid, such as methyl acrylate, ethyl acrylate, butyl acrylate and the like, which enhance thermal stability and maintain the weather resistance of the matrix. Especially preferred are copolymers from about 0.5 to about 5 weight percent of methyl or ethyl acrylate.
The molecular weight of the matrix polymer may be varied depending on whether the resulting polymer is to be extruded into sheet or capstock or is to be injection-molded into useful objects. A molecular weight (weight average) above about 80,000 is desired to maintain physical properties, such as toughness and heat distortion temperature, while values of above about 200,000 are too high in melt viscosity to be readily fabricated into useful objects.
The matrix polymer may be prepared by many methods, such as in emulsion, by suspension process, by solution process, or by bulk polymerization. Continuous processes may be used. If an emulsion process is used, the treatment with a reducing agent disclosed herein may also be employed. Preferred is a continuous bulk process, in which a mixture of monomers with organic peroxide initiators and mercaptan chain-transfer agents are pumped to a continuous flow, stirred tank reactor, the polymerization conducted to about 50% conversion, the polymer-monomer mixture pumped to a devolatilizing extruder, preferably a twin-screw extruder, where residual monomer is removed and other additives, including the impact modifier, may be added.
The preferred type of modifier resin for use in the practice of the present invention is described in the aforementioned U.S. Patents to Owens. The impact modifier resin comprises multi-layered polymeric particles. Speaking generally such resins are prepared by emulsion polymerizing a mixture of monomers in the presence of a previously formed polymeric product. More specifically, such resins are prepared from monomers in aqueous dispersion or emulsion and in which successive monomeric charges are polymerized onto or in the presence of a preformed latex prepared by the polymerization of a prior monomer charge and stage. The polymeric product of each stage can comprise a homopolymer or a copolymer. In this type of polymerization, the polymer of the succeeding stage is attached to and intimately associated with the polymer of the preceding stage.
In such core/shell structures for the present use, required is at least one rubbery stage which is predominantly derived from units of a lower alkyl acrylate, preferably butyl acrylate, copolymerized with a sufficient amount of at least one other monomer which will raise the refractive index of the rubbery stage to match that of the matrix resin, such as phenyl acrylate, butadiene, vinyl benzoate, and the like. Useful for this purpose, and detracting little from the weatherability and impact of the impact modifier, are monomers designated vinyl aromatics, such as styrene, alpha-methylstyrene, para-methylstyrene, vinyl toluene, monochlorostyrene, and the like. Styrene is preferred. The amount of styrene will vary depending on the exact composition of the matrix polymer, but is generally from about 15 to about 20 weight percent of the rubbery stage.
The amount of outer stage may vary, depending on how the impact modifier is to be isolated. To spray-dry, sufficient outer stage is required to allow the resultant product to flow freely. The composition of the outer stage is preferably very similar to that of the matrix polymer, that is, a polymer predominantly comprised of units derived from methyl methacrylate, but optionally with small amounts of a copolymerized alkyl acrylate.
Multi-stage structures may be utilized in the core/shell polymer, as longer as the outer stage and at least one rubbery stage are present, so that three-, four- and multi-stage structures may be formed.
Preferred, as taught in Owens '402, is a multi-layered polymeric particle comprising three sequential stages of a non-rubbery non-shell stage, first stage polymer, an elastomeric second stage polymer and a relatively hard third stage polymer, with the monomers (co-monomers) used in preparing each stage of the resin being selected, as described in the '402 patent, to provide stages or layers that have the aforementioned non-elastomeric, elastomeric, and hard properties.
As taught in the Owens patents, it is preferred that at least one of the rubbery or non-shell non-rubbery stage contains units derived from at least one monomer having more than one copolymerizable double bond.
As discussed in the '402 patent, the non- elastomeric polymer or "hard core" polymer formed in the first stage of polymerization has a glass transition temperature of greater than 25° C., and it is linked to an elastomeric polymer prepared in a subsequent stage from monomeric constituents such that the glass transition temperature thereof is 25° C. or less, preferably less than 10° C., and such elastomeric polymer is in turn linked to a polymer prepared in a subsequent stage from monomers such that the glass transition temperature of the polymer is preferably greater than 25° C., and most preferably at least about 60° C.
Preferred particles are those in which the core layer and the outer layer thereof comprise resins which are made from the same monomer(s) that are used to prepare the matrix resin of the composition, that is, homopolymers of methyl methacrylate or random copolymers of methyl methacrylate (about 88 to about 99.9 wt. %) and a C1 to C4 alkyl acrylate (about 0.1 to about 5 wt. %), most preferably ethyl acrylate, a graft-linking monomer, such as allyl methacrylate, diallyl maleate, and the like, and optionally, a polyfunctional cross-linking monomer, such as ethylene glycol dimethacrylate, butylene glycol diacrylate, and the like. When the matrix resin comprises a copolymer of methyl methacrylate and ethyl acrylate, it is highly preferred that the core and the outer layers of the particles comprise about 96 to about 99 wt. % of methyl methacrylate and about 1 to about 4 wt. % of ethyl acrylate, with the graft-linking monomer comprising about 1 wt. %. In accordance with the teachings of the '402 patent, various types of monomers can be used to prepare the intermediate layer of the particles. An exemplary intermediate layer comprises a random copolymer of butyl acrylate, styrene, and less than about 2 wt. % of the cross-linking and graft-linking monomers.
The impact modifier component is most effectively prepared in emulsion. A variety of surfactants may be used, such as cationic, anionic, and non-ionic. Preferred are anionic surfactants for rapid rates, use of relatively low levels to create stable latices without new particle formation, and little effect on color or haze. Preferred are sulfonic acid salts, usually the sodium salts of alkanes or alkaryl compounds, or ethoxylated alkaryl compounds, such as sodium dodecyl sulfonate, sodium dioctylsulfosuccinate, sodium dodecylbenzene sulfonate, and the like.
Initiation may be conducted by use of conventional initiators for emulsion polymerization, such as peroxides, hydroperoxides, persulfates, and the like, and such may be used in conjunction with common components of redox pairs, such as sodium formaldehyde sulfoxylate, sodium hydrosulfite, and the like. The presence of absence of such sulfur-containing reducing agents in the initiation system does not appear to create or correct the color problem which is overcome by the post-addition of reductant materials.
The ratios of useful stages are fully discussed in the Owens patents. It is preferred that the outer stage of the core/shell polymer be no more than about 25% of the total core/shell polymer for obtaining the highest impact efficiency. However, if all the product is to be isolated by a coagulative process from emulsion, it is acceptable to polymerize most or all of the matrix polymer in the presence of the elastomeric phase or phases.
The impact modifier may be blended with other emulsions for use in modifying the viscosity of the molten blend with the matrix polymer, or in aiding the isolation of the relatively soft impact modifier during spray-drying or coagulation. Useful for the former purpose are random copolymers comprised predominantly of units derived from methyl methacrylate with from about 0.1 to about 10% of a copolymerized alkyl acrylate, such as ethyl acrylate, the molecular weight being from about 80,000 to about 150,000. Useful for the latter purpose are high molecular weight polymers or copolymers comprised predominantly of units derived from methyl methacrylate and having a molecular weight of at least 1,000,000.
Such optional resins can comprise from about 1 to about 20 weight percentof the polymer blend to be isolated.
The post-treatment of the emulsion or blend of emulsions is conducted by contacting the emulsion at a temperature from just above the freezing point to just below the boiling point, but preferably between room temperature and 80° C., with a small amount of an aqueous solution or dispersion of a phosphorus-containing reductant, so that the concentration of the reductant is from about 0.005 to about 0.10 parts per 100 parts of emulsion.
The reductants of the present invention are organic or inorganic compounds which lower the color of the isolated polymer after treatment and do not contribute themselves to color or haze of the resultant product. Preferred as reductants are phosphorous-containing compounds wherein the valence of the phosphorus atom is +3 or +1. The major classes thus included are phosphites (+3) and hypophosphites (+1), but other compounds, such as phosphonites and phosphinites may also be utilized. The components may be organic, such as tris(nonylphenyl phosphite) or may be inorganic, such as hypophosphite salts. For ease of addition, water-soluble materials are preferred. To prevent precipitation of insoluble salts, it is preferred to use salts of the alkali metals or ammonium salts. Especially preferred is sodium hypophosphite.
The impact modifier, singly or combined with the optional resins, may further be blended with emulsion of the matrix polymer for co-isolation, such as by spray-drying, freeze-drying, and the like, and especially by coagulation, such as with salts, acids, methanol, and the like.
Co-isolation in an extruder, wherein the water from the emulsion and coagulative additives is removed as a liquid, as described in Hung, may also be practiced with the emulsion or emulsions treated wit the reductant chemical or chemicals. However, the results obtained, although generally showing some improvement in the optical properties, are inconsistent with the level of reductant used. It may be that color and other optical properties in the extruder-coagulated samples is dominated by other factors which the emulsion post-treatment does not fully address.
The co-blending may also be utilized in aiding the isolation of the relatively soft, rubber-rich additive by spray-drying. Sequential co-blending, such as described in Grandzol et al., U.S. Pat. No. 4,463,131, may be used in coagulation to isolate the impact modifier in a more free-flowing form.
If the impact modifier or impact modifier blend, having been treated with the reductant, is to be isolated and blended with the matrix polymer in the solid state, the matrix being in pelletized form, a powder/pellet dryblend may be fed to a single screw extruder (25 mm diameter; 600 mm screw effective length) in which the dryblend is melted and dispersively mixed. Barrel temperatures from the feed zone to the die zone are in the range 204° C./227° C./243° C.; the die temperature is controlled at about 232° C. The melt is extruded as a strand, cooled in water, and then cut into pellets. An alternative method is to pass the dryblend through a co-rotating intermeshing twin-screw extruder (30 mm diameter; 720 mm effective length of screws), rather than a single screw extruder.
The matrix polymer may be from about 40 to about 90 weight percent of the impact-modified acrylic plastic, and the core/shell polymer or blend containing core/shell polymer from about 10 to about 60 parts. The higher the amount of core/shell polymer, the tougher the impact-modified plastic, but the heat distortion temperature and tensile modulus will be decreased. Preferably the matrix resin will be from about 50 to about 70 parts of the impact-modified plastic.
Optional ingredients may be present in the impact-modified acrylic plastic generally added to the molten matrix polymer. Such ingredients may include toners, dye, pigment, lubricants, ultraviolet stabilizers, thermal stabilizers, and the like.
The impact-modified acrylic plastic may be isolated from the molten stage either by direct processing into a film, sheet, or molded object. Usually, the molten impact-modified acrylic plastic is extruded from the molten stage through a die, stands are formed, cooled, and chopped into pellets, which are subsequently remolded or re-extruded into useful objects.
The resulting impact-modified acrylic plastic may be formed into transparent films useful as overlays, protective coatings for other plastics, capstock, and the like. Thicker sheets may be extruded useful as glazing, picture framing, sun roofs, sky lights, automotive glazing, storm windows, toy parts, vending machine windows, lighting lenses and many other uses requiring high clarity, lack of yellowness, and toughness. The sheets may be treated with appropriate abrasion-resistant coatings, well-known to the art.
The pellets may also be injection- or compression-molded by techniques well-known to the art into useful objects, such as containers, boxes, decorative objects, window scrapers, and the like.
EXAMPLES
The examples are intended to illustrate the present invention and not to limit it except as it is limited by the claims. All percentages are by weight unless otherwise specified, and all reagents are of good commercial quality unless otherwise specified.
Polymers for the following study were generally prepared in emulsion, except where a component was prepared by continuous bulk polymerization, and isolated by various methods described in the specific examples.
Injection molding was conducted on extruded samples. Extrusion was carried out in a 25.4 mm. single-screw extruder with a barrel setting at 227° C., then pelletized. Injection molding was conducted on a Newbury machine with a cycle of 45 seconds. Plaques 50.8 by 76.2 by 3.2 mm. were prepared. Barrel temperatures of ca. 218° C. and mold temperatures of 65° to 82° C. may be employed.
Yellowness index (ASTM D 1925 ), haze (D 1003) and TWLT (D 1746) were measured by well-known methods.
EXAMPLES 1-4
The following examples illustrate the preparation of matrix polymers and of core//shell impact modifiers Matrix Polymer A:A commercial copolymer of methyl methacrylate (MMA) 95.5/ ethyl acrylate (EA) 4.5, weight-average molecular weight ca. 110,000, prepared by continuous bulk polymerization. Contains no toner. (Example 1).
Matrix Polymer B: A copolymer of MMA/EA 96/4, MV 110,000, prepared with sodium persulfate initiator, n-dodecyl mercaptan chain transfer agent, t-dodecyl disulfide as stabilizer, and sodium dodecylbenzene sulfonate as emulsifier. (Example 2).
Impact Modifier Blend C: A three-stage polymer of stage ratio (by weight) MMA/EA/allyl methacrylate (ALMA)=33.5/1.4/0.07//butyl acrylate (BA)/styrene (St)/ALMA=36.3/7.9/0.9// MMA/EA 19.2/0.8, made by the method of Owens, initiated with potassium persulfate and stabilized with potassium dodecylbenzene sulfonate. (Example 3).
Impact Modifier Blend D: The emulsifier of impact modifier C (84 parts on a solids basis) is blended with 10 parts of the emulsion of matrix polymer B and 6 parts of a high molecular weight methyl methacrylate/ethyl acrylate polymer prepared with sodium lauryl sulfate as emulsifier and sodium persulfate as initiator (Example 4).
EXPERIMENT 5
This experiment demonstrates the effect of phosphorus-based reductants on the impact modifier of Example 3. To the portions of the emulsion were added various levels of potential reductants. Samples were added as a 1% aqueous solution, with 0.5% sodium dodecylbenzene sulfonated added to disperse the organic additives. The sample was then dried in air at 110° C., then exposed to a 220° C. oven in air for 20 minutes, and the samples visually checked for appearance. Siponate DS-4, sodium dodecylbenzenesulfonate emulsifier at levels up to 0.2% additional had little or no effect on color. Sodium sulfite, a known reductant, but not based on phosphorus, showed some color reduction at the 0.2% level, but was ineffective at lower levels. Naugard PHR, tri(nonylphenylphosphite), showed some color reduction at the 0.05,0.1, and 0.2% levels. Hypophosphorus acid showed strong color reduction at all three levels, as did sodium hypophosphorus.
EXAMPLE 6
This example demonstrates the effect of the phosphorus-based reductant on the color of molded pieces. Here equal weights (solids basis) of the latex of Examples 2 and 4 were blended, the reductant added, the mixture freeze-dried, the impact-modified acrylic blend extruded, pelletized and injection molded into plaques. The level of reductant is calculated on a solids/solids basis. In the tables, NaH2PO2 is sodium hypophosphite, TNPP is tris(nonylphenyl phosphite), YI is yellowness index and TWLT is total white light on 3.18 mm. plaques. In this test, TNPP was less effective than sodium hypophosphite.
______________________________________Additive level, % YI % haze % TWLT______________________________________none (control) -- 5.2 2.4 91.2NaH.sub.2 PO.sub.2 0.025 3.7 2.3 91.7 0.05 3.6 2.4 91.7 0.10 3.1 2.9 91.0TNPP 0.05 5.9 2.4 90.3 0.10 5.8 2.5 90.6______________________________________
EXAMPLE 7
To demonstrate the effect of the reductant on treatment of the impact modifier which is then blended with a bulk-prepared matrix polymer, the latex blend of Example 4 was treated with the reductant prior to spray-drying at an inlet/outlet temperature of 150° C./50° C. The spray-dried powder was blended with an equal weight of the pellets of the polymer of Example 1, extruded into pellets, and the pellets compression molded as in Example 9.
______________________________________Additive level, % YI YI-2______________________________________none (control) -- 4.44 4.58NaH.sub.2 PO.sub.2 0.025 1.97 1.83 0.05 1.94 1.89 0.10 2.02 2.00TNPP 0.05 3.05 2.04 0.10 2.94 2.98______________________________________
EXAMPLE 8
This example demonstrates the effect of lower levels of the reductant on the injection molded impact-modified acrylic plastic. The emulsion of Example 4 was treated with various reductants, freeze-dried, blended with an equal amount of the polymer of Example 1, extruded into pellets, and injection molded into 3.18 mm. plaques which are measured by Hunter colorimeter. Here Ca(H 2 PO 2 ) 2 hypophosphite and H 3 PO 2 hypophosphorus acid.
______________________________________Additive level, % YI % haze % TWLT______________________________________none (control) -- 3.60 2.14 91.6NaH.sub.2 PO.sub.2 0.005 2.51 2.54 91.9 0.015 1.69 1.96 92.5 0.025 2.00 2.96 91.7Ca(H.sub.2 PO.sub.2).sub.2 0.025 1.54 2.01 92.7H.sub.3 PO.sub.2 0.025 2.10 2.00 92.5______________________________________
EXAMPLE 9-10
This example illustrates that sodium hypophosphite can be added to the isolated impact modifier to reduce color when the impact modifier is then blended with the matrix resin and processed.
The impact modifier of Example 4, in the form of a spray-dried powder, was blended with an equal weight of a commercial methyl methacrylate/ethyl acrylate copolymer containing no toner and various levels of sodium hypophosphite; the amounts are in parts per million of the total polymer weight. The blends were then extruded in a single screw extruder at 232° C. and 80 rpm through a pelletizing dye, the resulting strand cooled, and pellets preparing by chopping the strand. After drying the pellets were compression molded into plaques at 226° C. under pressure in a Carver press. The plaques were 3.2 mm. thick, and optical properties were measured as above.
______________________________________ Sodium hypophosphite, YellownessExample ppm Index______________________________________9a 0 (control) 2.579b 50 2.059c 100 1.929d 200 1.80______________________________________
In a similar manner, sodium hypophosphite was dry-blended with a commercial acrylic molding resin of similar molecular weight but containing only about 0.5% ethyl acrylate and with an impact modifier which contained no high molecular weight acrylic polymer. The weight ratio of matrix to modifier was 1:1. A similar improvement in color was observed.
______________________________________ Sodium hypophosphite, YellownessExample ppm Index______________________________________10a 0 (control) 1.8610b 50 1.6410c 100 1.4410d 200 1.41______________________________________
While the invention has been described with reference to specific examples and applications, other modifications and uses for the invention will be apparent to those skilled in the art without departing from the spirit and scope of the invention defined in the appended claims. | Plastics prepared from blends of polymers of methyl methacrylate with heterogeneous core/shell polymers having an poly(alkyl acrylate) core and a poly(alkyl methacrylate)shell exhibit improved color when the heterogeneous core/shell polymer is treated with a reducing agent. | 2 |
BACKGROUND ART
1. Field of the Invention
The invention relates to an exterior rear view mirror for vehicles. More particularly, the invention relates to an exterior rear view mirror with an attachment secured thereto.
2. Description of the Related Art
It is a known practice to provide signal, peripheral, or indicator lights on the exterior rear view mirror. They are either provided in the mirror housing or in the mirror foot. Many of these systems are completely integrated into the mirror housing. This design incorporation allows for a sleeker profile and good moisture sealing qualities. This type of combination does, however, render it difficult to change out light units that fail prematurely. Sonic welds and bonding materials need to be severed to access the light unit in order to service it.
SUMMARY OF THE INVENTION
An external rearview mirror assembly is designed for a motor vehicle. The external rearview mirror assembly includes a mirror housing. A mirror glass carrier is operatively connected to the mirror housing. A piece of mirror glass is fixedly secured to the mirror glass carrier and is movable with respect to the mirror housing. The mirror glass defines a peripheral edge. An attaching part is fixedly secured to the mirror glass carrier wherein the attachment part extends about a portion of the peripheral edge.
BRIEF DESCRIPTION OF THE DRAWINGS
Advantages of the invention will be readily appreciated as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings, wherein:
FIG. 1 is an exploded side view of one embodiment of the invention;
FIG. 2 is an exploded side view of a second embodiment of the invention;
FIG. 3 is a cross-sectional side view taken along the line III-III in FIG. 2 with the attaching part mounted;
FIG. 4 is an enlarged representation a part of an additional form of embodiment of an exterior rear view mirror according to the invention in a section corresponding to FIG. 3 ;
FIGS. 5 and 6 are cross-sectional side views of alternative embodiments of the invention; and
FIG. 7 is a view in the direction of the arrow X in FIG. 6 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The exterior rear view mirror 1 , represented in simplified form in FIG. 1 , is provided for motor vehicles. It includes in a known manner a housing (not represented) in which a mirror glass carrier (also not represented) is disposed which carries a mirror glass 2 formed as EC or normal glass. The exterior rear view mirror 1 also includes an encircling mirror glass frame 3 . It is, however, also possible to form the mirror glass without a frame ( FIG. 3 ). As is represented in FIG. 1 , the mirror glass frame 3 includes in a relatively narrow edge area.
The mirror glass frame 3 defines an insertion opening 4 for a push-in module, or attaching part, 5 which can be pushed into the recess in the direction of the arrow P and engagable with a catch formed therein. The attaching part 5 can be a modular indicator, signal, or peripheral light. It includes a housing 6 in which a circuit board 7 with electrical/electronic components 8 and one or more light sources 23 is disposed. The light sources 23 are preferably formed by LEDs. They can also be incandescent lamps or the like which are disposed on the circuit board. The circuit board 7 can, in a known manner, be formed to be rigid or as a flexible foil. As is still to be described in the following, the light emitted by the light source 23 exits via at least one light exit surface of the module housing 6 above the mirror glass 2 . The light exit surface being formed as a light plate 9 , so that the light emitted from the attaching part 5 , which has the function of a display, can be seen clearly by the driver of the motor vehicle. If the attaching part 5 has no display function, e.g., serves as a blinking light or as a peripheral light, it is not necessary that the driver sees the light emitted by the attaching part 5 .
Since the light source 23 is integrated into the mirror glass frame 3 , it needs only a little mounting space. And, along with the attaching part 5 , if the light source 23 and/or the attaching part 5 is damaged or if, for example, it is supposed to be replaced by another attaching part of a desired color, the attaching part 5 can be taken out of the insertion opening 4 simply and quickly at any time, and then another component can be pushed in the direction of the plug-in arrow P into the insertion opening 4 , until it is disposed in a form-locking manner on the frame 3 .
In this position, the circuit board 7 lies with the components 8 below the mirror glass 2 (cf. the dashed lines in FIG. 1 ) and is engaged so as to catch there, as is still to be described with the aid of the additional forms of embodiment. If a LED is used as the light source, it can be formed so that it also forms a light plate. In this instance, the light plate as a separate structure could be omitted.
The housing 6 has a flat base 51 on which the circuit board 7 lies. The base 51 is formed so as to be approximately rectangular. The two longitudinal edges 52 , 53 of the base 51 extend in the longitudinal plug-in direction P. Contacts 55 extend over the front, in the plug-in direction P, edge 54 of the base 51 . Upon insertion of the push-in part 5 , the contacts 55 engage counter contacts (not represented).
On the opposite edge 56 , an edge section 57 stands out from the base 51 , the edge section of which being shaped and formed so that it forms, in the mounted position of the push-in module 5 , a continuous continuation of the mirror glass frame 3 in the area of the push-in opening 4 . More specifically, the edge section has the same contour as the mirror glass frame 3 .
The edge section 57 has a side wall 58 which connects approximately perpendicularly to the base 51 and at a distance from the base 51 turns into a roof-like upper part 59 under which the light sources 23 are located. The upper part 59 can terminate a light plate (not represented) which reaches, in the mounted position of the push-in module 5 , up to the mirror glass 2 and through which the light emitted by the light sources 23 exits to the outside.
The base 51 comprises near to the edge 54 on each of its two longitudinal edges 52 , 53 a catch 60 , 61 with which the push-in module 5 , in the mounted position, engages so as to catch in counter catch elements of the mirror glass carrier.
If no display function is required, or this is not desired, merely a blind part can also be used instead of the attaching part 5 . The blind part includes no circuit board and no light source. This blind part has essentially the same form as the attaching part 5 so that, for a form-locking complementation of the mirror glass frame 3 , it can be pushed into the insertion opening 4 and engaged so as to catch there. The blind part, which needs no LED, is advantageously lower than the attaching part 5 so that it has the same height as the mirror glass frame 3 . If necessary, the blind part can be replaced at any time with an attaching module 5 with electrical/electronic components 8 and/or light sources 23 so that the exterior rear view mirror 1 can be used, depending on the attaching part used, for the most varied functions. The components 8 and the light sources 23 are disposed on the circuit board 7 in a known manner and connected to it.
The form of embodiment according to FIGS. 2 and 3 is distinguished from the previously described embodiment essentially by the fact that the attaching part 5 is not plugged into an insertion opening of the mirror glass frame 3 . Rather, the attachment part 5 is plugged onto an edge 11 of the mirror glass carrier plate 10 . It is bent approximately perpendicularly ( FIG. 3 ) and encircles the mirror glass 2 held on the carrier plate 10 . In this form of embodiment, an EC glass can be used. The EC glass may be glued on the edge side to the carrier plate 11 , whereby the is prevented from running out of the exterior rear view mirror 1 during manufacture. Obviously, a normal, economical glass can be used instead of the EC glass.
The attaching part 5 is plugged or clipped on the edge 11 of the mirror glass carrier plate 10 . The mirror glass 2 is formed without an edge as a plane plate and advantageously lies, with the interposition of a heating foil 12 , on the mirror glass carrier plate 10 . At the connecting point for the attaching part 5 , the mirror glass carrier plate 10 includes a mounting bracket 26 projecting downwardly over the plane of its plate. The mounting bracket includes, for the catch element, a receiving space 31 into which, in the mounted position of the attaching part 5 , at least one catch element 32 of the housing 6 projects. The catch element 32 is provided on the base 51 of the housing 6 . The base in the mounted position is approximately flush with the mirror glass carrier plate 10 . On the base 51 , the circuit board 7 is disposed with electrical/electronic components 8 and the light sources 23 .
The circuit board 7 is provided at its edge facing towards the side wall 58 of the housing 6 with an upwardly directed leg 20 which extends approximately parallel to the side wall 58 and ends at a distance from the upper part 59 of the housing 6 . Between the free end of the upper part 59 of the housing and the mirror glass 2 the light plate 9 extends over the width of the push-in module 5 , behind which the light sources 23 are located. The light plate 9 can be omitted if the light sources 23 are formed as a correspondingly shaped LED, which then serves as a light plate. The light sources 23 sit on the leg 20 of the circuit board on the side facing towards the light plate 9 . According to the previous form of embodiment, the light sources 23 are advantageously formed by at least one LED which emits its light in the area above the mirror glass carrier 2 through the light plate 9 .
Between the front, in the plug-in direction P, edge 15 of the mounting bracket 26 and a neighboring edge 14 of the mirror glass carrier plate 10 , a gap 16 is formed through which at least one line 19 projects. The line 19 provides the current/voltage supply to the components seated on the circuit board 7 . It is, however, also possible in the exterior rear view mirror 1 to provide a plug-on connector strip (not represented) into which the plug-in contacts 55 of the circuit board 7 engage. In this way the current/voltage supply for the components 8 and the light sources 23 of the push-in module 5 is produced automatically in the plug-in process, as in the previous form of embodiment.
The push-in module 5 is reliably held in the mounted position as a consequence of the catch connection described. The light plate 9 advantageously lies with its edge on the mirror glass 2 so that protection against the penetration of dirt, moisture, and the like into the push-in module 5 is, at least substantially, prevented.
The upper part 59 of the housing is formed in plan view in the form of a sickle ( FIG. 2 ) and thus approximately adapted to the form of the edge 11 of the mirror glass carrier plate 10 . The sickle form has the advantage that the light emitted by the light sources 23 in the case of indicator functions of the attaching part 5 is deflected at least partially in the direction towards the driver side of the motor vehicle.
As in the previous embodiment example, the push-in module 5 is disposed at an edge area of the exterior rear view mirror 1 , specifically the edge area lying furthest removed from the motor vehicle. In other words, the attaching part 5 is secured to the exterior rear view mirror 1 at its outboard surface. Therefore, the light emitted from the light sources 23 can be seen clearly by the driver of the motor vehicle.
In the mounted position, the mounting bracket 26 lies with its leg 24 flat on a side of the base 51 , specifically that side facing away from the mirror glass carrier plate 10 . The push-in module 5 is supported securely thereby.
If necessary, the catch connection can be released in a simple manner and the push-in module 5 can be withdrawn.
In the embodiment example according to FIG. 4 , the mirror glass 2 lies, with the interposition of the heating foil 12 , on the mirror glass carrier plate 10 . It has the edge 11 which is beveled in a rounded manner and encircles the mirror glass 2 at a slight distance from it. On the side facing away from the mirror glass 2 , the mirror glass carrier plate 10 is provided on the edge side with the mounting bracket 26 , which is formed according to the previous form of embodiment as one piece with the mirror glass carrier plate 10 . In contradistinction to the previous embodiment example, the mounting bracket 26 is not formed to be U-shaped but rather to be L-shaped. Its short leg 29 connects to the mirror glass carrier plate 10 at a right angle. The longer leg 28 lies at a distance from the mirror glass carrier plate 10 and parallel to it. The leg 28 reaches approximately up to the level of the edge 11 of the mirror glass carrier plate 10 .
The leg 28 of the mounting bracket 26 is provided with a catch opening 62 into which the catch element 32 of the push-in module 5 engages. It has the flat base 51 on whose side facing away from the mirror glass 2 the catch element 32 is provided. Corresponding to the previous embodiment examples, the catch element 32 is advantageously formed as one piece with the base 51 .
The base 51 turns through the form of an arc into the side wall 58 , which runs perpendicular to the base 51 and in the form of an arc into the upper part 59 of the housing. It extends at a distance from the mirror glass 2 beyond its edge. Between the free edge of the upper part 59 of the housing and the mirror glass 2 , the light plate 9 extends over the width of the push-in module 5 . Its inner side 22 facing toward the light sources 23 advantageously lies in a plane with the edge 2 a of the mirror glass 2 .
The edge 11 of the mirror glass carrier plate 10 extends up to the level of the outer side of the mirror glass and, as in the previous embodiment example, is projected over by the housing 6 of the push-in module 5 . The light source 23 is located in the area between the edge 11 of the mirror glass carrier plate 10 and the upper part 59 of the housing. The light source 23 is advantageously formed by at least one LED. It sits on the circuit board leg 20 , which has a slight spacing from the rear wall 58 of the housing and extends up to the upper part 59 of the housing. The circuit board 7 with the components 8 is fastened on the base 51 . The components 8 lie at a sufficient distance from the mirror glass carrier plate 10 .
On the circuit board 7 , plug-in contacts 55 are provided which extend in the plug-in direction P of the push-in module 5 beyond the base 51 . When pushing on the push-in module 5 , the plug-in contacts 55 reach into push-through openings 30 in the leg 29 of the mounting bracket 26 . During mounting, the push-in module 5 is guided with its base 51 on the leg 28 of the mounting bracket 26 so that the plug-in contacts 55 reach reliably into the push-through openings 30 . Behind the leg 29 , a plug-in connector jack 25 is located, in which the plug-in contacts 55 engage and which ensure the current/voltage supply of the components 8 and the light sources 23 of the circuit board 7 .
The mounting bracket 26 can be formed so that it extends over the entire circumference of the mirror glass carrier plate 10 , therefore the legs 29 are formed as a ring and the legs 28 as an annular disk. In such a case the push-in module 5 can be mounted at any point of the edge 11 .
In the form of embodiment according to FIG. 5 the attaching part 5 is fastened to the frame 3 of an EC mirror glass 2 . The frame 3 has an approximately L-shaped cross section and lies with its free end 13 on the EC glass 2 . As in the previous embodiment examples, it is, with the interposition of a heating foil 12 , fastened to the mirror glass carrier plate 10 . Its edge 21 is set back relative to the edge 14 of the mirror glass 2 . The heating foil 12 projects over the mirror glass carrier plate 10 and extends up to near the edge 14 of the mirror glass 2 .
To the underside of the mirror glass carrier plate 10 , the base 51 of the module housing 6 is fastened in some manner, such as gluing, welding, or engaging with a catch. For this, the base 51 has an approximately z-shaped edge 15 slanted outwards, which with its free edge 16 lies flat on the mirror glass carrier plate 10 . The push-through opening 30 for the plug-in contacts 55 is disposed near to the edge 15 the base 51 . It carries the electronic components 8 and, in the area of the rear wall 58 of the housing 6 , the light sources 23 .
The circuit board 7 lies on the base 51 of the housing 6 and extends up to the housing's side wall 58 , which runs in the form of a curve approximately in the area above the EC mirror glass 2 and extends up to beyond the edge 3 of the EC mirror glass 2 . Between the housing's side wall 58 and the frame 3 , at least one light conductor or wave guide 42 is disposed, which extends from the light sources 23 up to the free edge 43 of the housing's side wall 58 . As stated above, a specially formed LED can be provided instead of the light conductor 42 .
The light emitted from the light sources 23 enters the light conductor 42 , which conducts the light up to the light exit surface 42 ′. It lies at the level of the free edge 43 of the housing's side wall 58 and in the area of the highest point of the mirror glass edge 3 . The light shines, as in the previous embodiment examples, approximately parallel to the mirror glass's outer side in the direction towards the driver side of the motor vehicle.
The mirror glass edge 3 is not formed thinner at the point at which the attaching part 5 is supposed to be mounted. The attaching part 5 is formed so that to the light exit surface 42 ′ lies above the frame 3 . With this configuration, the attaching part 5 can be mounted in a simple manner at any desired point of the frame 3 .
In the embodiment example 1 according to FIGS. 6 and 7 , the push-in module 5 is engaged in such a manner that it catches on the mirror glass carrier plate 10 . It has the U-shaped mounting bracket 26 , on whose leg 24 the push-in module 5 is engaged in such a manner that it catches with at least one hook-like catch element 32 . It is formed as one piece with the base 51 of the module housing 6 and provided at the edge 15 of the housing base 51 and at a right angle in the direction of the mirror glass carrier plate 10 .
The edge 15 is provided with at least one push-through opening 36 for the plug-in contacts 55 of the circuit board. The components 8 are provided on a side of the circuit board 7 , specifically the side 7 facing away from the EC mirror glass 2 , in contradistinction to the previous embodiment examples. The circuit board 7 extends through a plane and lies at a distance from the mirror glass carrier plate 10 and the base 51 of the housing 6 .
The housing base 51 connects, via an edge 37 with a z-shaped cross section, to the housing's side wall 58 . It has an opening 63 into which the edge 37 projects with its free end 45 ′. The side wall 58 turns into the upper part 59 of the housing, said upper part lying at a distance from the EC mirror glass 2 . An edge 3 which is L-shaped in cross section engages over the upper part.
Near to an edge of the circuit board 7 , specifically the edge neighboring the housing's side wall 58 , the light source 23 is fastened with contact feet 38 . The light source 23 is disposed in the area between the housing's side wall 58 and the frame 3 of the EC mirror glass 2 . The light source 23 connects to the light conductor 42 which extends between the housing's side wall 58 and the housing's upper part 59 as well as the frame 3 of the EC mirror glass 2 . At the level of the free end of the housing's upper part 59 the light conductor 42 is provided with an edge section 44 extending perpendicularly from the EC mirror glass 2 . The edge section lying with its plane front side 45 directly abutting the frame 3 on the EC mirror glass 2 . Through the plane light exit surface 48 of the edge section 44 , the light exit surface lying perpendicular to the EC mirror glass 2 , the light emitted by the light source 23 and conducted further in the light conductor 42 exits in the direction of the driver side of the motor vehicle.
The EC mirror glass 2 lies, with the interposition of the heating foil 12 , on the carrier plate 10 .
As FIG. 7 shows, two light sources are housed in the housing 6 , where the light beams emitted by said lighting means and exiting from the light exit surface 45 can be seen.
The mirror head and/or the mirror foot of the exterior rear view mirror 1 can include additional elements, such as blinking lights, a camera, a GPS module, a washing unit for the mirror glass, a loudspeaker, an antenna, a part of the garage door opener, and the like. These elements can be provided in any combinations with one another in addition to the attaching part 5 .
The invention has been described in an illustrative manner. It is to be understood that the terminology, which has been used, is intended to be in the nature of words of description rather than of limitation.
Many modifications and variations of the invention are possible in light of the above teachings. Therefore, within the scope of the appended claims, the invention may be practiced other than as specifically described. | An external rearview mirror assembly is designed for a motor vehicle. The external rearview mirror assembly includes a mirror housing. A mirror glass carrier is operatively connected to the mirror housing. A piece of mirror glass is fixedly secured to the mirror glass carrier and is movable with respect to the mirror housing. The mirror glass defines a peripheral edge. An attaching part is fixedly secured to the mirror glass carrier wherein the attachment part extends about a portion of the peripheral edge. | 1 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of PCT Application PCT/EP2015/075458, filed Nov. 2, 2015, which claims priority to German Application DE 10 2014 222 396.2, filed Nov. 3, 2014. The disclosures of the above applications are incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The invention relates to a positive displacement pump, in particular for conveying oil in a gearbox or a combustion engine of a motor vehicle, having a pump stage that is driven by a drive unit, having a suction port for introducing oil and a pressure port for delivering oil and having a switchover device for creating two operating stages.
BACKGROUND OF THE INVENTION
[0003] Such positive displacement pumps are used in modern-day motor vehicles, for example for conveying lubricating oil in the combustion engine or gear oil in the gearbox, and are known from practice. The areas of application mostly have different design points; however, these design points are achieved by means of corresponding operating stages of the pump stage and of the drive unit. The design points relate in particular to a small conveying quantity at high pressure or a large conveying quantity at low pressure, according to the operating state of the gearbox or of the combustion engine.
[0004] A positive displacement pump has become known from DE 36 14 819 C2, in which a supply is provided to a high-pressure circuit and a low-pressure circuit by means of a divided kidney-shaped pressure cavity. The pump stage also has two pump chambers separated by a center wall.
SUMMARY OF THE INVENTION
[0005] The invention is based on the problem of designing a positive displacement pump of the type initially mentioned so that it has a particularly compact structure.
[0006] This problem is solved according to the invention by virtue of the fact that the suction port is connected to a central kidney-shaped suction cavity and the pressure port is connected to two kidney-shaped pressure cavities according to the selected operating stage.
[0007] This configuration allows the suction and kidney-shaped pressure cavities to be arranged on one side of the housing. The positive displacement pump is thus particularly compact. The position and size of the kidney-shaped pressure cavities is adapted to the desired conveying volumes and conveying pressures of the intended design points. By connecting the respective kidney-shaped pressure cavity to the single pressure port, the operating stage that is appropriate to the design point is selected. The rotational speed and the torque of the drive unit may thus be adapted to the operating stages in a simple manner and the degree of efficiency is increased.
[0008] According to another advantageous refinement of the invention, the switchover device is particularly simple if the switchover device is connected to the drive unit for the purpose of selectively controlling the drive direction of the pump stage. This configuration allows the operating stages to be established by the direction of rotation of the drive unit. In the simplest case, the switchover device requires switches for setting the polarity of an electric motor of the drive unit.
[0009] According to another advantageous refinement of the invention, the control of the flow from the kidney-shaped pressure cavities to the pressure port is particularly simple if the two kidney-shaped pressure cavities are connected to the single pressure port via check valves.
[0010] According to another advantageous refinement of the invention, pressure equalization of the kidney-shaped pressure cavity not used in the respective operating stage with the environment is ensured in a simple manner if the two kidney-shaped pressure cavities are connected to the suction port via check valves. The check valves connecting the kidney-shaped pressure cavities to the suction port are aligned in such a manner that, in case of negative pressure in the kidney-shaped pressure cavity, oil may flow in.
[0011] According to another advantageous refinement of the invention, the constructional complexity for connecting the pressure port to the selected kidney-shaped pressure cavity is kept particularly low if the switchover device is designed for connecting the pressure port to one or the other of the kidney-shaped pressure cavities.
[0012] According to another advantageous refinement of the invention, a large number of check valves is avoided in a simple manner if a multi-directional valve is connected downstream of the pump stage and if the switchover device is designed for activating the multi-directional valve, so that a selective connection of one kidney-shaped pressure cavity or the other kidney-shaped pressure cavity to the pressure port is established. As a result of this, the number of components susceptible to faults is kept low. It is simultaneously ensured that in each case only the intended kidney-shaped pressure cavity is connected to the pressure port. A further advantage of this configuration is that the positive displacement pump is consequently of particularly compact structure. In the case of a positive displacement pump intended for conveying oil in a gearbox of the motor vehicle, the multi-directional valve may, in the simplest case, be arranged in a gearbox control system that is present anyway. As a result of this, the installation space required for the positive displacement pump is kept particularly small.
[0013] According to another advantageous refinement of the invention, pressure equalization of the kidney-shaped pressure cavity not used in the respective operating stage with the environment is realized in a simple manner, when using a multi-directional valve, if the multi-directional valve has two switching stages, wherein the switching stages are configured for connecting the suction port to the kidney-shaped pressure cavity not used in the respective operating stage.
[0014] According to another advantageous refinement of the invention, a drop in the oil pressure in the gearbox or the combustion engine, with the positive displacement pump switched off, is avoided in a simple manner if the multi-directional valve has a switching stage in which the pressure port is shut off.
[0015] According to another advantageous refinement of the invention, in case of use in a motor vehicle, the positive displacement pump has a long service life if the pump stage is designed as an internal gear pump or as a G-rotor pump. Of course, it is also possible for two pump stages arranged in parallel to be able to be driven by a single drive unit.
[0016] According to another advantageous refinement of the invention, differing conveying volumes and conveying pressures is established in a simple manner in the operating stages if a separation region between the kidney-shaped suction cavity and one of the kidney-shaped pressure cavities, in the case of the pump stage designed as an internal gear pump, is arranged inside the region of maximum eccentricity between an inner rotor and an outer rotor and another separation region of the kidney-shaped suction cavity and the other of the kidney-shaped pressure cavities is arranged outside the region of maximum eccentricity.
[0017] Further areas of applicability of the present invention will become apparent from the detailed description provided hereinafter. It should be understood that the detailed description and specific examples, while indicating the preferred embodiment of the invention, are intended for purposes of illustration only and are not intended to limit the scope of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] The invention permits numerous embodiments. For the purpose of further clarifying its basic principle, several of the embodiments are illustrated in the drawing and are described below. The present invention will become more fully understood from the detailed description and the accompanying drawings, wherein:
[0019] FIG. 1 is a diagrammatic illustration of a positive displacement pump, according to embodiments of the present invention;
[0020] FIG. 2 is a sectional view of a pump stage with adjacent regions of a positive displacement pump, according to embodiments of the present invention;
[0021] FIG. 3 is a sectional view of an alternate embodiment of a pump stage with adjacent regions of a positive displacement pump, according to embodiments of the present invention; and
[0022] FIGS. 4 a -4 c are sectional views of various switching positions of a multi-directional valve used as part of a pump stage of a positive displacement pump, according to embodiments of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0023] The following description of the preferred embodiment(s) is merely exemplary in nature and is in no way intended to limit the invention, its application, or uses.
[0024] FIG. 1 diagrammatically shows a positive displacement pump 1 having a motorized drive unit 2 and a pump stage 3 . The motorized drive unit 2 is connected to a switchover device 4 and selectively drives the pump stage 3 in one or the other direction of rotation. The positive displacement pump 1 has a suction port 5 , via which oil is sucked in from a tank 6 or an oil pan, and a pressure port 7 , via which oil is conveyed to a consumer (not shown), such as lubrication points of a combustion engine or of a gearbox of a motor vehicle. The pump stage 3 is connected to the pressure port 7 and to the suction port 5 via a total of four check valves 8 - 11 .
[0025] As FIG. 2 diagrammatically shows in a sectional illustration, the pump stage 3 from FIG. 1 has two kidney-shaped pressure cavities 12 , 13 and one central kidney-shaped suction cavity 14 . Oil is sucked in via the kidney-shaped suction cavity 14 in both directions of rotation of the pump stage 3 . The kidney-shaped pressure cavities 12 , 13 are connected to the pressure port 7 via two of the check valves 8 , 9 . Furthermore, the kidney-shaped pressure cavities 12 , 13 are connected to the suction port 5 via the further check valves 10 , 11 . The pump stage 3 is designed as an internal gear pump and has an inner rotor 15 and an outer rotor 16 . The kidney-shaped suction cavity 14 and the kidney-shaped pressure cavities 12 , 13 are arranged in a housing 17 that seals off the front faces of the rotors.
[0026] In the case of a rotation of the inner rotor 15 , as a result of a corresponding current feed to the drive unit 2 , in the anticlockwise direction, oil is sucked in from the tank 6 or the oil pan via the central kidney-shaped suction cavity 14 and conveyed to the pressure port 7 via the kidney-shaped pressure cavity 12 illustrated on the left in the diagram.
[0027] In case of negative pressure, the kidney-shaped pressure cavity 13 illustrated on the right in the diagram also sucks in oil from the suction port 5 and thus complements the function of the kidney-shaped suction cavity 14 . The connection of the kidney-shaped pressure cavities 12 , 13 to the suction port 5 or the pressure port 7 is realized via the check valves 8 - 11 . In case of the inner rotor 15 being driven in the clockwise direction, the oil is conveyed to the pressure port 7 via the kidney-shaped pressure cavity 13 illustrated on the right in the diagram. FIG. 2 furthermore shows that the pump stage 3 has separation regions t 1 , t 2 of differing sizes between the common kidney-shaped suction cavity 14 and the kidney-shaped pressure cavities 12 , 13 that are used, according to the selected direction of rotation. The kidney-shaped suction cavity 14 is arranged outside the region of maximum eccentricity of the pump stage 3 . Consequently, one of the separation regions t 1 is arranged in the region of maximum eccentricity and the other of the separation regions t 2 is arranged outside the maximum eccentricity. Additionally, the kidney-shaped pressure cavities 12 , 13 have differing dimensions, so that the pump stage 3 has differing conveying pressures and conveying volumes according to the kidney-shaped pressure cavity 12 , 13 that is used for conveying.
[0028] FIG. 3 diagrammatically shows a further embodiment of a pump stage 18 , which differs from the embodiment of FIG. 2 only in that a multi-directional valve 19 is provided for controlling two kidney-shaped pressure cavities 20 , 21 with the suction port 23 and with the pressure port 24 . One kidney-shaped suction cavity 22 is, as in the case of the embodiment according to FIG. 2 , connected to the suction port 23 without control. Control lines for controlling the multi-directional valve are illustrated in dotted form in the drawing, via which lines the position of the multi-directional valve 19 is controlled according to the direction of rotation of the pump stage 18 . Alternatively, the multi-directional valve 19 may be connected to the switchover device 4 illustrated in FIG. 1 and is activated at the same time as the switchover of the direction of rotation of the pump stage 18 .
[0029] The multi-directional valve 19 has three switching positions, wherein one of the switching positions shuts off the kidney-shaped pressure cavities 20 , 21 and the pressure port 24 .
[0030] FIGS. 4 a to 4 c show a multi-directional valve 25 which, for example, is used in the embodiment according to FIG. 3 and has a valve body 26 and a valve housing 27 . The multi-directional valve 25 respectively has a port 28 , 29 which is led to a kidney-shaped pressure cavity, a suction port 30 and two pressure ports 31 . In the middle position illustrated in FIG. 4 a , all ports 28 - 31 are closed. In FIGS. 4 b and 4 c , one or the other of the ports 28 , 29 that is led to the kidney-shaped pressure cavities is selectively connected to the pressure port 31 . At the same time, the port 29 , 28 not used for conveying oil in each case is connected to the suction port 30 . Spring elements 32 , 33 preload the multi-directional valve 25 into the middle position illustrated in FIG. 4 a . The position of the valve body 26 may, for example, be controlled by the switchover device 4 by means of an electromagnet (not shown). Control lines 34 , 35 are provided for controlling the multi-directional valve 25 , via which lines the position of the multi-directional valve 19 is controlled according to the direction of rotation of the pump stage 18 .
[0031] The description of the invention is merely exemplary in nature and, thus, variations that do not depart from the gist of the invention are intended to be within the scope of the invention. Such variations are not to be regarded as a departure from the spirit and scope of the invention. | A positive displacement pump for pumping oil in a motor vehicle transmission comprises a pump stage that has a central kidney-shaped suction cavity and two kidney-shaped pressure cavities. Oil is selectively pumped via one kidney-shaped pressure cavity or the other kidney-shaped pressure cavity in accordance with the direction of rotation of the pump stage. This makes it possible to create, with little complexity, two operating stages for the positive displacement pump. | 5 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a high activity titanium trichloride catalytic component which is advantageously usable in the manufacture of highly stereospecific α-olefin polymers and also to a method of homo- or co-polymerization of α-olefin in which a highly crystalline polymer can be advantageously manufactured in the presence of said catalytic component and an organo-aluminum compound. More specifically stated, the invention relates to an α-olefin polymerizing titanium trichloride catalytic component which is prepared by precipitating said catalytic component from a solution prepared by dissolving titanium tetrachloride, an organic ether compound and an organo-aluminum compound having the generic formula AIR n X 3-n (wherein R is an alkyl group having a carbon number of 1 to 10 (i.e., 1 to 10 carbon atoms), X is a halogen or hydrogen atom and n is a real number of 0<n≦3), in a solvent comprising an aliphatic hydrocarbon and/or alicyclic hydrocarbon. The organo-aluminum compound is added at a solvent temperature of 55° C. or lower in the concomitant presence of an aromatic hydrocarbon halide and, following this, the solvent temperature is adjusted to between 45° and 150° C. over a period of time 10 minutes to 24 hours to obtain the titanium trichloride catalytic component having an uniformed particle diameter between 10 and 1000μ. This invention also relates to a method for carrying out homo- or co-polymerization of α-olefins in the presence of a catalyst system comprising the titanium trichloride catalytic component and an organo-aluminum compound.
It is the most important feature of the invention that the average particle diameter of the titanium trichloride catalytic component which is precipitated from solution in accordance with the invention is adjustable within the wide range from 10 to 1000μ as desired and that the catalytic component thus obtained is highly active when it is used for the polymerization of α-olefins. In addition, polymers of extremely uniform particle diameter can be obtained by carrying out homo- or co-polymerization of α-olefins with a catalyst which is prepared using this catalytic component in combination with an organo-aluminum compound. In case of α-olefin polymers prepared in accordance with the method of this invention, the deashing process and the washing process which are normally considered indispensable in the manufacture of an α-olefin polymer can be either omitted or simplified. Further, in accordance with this invention, a pelletizing process can also be omitted.
2. Description of the Prior Art
Nowadays, a catalytic component usable for α-olefin polymerization is required (a) to have a polymerizing activity sufficiently high to permit omission of the deashing and washing processes for removal of catalyst residue and non-stereospecific polymer from the polymer produced, (b) to have a high productivity for a stereospecific polymer and (c) to ensure that the catalytic component and the polymer produced therewith have a suitable particle diameter and a uniform particle size. The reason for such requirements lies in the fact that the catalytic components and the polymer products of conventional methods are obtained in a powdery state having uneven particle sizes which makes separating, drying and transporting them difficult. This has caused trouble in the manufacturing operations and has lowered industrial productivity.
It is also desired that a catalyst or catalytic component permits omission of a pelletizing process in the manufacture of an α-olefin. In an α-olefin polymer manufacturing plant using a titanium trichloride catalytic component which is obtained by a conventional method, the powdery polymer obtained is dried and pelletized for melting kneading, extruding and molding before it is shipped as polymer product for use in molding processes. At such an α-olefin polymer manufacturing plant, the pelletizing process is expensive and consumes a great amount of energy. Preparation of a catalytic component that permits the manufacture of a polymer which is highly homogeneous in particle diameter distribution is free of minute polymer particles would enhance the operational efficiency of the polymer manufacturing plant and eliminate troublesome process of pelletizing the polymer product. This would reduce the cost of facilities and energy consumption, thereby contributing greatly to the economical operation of the polymer manufacturing processes. Therefore, development of such an ideal catalytic component has been strongly desired.
Heretofore, Ziegler-Natta catalysts have been generally employed in the polymerization of α-olefins. A typical example of such catalysts is a catalytic system consisting of a combination of a δ-type titanium trichloride-aluminum chloride eutectic mixture (hereinafter called the δ-type eutectic mixture) and an organo-aluminum compound. The δ-type eutectic mixture is obtained by pulverizing and activating, in accordance with a known method using a ball mill, a vibration mill or the like, a γ-type titanium trichloride-aluminum chloride eutectic mixture (hereinafter called the γ-type eutectic mixture) which is obtained by reducing titanium tetrachloride with aluminum powder in the presence of aluminum chloride. However, with the δ-type eutectic mixture employed as a catalyst component for α-olefin polymerization, both polymerization activity and the productivity of stereospecific polymer are low and unsatisfactory. There have been proposed many methods for reformation the δ-type eutectic mixture, including for example: (1) A method of co-pulverizing the δ-type eutectic mixture or the γ-type eutectic mixture and a reforming agent such as an electron donor compound or allowing them to react upon each other; (2) a method of washing the γ-type or δ-type eutectic mixture with an inert hydrocarbon solvent; and (3) a method of heating the γ-type or δ-type eutectic mixture. The reformation or denaturation by these methods improves the polymerization activity of the catalytic component and the productivity of a stereospecific polymer to a certain degree. Such methods, however, are utterly incapable of controlling the particle diameter of the catalytic component and also are far from meeting the requirement of obviating the necessity of the deashing and washing processes.
Recently, there has been developed some catalytic components which have a high polymerization activity and ensure a high degree of productivity of a stereospecific polymer. An example of methods for obtaining such catalytic components is a method disclosed by Japanese laid-open patent application No. 47-34478. In this method, (1) a β-type titanium trichloride is prepared by reducing titanium tetrachloride with an organo-aluminum compound at a low temperature; (2) a portion of the aluminum compound is removed from the resulting β-type titanium trichloride eutectic mixture by treating the β-type titanium trichloride eutectic mixture with a complex-making agent; and then (3) heat-treating it in titanium tetrachloride to obtain a δ-type eutectic mixture having a dark purple color. The catalytic component is excellent-having polymerization activity several times greater than that of a catalytic component of the δ-type eutectic mixture which is prepared by the above stated pulverization process. This method for the manufacture of a catalytic component, has the following drawbacks: (1) a long period of time is required for its manufacture; (2) a large quantity of a washing liquid is required for washing the catalytic component; (3) a large quantity of waste liquid containing titanium ions and aluminum ions results; and (4) it necessitates the use of a large quantity of a neutralizing reagent and thus requires a great amount of energy to prevent environmental pollution and to recover the solvent used. This results in a very high manufacturing cost.
To eliminate the above stated drawbacks, there have been proposed improved methods for manufacturing a catalytic component. These improved methods include: (1) A method which has been disclosed in Japanese laid-open patent applications Nos. 51-16298 and 51-76196 in which a liquid matter obtained by treating titanium tetrachloride in the presence of an organic ether compound with an organo-aluminum compound expressed by a generic formula of AlR n X 3-n (wherein R represents an alkyl group having 1 to 10 carbon atoms; X a halogen atom; and n a real number of 0<n≦3) is brought into contact with a liberating agent such as Lewis acid at a temperature not exceeding 150° C. (2) An improvement over the above stated method (1) not using the liberating agent used in the method (1) (this improved method has been disclosed in Japanese laid-open patent application No. 52-47594). (3) A method which has been disclosed in Japanese laid-open patent application No. 51-94496 and in which a titanium trichloride catalytic component is crystallized by using seed crystals in carrying out the above state method (1). (4) A method which has been disclosed in Japanese laid-open patent application No. 51-90998 and in which a titanium trichloride catalytic component is separated out by varying the operating temperature in carrying out the above stated method (1). Each of these catalytic component manufacturing methods does not require the use of a solvent in large quantity and, accordingly, produces only a small quantity of waste liquor. However, each of them has a drawback in that the average particle diameter of the titanium trichloride catalytic component obtained by the method is at the most about 30μ and normally measures only several μ. Thus, the catalytic component is obtained in an extremely small particle size and at low bulk density which causes the catalytic component to be difficult to handle. Further, when the catalytic component is used for α-olefin polymerization, the particle diameter of the polymer product is small, its bulk density is low, and yield of stereospecific polymer is low.
As described in the foregoing, properties of the catalytic components for α-olefin polymerization manufactured by conventional methods and those of the α-olefin polymers polymerized in the presence of such catalysts are not satisfactory. Therefore, further improvement over these conventional catalytic components is desired.
The inventors of the present invention strenuously conducted studies for a method of manufacturing a titanium trichloride catalytic component which has a high degree of polymerizing activity as well as a high productivity for a stereospecific polymer and which, at the same time, permits free control of the particle diameter of such catalytic component, and also permits control of the particle diameter of the α-olefin polymer product. As a result of these studies, the applicants have completed the present invention.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a titanium trichloride catalytic component for α-olefin polymerization which is prepared by precipitating the titanium trichloride catalytic component from a solution of titanium trichloride in a solvent comprising a saturated aliphatic hydrocarbon and/or an alicyclic hydrocarbon. Such solution is obtained by dissolving (a) titanium tetrachloride; (b) an organic ether compound; and (c) an organo-aluminum compound which has the generic formula of AlR n X 3-n (wherein R represents an alkyl group having 1 to 10 carbon atoms (i.e., a carbon number of 1 to 10), and X represents a halogen or hydrogen atom, and n a real number of 0<n≦3) in the solvent. The organo-aluminum compound is added at a solvent temperature not exceeding 55° C. in the concomitant presence of an aromatic hydrocarbon halide; subsequently, the solvent temperature is raised to between 45° and 150° C. over a period of 10 minutes to 24 hours to precipitate a titanium trichloride catalytic component having a uniform particle diameter between 10 and 1000μ, which is freely adjustable within this range. The resulting catalytic component has a highly uniform particle diameter and a high degree of catalytic (polymerization) activity forming a stereospecific polymer at a high degree of productivity.
It is another object of the present invention to provide a method for homo- or co-polymerization of α-olefins in which the polymerization is carried out in the presence of the above-stated titanium trichloride catalytic component to obtain highly stereospecific polymers having highly uniform particle diameters.
In the present invention, it is mandatory that the solvent (which is used for dissolving, (a) the titanium tetrachloride, (b) the above-mentioned organic ether compound, and (c) the above-mentioned organo-aluminum compound) includes an aromatic hydrocarbon halide in addition to the above-mentioned saturated aliphatic hydrocarbon and/or the alicyclic hydrocarbon. This makes it possible to adjust the particle diameter of the titanium trichloride catalytic component as desired. On the other hand, if the solvent consists of only the saturated aliphatic hydrocarbon and/or the alicyclic hydrocarbon without having the aromatic hydrocarbon halide mixed therein or if the solvent consists of only the aromatic hydrocarbon halide, there is produced a titanium trichloride catalytic component of extremely fine particle size with which the objects and the effects of the present invention hardly can be attained and which is hardly usable as catalytic component for α-olefin polymerization.
This fact is an amazing discovery which has never been expected from the known prior art. The invention is of great significance for industrial applications. The titanium trichloride catalytic component has a high degree of activity and also a high productivity for a stereospecific polymer, so that the conventional deashing and washing processes can be either omitted or simplified. Further, the titanium trichloride catalytic component obtained in accordance with this invention and a polymer obtained from the use of this catalytic component respectively have highly uniform particle diameters. In addition to these advantages, the particle diameter is adjustable as desired, so that the properties such as fluidity can be adjusted to be suitable for use at any type of plant. It is another advantageous feature of the invention that the adjustability of the polymer product to any desired particle diameter makes it possible to omit a pelletizing process. The objects and the features of the invention will become more apparent from the following detailed description thereof:
DETAILED DESCRIPTION OF THE INVENTION
The halogen of the aromatic hydrocarbon halide to be used in accordance with the invention is preferably selected from the group consisting of chlorine, bromine, iodine and fluorine. Taking chlorinated aromatic hydrocarbons and brominated aromatic hydrocarbons as examples, the aromatic hydrocarbon halide may be selected from the group consisting of chlorinated aromatic hydrocarbons such as chlorobenzene, chlorotoluene, chloroxylene, chloroethyl benzene, dichlorobenzene, dichlorotoluene, dichloroxylene, trichlorobenzene, trichlorotoluene, chlorobromobenzene, etc. and brominated aromatic hydrocarbons such as bromobenzene, bromotoluene, bromoxylene, bromoethyl benzene, dibromobenzene, dibromotoluene, dibromoxylene, tribromobenzene, tribromotoluene, etc. Of these chlorinated and brominated aromatic hydrocarbons, it is preferable to use chlorobenzene, chlorotoluene, chloroxylene, dichlorobenzene, dichlorotoluene, dichloroxylene, bromobenzene, bromotoluene, bromoxylene, dibromobenzene, dibromotoluene, dibromo.
The saturated aliphatic hydrocarbon is a compound having a boiling point of at least 65° C. and preferably above 80° C. For example, the saturated aliphatic hydrocarbon may be selected from the group consisting of n-hexane, n-heptane, n-octane, and n-decane. The alicyclic hydrocarbon preferably has a boiling point of at least 65° C. and may be selected, for example, from the group consisting of cyclohexane, cycloheptane, cyclooctane, methylcyclohexane, etc.
In one of the methods for adjustment of the particle diameter of the titanium trichloride catalytic component, using an admixture of aromatic hydrocarbon halide and a saturated aliphatic hydrocarbon and/or an alicyclic hydrocarbon (hereinafter this mixture will be called the mixed solvent), the particle diameter can be controlled as desired by adjusting the concentration of the aromatic hydrocarbon halide in the mixed solvent. Further, when allowing the titanium trichloride catalytic component to separate out in the presence of the aromatic hydrocarbon halide, the temperature of the mixed solvent is raised to between 45° and 150° C., preferably to a temperature between 65° and 120° C. and most preferably to a temperature between 75° and 110° C. over a period of 10 minutes and 24 hours, preferably between 30 minutes and 12 hours and most preferably between 1 and 8 hours. The concentration of the aromatic hydrocarbon halide in the mixed solvent is 20 to 70% by volume, preferably 25 to 65% by volume and most preferably 30 to 60% by volume. Within this prescribed range of concentration, the particle diameter of the titanium trichloride catalytic component produced becomes smaller as the concentration of the aromatic hydrocarbon halide increases. Conversely, the particle diameter becomes larger as the concentration of the aromatic hydrocarbon halide decreases. The particle diameter of a titanium trichloride catalytic component produced when the concentration of the aromatic hydrocarbon halide in the mixed solvent is set, for example, at below 20% by volume is uneven and the polymerization activity and the stereospecificity of the polymer product obtained by using this catalytic component are extremely poor. On the other hand, when the concentration of the aromatic hydrocarbon halide exceeds 70% by volume, the particle diameter of a catalytic component produced thereby is so small that it makes filtering and washing for the catalytic component difficult and results in lower productivity of the catalytic component.
The titanium tetrachloride is used in the ratio of 5 mol and less to 1 liter of the aforesaid mixed solvent, preferably 2 mol and less, and most preferably 1.5 mol and less; there is no particular lower limitation to said ratio. However, in consideration of the productivity of the titanium trichloride catalytic component, it is preferable to set the lower limit at 0.01 mol.
The organic ether compound to be used in accordance with this invention is preferably a compound that is expressed by a generic forumla ROR', wherein R and R' represent alkyl groups which are the same or different from each other, at least one of them having a carbon number not exceeding 5 (i.e., not more than 5 carbon atoms). The compound may be selected from the group consisting of di-n-amyl ether, di-n-butyl ether, di-n-propyl ether, n-amyl-n-butyl ether, n-amyl isobutyl ether, n-butyl-n-propyl ether, n-butyl isoamyl ether, n-propyl-n-hexyl ether, n-butyl-n-octyl ether, etc. Of these compounds, the use of di-n-butyl ether produces the best result. The organic ether compound is used in quantity 0.8 to 3 mol for 1 mol of the titanium tetrachloride and preferably 1.0 to 2.5 mol. If the organic ether compound is used in quantity less than 0.8 mol for 1 mol of the titanium tetrachloride, the polymerizing activity of the titanium trichloride catalytic component thus produced is decreased, causing a lower degree of stereospecific polymer productivity. Also, if the quantity of the organic ether compound exceeds 3 mol for 1 mol of the titanium tetrachloride, are lowered and the polymerizing activity and the stereospecific polymer productivity are lowered and the yield of the catalytic component is also lowered.
The organo-aluminum compound to be used in accordance with this invention is preferably a compound that is expressed by a generic formula of AlR n X 3-n , wherein R represents an alkyl group having 1-10 carbon atoms, X a halogen or hydrogen atom and n a real number of 0<n≦3. The compound in which n=3, for example, may be selected from the group consisting of trimethyl aluminum, triethyl aluminum, tri-n-propyl aluminum, tri-n-butyl aluminum, triisobutyl aluminum, tri-n-pentyl aluminum, tri-n-hexyl aluminum, triisohexyl aluminum, tri-n-octyl aluminum, etc. The compound in which X is a hydrogen atom may be selected out of the group consisting of dimethyl aluminum hydride, methyl aluminum hydride, diethyl aluminum hydride, ethyl aluminum hydride, di-n-butyl hydride, n-butyl aluminum dihydride, diisobutyl aluminum hydride, isobutyl aluminum dihydride, di-n-pentyl aluminum hydride, di-n-hexyl aluminum hydride, diisohexyl aluminum hydride, di-n-octyl aluminum hydride, etc. As for the compound in which X is a halogen atom, taking chlorides as example, the compound may be selected out of the group consisting of dimethyl aluminum chloride, diethyl aluminum chloride, di-n-propyl aluminum chloride, di-n-butyl aluminum chloride, diisobutyl aluminum chloride, di-n-pentyl aluminum chloride, di-n-hexyl aluminum chloride, diisohexyl aluminum chloride, di-n-octyl aluminum chloride, methyl aluminum sesqui-chloride, n-propyl aluminum sesqui-chloride, n-butyl aluminum dichloride, isobutyl aluminum dichloride, n-hexyl aluminum dichloride, isohexyl aluminum dichloride, etc. The organo-aluminum compound may be diluted to a suitable degree with an aromatic hydrocarbon such as benzene, toluene, xylene, etc., or with the aromatic hydrocarbon halide, the saturated aliphatic hydrocarbon or the alicyclic hydrocarbon which is used for the preparation of the mixed solvent in accordance with the invention, or with a mixture of them. The organo-aluminum compound is used for the purpose of reducing a tetravalent titanium to a trivalent titanium. Theoretically, addition of the organo-aluminum compound in quantity equivalent to the tetravalent titanium suffices. However, in the presence of the aromatic hydrocarbon halide, the addition quantity of the organo-aluminum compound is also interrelated with the particle diameter of the titanium trichloride catalytic component to be obtained. In view of this interrelation between the two, it is preferable to add the organo-aluminum compound in quantity 0.3 to 1.8 equivalent of the titanium tetrachloride. Addition of the organo-aluminum compound in a quantity less than 0.3 equivalent greatly lowers yield of titanium trichloride catalytic component. Conversely addition of the organo-aluminum compound in a quantity more than 1.8 equivalent lowers the polymerizing activity and the stereospecific polymer productivity. Further, within this range of addition quantity of the organo-aluminum compound, the particle diameter of the catalytic component decreases as the addition quantity increases.
As for another method for effecting adjustment of the particle diameter of the titanium trichloride catalytic component, the particle diameter can be adjusted as desired by adjusting the composition of the organic ether compound/titanium tetrachloride/organo-aluminum compound system. This requires the presence of the aromatic hydrocarbon halide; otherwise, the adjustment of the particle diameter of the titanium trichloride catalytic component obtained cannot be effected as desired. For example, when the concentrations of the organic ether compound and the titanium tetrachloride are fixed, the particle diameter of the catalytic component becomes smaller as the concentration of the organo-aluminum compound increases. Further, when the concentrations of the titanium tetrachloride and the organo-aluminum compound are fixed, the particle diameter of the catalytic component obtained decreases as the concentration of the organic ether compound increases.
Next, let us show an example of procedures for the manufacture of the titanium trichloride catalytic component of the present invention. The titanium tetrachloride and the organic ether compound are dissolved in the mixed solvent either separately or in the form of a complex. Following this, an organo-aluminum compound is added. It is necessary that the temperature of the mixed solvent does not exceed 55° C., and is preferably below 50° C. and most preferably below 45° C. when the organo-aluminum compound is added. If the organo-aluminum compound is added at a solvent temperature exceeding 55° C., the titanium tetrachloride will be immediately reduced and then the titanium trichloride catalytic component will separate in a state of minute particles. This not only makes the particle size adjustment difficult but also makes filtration and washing the catalytic component difficult, thus resulting in lowered productivity.
After addition of the organo-aluminum compound, the temperature of the mixed solvent is raised up to a temperature between 45° and 150° C., preferably between 65° and 120° C. and most preferably between 75° and 110° C. The length of time required for raising the temperature to the prescribed value is 10 minutes to 24 hours, preferably 30 minutes to 12 hours and most preferably 1 hour to 8 hours; however, this also depends upon the temperature difference between the temperature values before and after the temperature raising process or procedure. This process is required for reducing the titanium tetrachloride with the organo-aluminum compound to obtain the titanium trichloride catalytic component of highly uniform particle diameter. If the temperature is rapidly raised in a short period of time, e.g., in less than 10 minutes from temperature at which the organo-aluminum compound is added, the particle diameter of the titanium trichloride catalytic component obtained is uneven. When the temperature raising process is carried out over a long period of time, e.g., exceeding 24 hours, such a process does not bring about any particularly greater effect. On the other hand, when the temperature is less than 45° C., the reduction reaction takes place at a slow velocity which results in a poor productivity. The upper limit of the temperature must be lower than the boiling point of the compound that has the lowest boiling point among the components of the mixed solvent including, saturated aliphatic hydrocarbon or alicyclic hydrocarbon and the aromatic hydrocarbon halide. The upper limit is normally set at 150° C.
After completion of the temperature raising process, it is preferable to retain the raised temperature for a period of several minutes to several ten minutes to ensure the completion of the reducing reaction, though there is no particular restriction on the length of that period.
Through the above stated process, it is possible to obtain a novel titanium trichloride catalytic component having highly uniform particle diameter which is adjustable as desired between 10 and 1000μ. The catalytic component thus obtained is thoroughly washed with either a hydrocarbon solvent or an aromatic hydrocarbon halide solvent. After washing, the catalytic component can be stored either in a slurry-like state or in a dried state attained via filtration and drying.
The titanium trichloride catalytic component is used to form an α-olefin polymerizing catalyst system in combination with an organo-aluminum compound expressed by a generic formula of AlR n X 3-n wherein R represents an alkyl group (as defined supra), X a halogen atom and n a real number of 0<n≦3. The organo-aluminum compound may be selected from the group consisting of triethyl aluminum, diethyl aluminum chloride, ethyl aluminum dichloride, ethyl aluminum sesqui-chloride, triisobutyl aluminum, diisobutyl aluminum chloride, etc. The quantity ratio of the titanium trichloride catalytic component to the organo-aluminum compound can be varied within a wide range as desired by those skilled in the art. However, the mole ratio is normally between 1:1 and 1:20. Further, in carrying out the α-olefin polymerizing method of the invention, the catalyst system may be used in combination with an electron donor of the kind generally employed.
The polymerization may be carried out by (a) a suspension polymerization process in which an inert hydrocarbon selected from the group consisting of an aromatic hydrocarbon such as benzene, xylene, toluene etc., or an aliphatic hydrocarbon such as heptane, hexane, octane, etc., or an alicyclic hydrocarbon such as cyclohexane or cycloheptane is employed as a solvent, (b) by a liquid phase polymerization process which uses a liquefied monomer as solvent l or (c) by a gas phase polymerization process in which a monomer is used in a gas phase. The mode of carrying out the polymerization may be either a continuous processing mode or a batch processing mode. Polymerization temperature is set between 30° and 120° C. and preferably between 50° and 100° C. Polymerization pressure is between atmospheric pressure and 100 atm and preferably between atmospheric pressure and 50 atm.
The α-olefin that can be homo- or co-polymerized by the catalyst system of the present invention includes ethylene, propylene, butene-1,4-methyl pentene, etc. The adjustment of molecular weight of the polymer can be effected by a known method of using hydrogen or diethyl zinc.
When α-olefin is polymerized by using the titanium trichloride catalytic component in accordance with the polymerization method of the present invention, the polymerization activity is very high and the polymer thus obtained has high stereospecificity and high bulk density. With the particle size of the titanium trichloride catalytic component suitably adjusted, the resulting polymer has a highly uniform particle diameter within a range of diameters from 0.5 to 15 mm. The polymer is in an approximately spherical shape to have a good fluidity and, despite of its large particle diameter, the polymer also has a good deashing properties.
The invention will be understood more readily by reference to the following embodying examples. However, these examples are intended to illustrate the invention and are not to be construed as limiting the scope of the invention. Symbols which are used for the description of these examples and comparison examples denote the following:
a: Number of grams (g-pp) of the polymer produced in a unit period of time (hour), at a unit pressure (atm) per g (g-cat) of the catalytic component (g-pp/g-cat. hr. atm.)
p: Number of grams of the polymer produced per g of the catalytic component.
H.I.: A boiling n-heptane insoluble component in solid polymer produced (g)/solid polymer produced(g) X 100 (%) ##EQU1##
dc, dp: Average particle diameter values (μ) obtained by measuring, with a microscope, the diameters of 50 particles of each of the titanium trichloride catalytic component and the polymer obtained therefrom.
p: The bulk density (g/ml) of a boiling n-heptane insuluble polymer measured in accordance with the Method A or B of ASTM-D-1895-69.
EXAMPLE 1
Preparation of the Titanium Trichloride Catalytic Component
The inside of a four-necked flask equipped with a stirrer was purged with dry nitrogen. Following this, 250 ml of a monochlorobenzene and-n-heptane mixed solvent containing 33% by volume of monochloro benzene which was employed as the aromatic hydrocarbon halide was introduced into the flask. Then, 24.4 ml of titanium tetrachloride (0.22 mol--equivalent to 0.88 mol TiCl 4 /l mixed solvent) was added. The mixed solution was kept at a temperature between 23° and 27° C. To this was added, by dropping with stirring, 55.6 ml of di-n-butyl ether (0.33 mol--the mole ratio of di-n-butyl ether to the titanium tetrachloride was equivalent to 1.5) over a period of 10 minutes. After completion of this dropping process, a solution prepared by dissolving 13.8 ml of diethyl aluminum chloride (0.11 mol--the addition quantity of the diethyl aluminum chloride corresponded to 1.0 equivalent of the titanium tetrachloride) in 50 ml of mono-chloro benzene was added to the mixture over a period of 40 minutes. The mixture solution was then heated up to 95° C. in 4 hours. A titanium trichloride catalytic component began to separate out as the temperature rose. To complete the separation after the temperature raising process, the solution was kept at 95° C. for 30 minutes. Following this, the separated matter was immediately filtrated in a dry nitrogen atmosphere. The cake which was obtained in this manner was washed twice with 100 ml of mono-chloro benzene and three times with 200 ml of n-heptane.
After the washing process, the cake was dried at room temperature under reduced pressure to obtain 35 g of a titanium trichloride catalytic component having highly uniform particle diameter measuring 500μ on the average.
The titanium trichloride catalytic component thus obtained was analyzed with the following results the catalytic component is composed of 27.6% by weight of Ti, 60.9% by weight of Cl, 0.19% by weight of Al and 8.4% by weight of di-n-butyl ether. Further, a result of measurement by the B.E.T. method indicated that the specific surface area of the catalytic component was 125 m 2 /g.
Polymerization Procedures
The inside of a polymerization flask which was provided with a side arm and measured 1 liter in content volume was dried by thoroughly removing moisture therefrom. Then, the inside of the flask was purged with dry nitrogen. Following this, 400 ml of n-heptane, 106.9 mg of the titanium trichloride catalytic component and 1.6 m. mol of diethyl aluminum chloride were put in the flask. The nitrogen inside the polymerization flask was replaced with propylene. The temperature of the inside of the flask was raised up to 70° C. with vibration and stirring and, and the inside pressure of the flask was kept at 2 kg/cm 2 G with propylene gas, the polymerization of propylene was carried out for 2.5 hours.
Upon completion of polymerization, stirring and introduction of propylene was stopped; non-reacted propylene was purged; and then the catalyst was decomposed by introducing 100 ml of an alcohol mixture consisting of methanol and isopropanol in a mixing ratio of 3:1.
The polymer produced by this polymerization process was recovered by filtration. Then 65.7 g of polypropylene was obtained through washing and drying processes. The filtrate was evaporated and dried to recover 1.4 of polypropylene which had been dissolved in the polymerization solvent. The results of polymerization were as shown in Table 1.
EXAMPLES 2-5
A titanium trichloride catalytic component was prepared by varying the composition of the mixed solvent consisting of mono-chloro benzene and n-heptane as shown in Table 1. With the exception of this, the preparation of the catalytic component and the polymerization of propylene were carried out in exactly the same manner as in Example 1. The results of the runs constituting these examples (i.e., Examples 2 to 5) were as shown in Table 1.
TABLE 1______________________________________Preparation ofcatalytic component MonochloroExam- benzene Results ofple concentration polymerizationNo. (vol %) dc a p I.I. dp ρ______________________________________1 33 500 82 615 95.5 3500 0.242 30 1000 72 540 91.3 6000 0.213 43 300 80 600 95.3 2100 0.304 50 30 83 620 96.0 400 0.325 60 10 83 622 95.0 90 0.24______________________________________
EXAMPLES 6-8
The preparation of a titanium trichloride catalytic component and the polymerization of propylene were carried out in exactly the same manner as in Example 1 with the exception that: The composition of the mixed solvent consisting of monochloro benzene and n-heptane was varied as shown in Table 2 and 50 ml of n-heptane was used as diluent for the diethyl aluminum chloride. The results of the run constituting these examples were as shown in Table 2.
TABLE 2______________________________________Preparation ofcatalytic component MonochloroExam- benzene Results ofple concentration polymerizationNo. (vol %) dc a p I.I. dp ρ______________________________________6 46.8 500 70 525 91.2 3400 0.247 50.0 300 75 562 93.5 2200 0.288 53.2 10 80 600 95.4 93 0.27______________________________________
EXAMPLES 9-10
The preparation of a titanium trichloride catalytic component and the polymerization of propylene were carried out in exactly the same manner as in Example 1 with the exception of that: The composition of the mixed solvent consisting of monochloro benzene and n-heptane was varied as shown in Table 3 and a mixture solution consisting of monochloro benzene and n-heptane in a ratio by volume of 1:1 was used as diluent for diethyl aluminum chloride. The results of these runs were as shown in Table 3.
TABLE 3______________________________________Preparation ofcatalytic component MonochloroExam- benzene Results ofple concentration polymerizationNo. (vol %) dc a p I.I. dp ρ______________________________________ 9 43.2 250 78 585 93.5 2100 0.2810 50.0 60 81 607 95.0 800 0.31______________________________________
EXAMPLES 11-13
The preparation of a titanium trichloride catalytic component and the polymerization of propylene were carried out in exactly the same manner as in Example 1 with the exception of that: Titanium tetrachloride was added as shown in Table 4 and diethyl aluminum chloride and di-n-butyl ether were added in amounts to make their mole ratios to the titanium tetrachloride the same as in Example 1. The results of these runs were as shown in Table 4.
TABLE 4______________________________________Preparation ofcatalytic component Addition q'tyExam- of titanium Results ofple tetrachloride polymerizationNo. (ml) dc a p I.I. dp ρ______________________________________11 147 60 85 640 96.9 820 0.3212 110 40 51 380 95.5 520 0.3113 84.6 25 33 250 90.2 370 0.25______________________________________
EXAMPLES 14-17
The preparation of a titanium trichloride catalytic component and the polymerization of propylene were carried out in exactly the same manner as in Example 1 with the exception of that: The addition quantity of diethyl aluminum chloride was adjusted to give the equivalent ratios to titanium tetrachloride shown in Table 5. The results of these runs were as shown in Table 5.
TABLE 5______________________________________Preparation ofcatalytic component Diethyl aluminumExam- chloride/TiCl.sub.4 Results ofple equivalent polymerizationNo. ratio dc a p I.I. dp ρ______________________________________14 0.30 20 53 400 92.3 250 0.2615 1.0 500 82 615 95.5 3500 0.2416 1.36 100 60 450 90.0 980 0.4417 1.80 50 35 260 92.3 470 0.22______________________________________
EXAMPLE 18-21
The preparation of a titanium trichloride catalytic component and the polymerization of propylene were carried out in exactly the same manner as in Example 1 with the exception of that the addition quantity of di-n-butyl ether was adjusted to give the mole ratios of said ether to TiCl 4 shown in Table 6. The results of these runs were as shown in Table 6.
TABLE 6______________________________________Preparation ofcatalytic componentExam- Di-n-butyl Results ofple ether/TiCl.sub.4 polymerizationNo. mole ratio dc a p I.I. dp ρ______________________________________18 1.00 420 57 430 94.3 3000 0.3219 1.82 50 67 500 93.5 680 0.2420 2.00 40 64 483 91.0 520 0.2221 2.50 30 60 450 90.0 400 0.21______________________________________
EXAMPLES 22-26
The preparation of a titanium trichloride catalytic component and the polymerization of propylene were carried out in exactly the same manner as in Example 1 with the exception of that: In place of the n-heptane, various saturated aliphatic hydrocarbons and/or alicyclic hydrocarbons were used as shown in Table 7. The results of these runs were as shown in Table 7.
TABLE 7______________________________________Preparation ofcatalytic component SaturatedExam- aliphatic or Results ofple alicyclic polymerizationNo. hydrocarbon dc a p I.I. dp ρ______________________________________22 hexane 200 77 580 93.2 1800 0.2623 cyclohexane 230 81 610 94.8 2100 0.3224 Octane 480 80 600 95.0 3500 0.3125 methyl 400 82 615 95.2 3000 0.32 cyclohexane26 n-decane 490 81 607 95.1 3500 0.31______________________________________
EXAMPLES 27-34
The preparation of a titanium trichloride catalytic component and the polymerization of propylene were carried out in exactly the same manner as in Example 1 with the exception of that various other aromatic hydrocarbon halides were used in place of monochloro benzene as shown in Table 8. The results of these runs were as shown in Table 8.
TABLE 8______________________________________Preparation ofcomponentExam- Aromatic Results ofple hydrocarbon polymerizationNo. halide dc a p I.I. dp ρ______________________________________27 ortho-chloro 510 83 623 96.2 3600 0.28 toluene28 1,2,4-trichloro 300 83 620 95.3 2100 0.30 benzene29 ortho-dichloro 380 83 622 95.1 2600 0.31 toluene30 para-chloro 500 82 615 95.8 3400 0.28 toluene31 bromo-benzene 430 80 600 93.2 3000 0.2732 bromo-toluene 250 71 530 90.5 2200 0.2633 iodo-benzene 320 73 550 91.5 2400 0.2834 fluoro benzene 350 64 480 92.3 2600 0.30______________________________________
EXAMPLES 35-37
The preparation of a titanium trichloride catalytic component and the polymerization of propylene were carried out in exactly the same manner as in Example 1 with the exception of that various other organic ethers were used in place of di-n-butyl ether as shown in Table 9. The results of the runs consisting Examples 35-37 were as shown in Table 9.
TABLE 9______________________________________Preparation ofcatalytic componentExam- organic Results ofple ether polymerizationNo. compound dc a p I.I. dp ρ______________________________________35 diethyl ether 120 47 350 90.3 1300 0.2336 di-n-propyl 150 60 450 93.5 1700 0.30 ether37 di-n-amyl ether 170 69 520 94.0 1900 0.32______________________________________
EXAMPLES 38-42
The preparation of a titanium trichloride catalytic component and the polymerization of propylene were carried out in exactly the same manner as in Example 1 with the exception of that various other organo-aluminum compounds were used in place of diethyl aluminum chloride as shown in Table 10. The results of these runs were as shown in Table 10.
TABLE 10______________________________________Preparation ofcatalytic componentExam- Organo- Results ofple aluminum polymerizationNo. compound dc a p I.I. dp ρ______________________________________38 DEAL--H 520 81 610 97.0 3600 0.34 See Note 139 DIBAL--H 510 82 615 97.1 3500 0.33 See Note 240 EASC 30 80 600 95.8 420 0.34 See Note 341 EADC 35 73 550 96.0 400 0.35 See Note 442 DIBAC 450 80 600 96.6 3000 0.32 See Note 5______________________________________ NOTES 1 DEAL--H: diethyl aluminum hydride 2 DIBAL--H: diisobutyl aluminum hydride 3 EASC: ethyl aluminum sesquichloride 4 EADC: ethyl aluminum dichloride 5 DIBAC: diisobutyl aluminum chloride
EXAMPLES 43-47
In the preparation of a titanium trichloride catalytic component, the temperature at the time of addition of the diethyl aluminum chloride and/or the heating temperature was varied as shown in Table 11. With the exception of this the catalytic component was prepared in exactly the same manner as in Example 1 and propylene was polymerized using the thus prepared catalylic component) in exactly the same manner as in Example 1. The results of these runs were as shown in Table 11.
TABLE 11______________________________________Preparation ofcatalytic component Addi- Heat-Exam- tion ing Results ofple temp., temp., polymerizationNo. °C. °C. dc a p I.I. dp ρ______________________________________43 40 95 430 80 600 93.8 3200 0.2544 50 95 13 15 110 82.3 110 0.2145 27 70 400 56 420 87.8 2900 0.2446 27 80 450 83 620 95.0 3400 0.2447 27 120 470 82 618 95.6 3600 0.25______________________________________
EXAMPLE 48-50
In each of three runs (Examples 48-50), the inside of a 2-liter stainless steel autoclave was purged with dry nitrogen; then, in the respective runs, the autoclave was filled with 160 mg of the respective titanium trichloride catalytic component prepared as shown in Table 12, 5 m. mol of diethyl aluminum chloride and 1 liter of dry n-heptane in a dry nitrogen gas atmosphere. Following this, in each run, 5 m. mol of hydrogen gas was introduced into the autoclave and the inside temperature of the autoclave was then raised by heating to 70° C.
Then, in each run propylene was supplied into the autoclave with pressure and the polymerization thereof was carried out for 2 hours by keeping the temperature and pressure inside of the autoclave at 70° C. and 10 kg/cm 2 G respectively. Upon completion of each polymerization, propylene gas remaining in the autoclave was purged; then, the catalytic component was decomposed by injecting 100 ml of a mixture solution consisting of methanol and isopropanol in the ratio of 3:1. The suspension of polymer produced was, in each instance, filtrated, washed and dried under reduced pressure to obtain a solid polymer. Also, in each instance, a soluble polymer which was dissolved in the polymerization solvent was collected by evaporating the solvent. The results of the runs constituting Examples 48-50 were as shown in Table 12.
TABLE 12______________________________________Exam- Results ofple polymerizationNo. Catalytic component a p I.I. dp ρ______________________________________48 Catalytic component 134 2960 96.4 10500 0.27 of Example 149 Catalytic component 130 2860 96.0 6200 0.36 of Example 350 Catalytic component 125 2750 95.5 3300 0.46 of Example 11______________________________________
EXAMPLE 51
The inside of a 2-liter stainless steel autoclave equipped with a stirrer was purged with dry nitrogen. Then, 44.5 mg of a titanium trichloride catalytic component prepared in exactly the same manner as in Example 1 and 4 m. mol of diethyl aluminum chloride were put in the autoclave. Following this, 10 m. mol of hydrogen and 500 g of liquefied propylene was introduced into the autoclave with pressure to carry out polymerization for one hour at 80° C. After one hour of polymerization, heating and stirring were stopped and non-reacted propylene was purged to obtain 134.4 g of a polymer. The results of the polymerization were: a=75, p=3020, H.I.=95.3, dp=12000 and ρ=0.30.
EXAMPLE 52
The inside of a stainless steel autoclave measuring 2 liters in content volume and being equipped with a stirrer was purged with dry nitrogen before starting the run. Then 50 g of stereospecific polypropylene which had been prepared by extracting an atactic polypropylene with boiling n-heptane and then drying, and classifying it and subjecting it to deoxidization was put in the autoclave. Following this, 43 mg of a titanium trichloride catalytic component which had been prepared in exactly the same manner as in Example 1 and 100 ml of n-heptane containing 4 m. mol of diethyl aluminum chloride were put in the autoclave. Then, the temperature inside the autoclave was adjusted to 70° C. and feeding a supply of propylene into the autoclave was started to carry out gas phase polymerization under a pressure of 25 kg/cm 2 G. After two hours, the stirring, heating, and propylene were stopped and non-reacted propylene feeding was purged. 183.3 g of polypropylene was obtained. The results of this polymerization were: a=60, p=3100, H.I.=93.7, dp=9500 and ρ=0.26.
EXAMPLE 53
One liter of n-heptane, 5 m. mol of diethyl aluminum chloride and 50 mg of titanium trichloride which was prepared in exactly the same way as in Example 1 were put in a 2-liter stainless steel autoclave equipped with a stirrer. The inside temperature of the autoclave was raised by heating up to 70° C. An ethylene-propylene mixture gas containing 4.5% by volume of ethylene was introduced into the autoclave to carry out the desired polymerization. After 2 hours, heating, stirring and introduction of the mixed gas (ethylene-propylene mixture) were stopped; non reacted mixed gas was purged; and the content of the autoclave was filtered, washed and dried to obtain 157.5 g of a polymer. The polymer was analyzed by means of infrared absorption spectrum; it was found that the polymer contained 2.9% ethylene by weight. The results of this polymerization run were: a=143, p=3150, I.I.=80.5 and ρ=0.21.
EXAMPLE 54
A titanium trichloride catalytic component was prepared and propylene was polymerized in exactly the same manner as in Example 1 with the exception of that, in the preparation of the titanium trichloride catalytic component, the addition quantity of di-n-butyl ether was 0.5 mol for 1 mol of titanium tetrachloride. The results of the polymerization were: dc=15, a=7, p=50, I.I.=65.5 and dp=200.
EXAMPLE 55
A titanium trichloride catalytic component was prepared in exactly the same way as in Example 1 with the exception of that 4 mol of di-n-butyl ether was added for 1 mol of titanium tetrachloride. By this, 20 g of the catalytic component was obtained. Then, using this catalytic component, polymerization of propylene was carried out in exactly the same way as in Example 1 to obtain the following results: a=45, p=337 and I.I.=82.5.
COMPARISON EXAMPLE 1
A titanium trichloride catalytic component was prepared in exactly the same way as in Example 1 with the exception of that a mixture solution consisting of toluene and n-heptane was used in place of the mixed solvent consisting of monochlorobenzene and n-heptane. However, in this instance in the preparation process, the product which separated out was a large massive matter and was of a shape which was not suitable for use as a catalytic component. The massive matter was therefore pulverized. Using the pulverized matter as a titanium trichloride catalytic component, polymerization was carried out in exactly the same manner as in Example 1 to obtain the following results: a=35, p=263, I.I.=88.5 and ρ=0.29.
COMPARISON EXAMPLES 2-4
A titanium trichloride catalytic component was prepared and polymerization of propylene was carried out therewith in exactly the same way as in Comparison Example 1 with the exception of that, in the preparation of the titanium trichloride catalytic component, the composition of the mixture solution of toluene and n-heptane was varied as shown in Table 13. The results of the polymerization were also as shown in Table 13. It was impossible to adjust the particle diameter of the catalytic component and that of the polymer.
TABLE 13______________________________________Com-pari- Preparation ofson catalytic componentExam- Concentration Results ofple of toluene polymerizationNo. (vol %) dc a p I.I. dp ρ______________________________________2 20 -- 77 577 93.0 -- 0.283 40 -- 82 615 90.1 -- 0.314 60 -- 81 607 89.0 -- 0.27______________________________________
COMPARISON EXAMPLE 5
A titanium trichloride catalytic component was prepared in exactly the same way as in Example 1 with the exception of that the mixture solution consisting of monochlorobenzene and n-heptane contained by volume 10% monochloro benzene. However, the catalytic component obtained in this manner was not sufficiently uniform in particle diameter distribution, (dc=12). Polymerization of propylene was carried out using this catalytic component also in exactly the same way as in Example 1 to obtain the following results: a=25, p=187 and I.I.=78.5.
COMPARISON EXAMPLE 6
A titanium trichloride catalytic component was prepared in exactly the same way as in Example 1 with the exception of that the mixed solvent consisting of monochlorobenzene and n-heptane contained by volume 80% monochloro benzene. However, the matter which separated out through the process contained a great amount of minute particles of less than dc=7. Because of the filtration and washing processes were very difficult to carry out. After drying, the matter thus obtained was in a minute powery state with a low bulk density; it was found difficult to handle. Polymerization of propylene was carried out with the thus prepared catalytic component in exactly the same way as in Example 1 to obtain the following results: a=75, p=562, I.I.=92.5, dp=65 and ρ=0.18.
COMPARISON EXAMPLE 9
A titanium trichloride catalytic component was prepared in exactly the same way as in Example 1 with the exception of that the temperature at which the organoaluminum compound was added at 65° C. The catalytic component which was obtained in this manner contained a great amount of minute particles and was insufficiently uniform in particle diameter distribution. The properties of the polymerized product prepared by using this catalytic component were: a=57, p=428 and I.I.=91.4 which were satisfactory. However, a polymer which was obtained by using this catalytic component contained a great amount of minute particles and also had uneven particle diameter distribution.
COMPARISON EXAMPLE 10
The preparation of a catalytic component and the polymerization of propylene were carried out in exactly the same way as in Example 40 with the exception of that, in the preparation of the catalytic component, the process of raising the temperature from 45° to 95° C. was carried out in 5 minutes. The results of the polymerization were: a=75, p=562, I.I.=93.5 and ρ=0.30. The particle diameter of the catalytic component and that of the polymer product were not sufficiently uniform and they contained, respectively, a great amount of minute powder and minute particles. | A titanium trichloride catalytic component suitable for preparing highly stereospecific polymers having highly uniform particle diameters from α-olefins is prepared by precipitating such catalytic component from a solution of TiCl 4 in a solvent comprising a saturated aliphatic hydrocarbon and/or an alicyclic hydrocarbon. Such solution is obtained by dissolving TiCl 4 , an ether and an organo-aluminum compound having the formula AlR n X 3-n (wherein R, X and n are as defined hereinafter) in the solvent. The organo-aluminum compound is added at a solvent temperature not exceeding 55° C. in the concomitant presence of an aromatic hydrocarbon halide; subsequently, the temperature of the resulting system is raised to 45°-150° C. over a period of 10 minutes to 24 hours to precipitate the catalytic component which has a uniform particle diameter between 10 and 1000μ.
Homo- or co-polymerization of α-olefins is carried out in the presence of a catalyst system consisting of the above-described titanium trichloride catalytic component and an organo-aluminum compound (e.g., (C 2 H 5 ) 2 AlCl) to yield such polymers having highly uniform particle diameters and which are sufficiently pure to permit the omission or simplification of the conventional de-ashing and washing steps. | 2 |
This application is a division of Ser. No. 08/773,586 filed on Dec. 27, 1996 U.S. Pat. No. 5,816,042.
TECHNICAL FIELD
This invention relates to gas turbine engines for powering aircraft and particularly to means for vectoring the thrust by controlling the direction of the core stream and the fan stream without mixing the two streams. Full closure of the engine's working medium through the exhaust nozzle is independently provided for.
BACKGROUND ART
As is well known in the gas turbine engine technology, because of the advent of high speed, high performance and thrust vectoring engines for military use, the goal of the designer is to assure that the engine performance is maintained at a high efficiency level, the weight of the engine and its component parts are held to a minimum and the of different concepts for converting the gas turbine engine utilizing today's technology to perform short and vertical take-offs and landings (STOVL). For example, the Harrier aircraft which has short takeoff and vertical lift capabilities has been in service for several years. However, none of these structures or systems function with the separation of the core and fan flow when in the STOVL mode of operation.
For example U.S. Pat. No. 5,098,022 granted to Thayer on Mar. 24, 1992 and entitled "Flow Diverting Nozzle For A Gas Turbine Engine" discloses a gas turbine engine vertical thrust nozzles that diverts the engine's core stream to provide vertical or a combination of vertical and forward thrust. This mechanism is located in the up stream end of the afterburner.
U.S. Pat. No. 5,082,209 granted to Keyser on Jan. 21, 1992 entitled "Thrust Reverser Assembly" relates to a rotating drum type of configuration to divert the core stream to obtain thrust reversing.
Other patents of interest are U.S. Pat. No. 4,482,107 granted to Metz on Nov. 13, 1984 entitled "Control Device Using Gas Jets For Guided Missile", U.S. Pat. No. 4,552,309 granted to Szuminski et al on Nov. 12, 1985 entitled "Variable Geometry Nozzles For Turbomachinery", and U.S. Pat. No. 4,805,401 granted to Thayer et al on Feb. 21, 1989 entitled "Control Vent For Diverting Exhaust Nozzle".
This invention contemplates the use of valving structure and ducting that serve to separate the fan stream and core stream when the aircraft is placed in the STOVL condition. In accordance with this invention a rotating drum having a cylindrical shell with apertures adapted to communicate with an offtake for valving the core and flow streams in the STOVL operation mode is disposed between the turbine section and afterburner of the gas turbine engine (turbo fan) of the type that includes mechanism for fully closing the exhaust nozzle. The offtake may be a twin duct or coannular configuration. The system is designed so that a portion of the fan air which is typically utilize to cool the hot components of the engine continues to maintain the cooling requirements both for the offtake structure and the engine's downstream components such as the exhaust nozzle when the aircraft is in the STOVL operating condition.
SUMMARY OF THE INVENTION
The object of this invention is to provide an improved turbo fan engine structure for providing STOVL or thrust reversing operations for aircraft.
A feature of this invention is to provide a rotating shell and cooperating ducting to selectively change the direction of the core engine flow to obtain STOVL aircraft operation or thrust reversing and concomitantly change the direction of the fan air while directing a portion of the fan air to be utilized downstream of the rotating shell to cool the hot engine components downstream thereof and the offtake structure. The rotating shell valve separate core engine air flow and the fan discharge air flow to obtain the STOVL or thrust reversing operation.
A feature of this invention is that the separate core flow and fan flow feature of this invention can be utilized in various offtakes including a STOVL coannular offtake or a STOVL twin duct offtake.
The foregoing and other features of the present invention will become more apparent from the following description and accompanying drawings.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 is a schematic view of a STOVL aircraft with a turbo jet engine utilizing the invention to divert the core engine flow for STOVL operation, vane blockers and variable exhaust nozzle;
FIG. 2 is a partial view in section and schematic of a gas turbo fan engine illustrating the rotating drum of this invention being utilized on a STOVL twin duct offtake;
FIG. 3 is a section taken along lines 2--2 of FIG. 2. and is in the normal engine flow operation;
FIG. 4 is a section taken along lines 2--2 of FIG. 2 illustrating the STOVL operation;
FIG. 5 is a section taken along lines 5--5 of FIG. 4 and illustrates the flow pattern through the engine and one of the offtakes;
FIG. 6 is an enlarged sectional partial view of FIG. 5 illustrating the flow pattern of the fan discharge air;
FIG. 7 is a section taken along lines 7--7 of FIG. 4;
FIG. 8 is an enlarged sectional partial view of FIG. 7;
FIG. 9 is a sectional view taken along lines 9--9 of FIG. 3;
FIG. 10 is an enlarged sectional partial view of FIG. 9;
FIG. 11 is a sectional view taken along lines 11--11 of FIG. 3;
FIG. 12 is an enlarged sectional partial view of FIG. 11;
FIG. 13 is an exploded view in schematic of the rotary drum and twin duct offtake;
FIG. 14 is a schematic view in perspective of the rotary drum/twin duct offtake of FIG. 13 illustrating the STOVL mode of aircraft operation;
FIG. 15 is a schematic view in perspective of the rotary drum/twin duct offtake of FIG. 13 illustrating the normal flight aircraft operation.
FIG. 16 is an exploded view in schematic illustrating a rotary drum for diverting core engine flow to a coannular offtake for a STOVL aircraft;
FIG. 17 is a schematic view in perspective of the rotary drum/coannular offtake of FIG. 16 when in the STOVL aircraft mode of operation;
FIG. 18 is a schematic view in perspective of the rotary drum/coannular offtake of FIG. 16 when in the normal flight aircraft operation;
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
While this invention is shown in the preferred embodiment as being utilized in a STOVL type of aircraft it is to be understood that this invention has utility for other types of aircraft and may also be utilized in typical aircraft for thrust reversing. FIG. 1 schematically discloses the STOVL aircraft generally indicated by reference numeral 10 powered by the turbo jet engine generally indicated by reference numeral 12. The engine 12 may be of the twin spool type having the fan/low pressure compressor 14 driven by the low pressure turbine 16 and the high pressure compressor 18 driven by the high pressure turbine 20. The high pressure core stream 22 discharging from the high pressure compressor is fed into the combustor 24 where it is combusted with the fuel admitted thereto as is typical in engine operations. A portion of the energy of the heated and accelerated gasses or engine core discharging from the combustor 24 powers the high pressure turbine 20 and low pressure turbine 16 and the remaining energy from the core stream serves to power the aircraft in the form of thrust. The core stream 22 discharging from the turbines passes in an axial direction through the rotary drum 32 of this invention, the afterburner 26, the normally opened vane blockers 28 and the normally opened variable exhaust nozzle 30 and discharges into ambient in the normal forward flight aircraft operation. The fan air stream 23 discharging from the fan portion of the fan/low pressure compressor 14 flows in the annular by-pass duct 31 and a portion is utilized for cooling of engine components as will be described hereinbelow.
In STOVL flight either the vane blocker 28 or the variable exhaust nozzle 30 can be utilized to block the core stream and the core stream is diverted to pass through the offtakes as will be described hereinbelow. The portion of the fan discharge air 23 is utilized to cool the engine components throughout the entire engine and a portion of the fan discharge air 23 in the STOVL mode is used to cool the offtakes as well as will be described in more detail hereinbelow. Since the aircraft, the engine, the vane blockers and exhaust nozzles are well known mechanisms and do not form a part of this invention they will not be described herein. Typical turbo fan engines like the F-100, F-119 and TF-30 with augmentors are manufactured by Pratt & Whitney division of United Technologies Corporation, the assignee common to this patent application are examples of engines that may utilize this invention.
For an understanding of this invention reference is now made to FIGS. 2-15 where FIG. 2 shows a portion of the gas turbine engine 12 including the rotating drum assembly generally indicated by reference numeral 32 that is disposed between the turbines 16 and afterburner 26. The shell 34 of the rotating drum assembly 32 is hollow and generally cylindrical in shape and includes a pair of diametrically opposed discharge ports 36 and 38 configured to complement the openings 40 and 42 respectfully formed in the twin offtake ducts 44 and 46 serve to divert the core flow 22 from the engine and a portion of the fan discharge air flow 23 flowing in the annular passage 48 formed between the turbine case 50 and engine case 52. Shell 34 includes an inner shell portion or liner 54 concentrically disposed relative to the outer concentric portion 34 that are coextensive from the outer diameters of the ports 36 and 38 for defining the annular passage 56. A fixed annular portion or liner 58 is suspended from the inner diameter of the engine case 52 to define the annular passage 60.
As shown in FIG. 3 the rotary drum 32 is in the forward flight position and in FIG. 4 the rotary drum is rotated 90 degrees and in the STOVL mode of operation. Rotating shell 34 is accomplished by the controller shown in blank by reference numeral 62 that serves to control actuator 64 that drives gear 66 via shaft 67 which, in turn, drives a plurality of rotary geared rollers 68. An identical drive mechanism is located at the aft end of the shell 34 which includes the gear and geared rollers also driven by shaft 67. rollers 68 are disposed around the circumference of shell 34 and the number of rollers required are predicated by the particular embodiment. The controller 62 can take the form of any well known control and actuator mechanism may utilize electrical, electronic, hydraulic or mechanical medium recognizing that the control serves to rotate the rotary drum to any position in order to effectuate the envelope of aircraft operation. For the purposes of this description the apparatus is shown in two modes, namely, 1) forward flight with the offtakes blocked off and 2) STOVL flight with the rotary drum rotated to divert the core stream to the offtakes.
As is apparent from FIGS. 2-12 and controller 62 can take the form of any well known control and actuator mechanism may utilize electrical, electronic, hydraulic or mechanical medium recognizing that the control serves to rotate the rotary drum to any position in order to effectuate the envelope of aircraft operation. For the purposes of this description the apparatus is shown in two modes, namely, 1) forward flight with the offtakes blocked off and 2) STOVL flight with the rotary drum rotated to divert the core stream to the offtakes.
As is apparent from FIGS. 2-12 and particularly FIG. 6 the rollers 66 support the shell 34 for rotary motion via the annular drive member 72 affixed to the plurality of Z-shaped spacers 74 circumferentially spaced about the engine axis A and mounted between the engine case and shell 34. The Z-shaped spacers are well known devices and are commonly used to support the liners in the afterburner. Rollers 66 include a bifurcated portion that provide clearance ovefr gear teeth on member 76 that support the shell 34 for rotary motion about the engines axis A.
FIG. 5, 6 and 14 traces the flow paths of the core stream and fan streams during the STOVL aircraft operation. As seen in FIG. 5 the core stream 5 is diverted so that all the flow is through the openings 36 and 40 into the offtake ducts. The fan stream 23 in the passage 31 flows between the Z-shaped spacers and separates into two portions. One portion of the flow passes through passage 60 defined between the engine case 52 and shell 34 and a plurality of openings formed in the valve plate 80 and the remaining portion flows through passage 56 formed between shell 34 and liner 54. Valve plate 80 is a tyroidally shaped disk that is rigidly attached to the engine case 52 and abuts liner 58. The valve plate 80 is a disk shaped member with a flange 82 abutting the liner 58. The term engine case 52 as used throughout this disclosure refers to the modular construction that comprises a plurality cases. Each of the cases are circular in cross section and carry flanges that abut adjacent cases and held together by a plurality of circumferentially spaced nuts and bolt assemblies 84 that define the overall case.
As noted, the end of disk 80 is sandwiched between case flanges and secured by the nut and bolt assemblies. The holes or apertures 86 may take the form of slots or circular holes and serve as valve openings and cooperate with blocker doors to be described herein below. The fan air 23 then flows between the liner 58 and case 52 into the annular passage 60.
The end of liner 58 which is preferable made from sheet metal is faired at the edge adjacent the ports 36 and 38 to form a smooth aerodynamic transition for the flow of fan air into the annular passage 87 defined by the liners 88 which is concentric to and spaced from the offtake ducts 44 and 46. A finger seal 88 is attached to the shell 34 to prevent the fan air to leak into the core stream via the space between the shell and engine liner.
As is apparent from the foregoing the cooler fan air (relative to the temperature of the core stream) serves to maintain the offtake ducts cool and within their structural integrity when the hot engine core air flows therethrough. A portion of the fan air 31 flows into passage 60 formed between the liner 54 and shell 34 and around ports 36 and 40 to the back side and through the annular passage 86 as best seen in FIG. 5. The remaining portion of the fan air flows through passage 56 around the ports 36 and 38 and downstream of the engine so as to cool these components and maintain the structural integrity thereof.
FIGS. 7 and 8 trace the flow path of the fan air when the aircraft is in the STOVL mode of operation and the ports 36 and 38 and 40 and 42 are in alignment. The fan air 23 flows through the shell 34 via the passage 56 and discharges from the shell into the aft portion of the engine. This fan air obviously serves to cool the components of the engine located downstream of the shell 34. The flow in passage 60 is blocked by the blocker doors 90 that are supported by the retainer 92 affixed to the bracket 94 that is attached to the outer surface of shell 34. The blocker doors 90 are circumferentially spaced around the shell 34 and span the distance of the slot 86 of the valve plate 80. The judicious location of the passages in the shell and engine case and the valving arrangement of this invention assures that the fan air does not commingle with the core air and vice versa in all modes of operation. It is important that for assuring ultimate engine performance the fan air is not commingled so that the cooling effectiveness of the fan air will not result in a deficit. The amount of fan air utilized for cooling is precalculated for maximum engine performance and if the cooling air is infected by the core stream and its heat content is raised, the cooling effectiveness will obviously be adversely affected.
The blocker doors 90 are preferably fabricated from carbon or an alloy thereof and is spring loaded by wave spring 96 against the face of the valve plate 80. The opposite end of the wave spring 96 is grounded to the spring retainer 92. The face of the carbon blocker doors easily slide against the face of the valve plate when the shell 34 which carries the blocker doors, is rotated.
FIGS. 9, 10, 11 and 12 trace the flow paths of the core stream and fan air stream when the aircraft is in normal forward flight mode of operation and the ports 36 and 38 and 40 and 46 are not in alignment. Obviously, the core stream flows straight through the shell 34 and is directed to the exhaust nozzle for developing forward thrust. In this mode of operation all of the fan air is directed through passages 56 and 60 through the rotary drum 32 to cool the aft portion of the engine. The flow in the portion of passage 60 in proximity to ports 40 and 42 as evidenced from FIGS. 9 and 10 is blocked by the blocker doors 90. However, as is seen in FIGS. 11 and 12 a portion of the fan air is directed into a portion of passage 60 where it directed downstream of the rotary drum 32 to contribute to the cooling of the engine components. As is evidenced in FIG. 12 the flow of fan air in passage 56 is routed around the ports 40 and 42 to continue the flow path to the downstream end of the engine.
For the purpose of the description of this invention the passage 60 is annular in shape and the slots 86 in cooperation with the blocker doors 90 determine the portion of the annular passage 60 is utilized to flow the fan air. This aspect of the invention will be better understood in connection with the description of FIGS. 13-15. described immediately herein below.
As can be seen in FIGS. 13-15 the rotary drum 32 which is rotatably mounted about the engine's center line A and concentrically mounted relative to the engine case 52 in proximity to the offtakes serves to divert the normally axially flowing core stream and a portion of the normally axially flowing fan air. Like reference numerals depict like elements in all of the Figs. The embodiment schematically shown in perspective in FIGS. 13-14 is substantially the embodiment disclosed in FIGS. 1-12 except for the mechanism schematically illustrating the mechanism for effectuating rotary motion of the rotary drum 32. In this instance schematically shown is a rotating pulley or sprocket gear 100 that drives the chain or belt 102 that in turn drives the shell 34 which may have a mating sprocket gear (not shown). As noted the rotary drum 32 includes the shell 34 and liner 54 and the ports 40 and 42 adapted to align with the twin offtake ducts 44 and 46. The liner 54 which is concentrically disposed relative to the shell 34 defines the annular passage 56. The liner is suspended from the shell 34 and rotatable therewith by the connection obtained by the interconnecting contoured insert 104 that also serves to prevent the core stream to migrate into the fan air stream. In addition it provides a transition in passage 56 to flow the fan stream around ports 40 and 42.
The engine case 52 including the offtake ducts 44 and 46 includes the concentric liner 58 spaced therefrom and supported by the circumferentially spaced ribs 106. The annular space defines the passage 60. It will be appreciated that the spacing of the four (4) ribs define four (4) quadrants which are the portions of the passage 60 that are opened and blocked in order to direct a portion of the fan air in the annular passage 87 (see FIGS. 5 and 6). For the sake of simplicity and convenience the valve plate 80 is removed from the FIGS., 13-15 as well as 16-18 to facilitate the understanding of this invention. The valve plate 80 would be mounted to abut the face of the case 52 as shown in FIGS. 13-18 and the slots would coincide with the sub-passages (space between adjacent ribs) in annular passage 60.
The flow patterns of the core stream and fan air streams for STOVL operations and forward flight (cruise) operations are depicted in FIGS. 14 and 15. As noted the core stream A is diverted through the offtakes 44 and 46 by virtue of the position of shell 34 of the rotary drum 32. A portion of the fan air C flows straight through the shell 34 by way of passage 56. The remaining portion of the fan air flows in the sub-passages of passage 60 that are in the quadrants adjacent the ports 40 and 42 leading the fan air B into the annular passage 87. As note the inserts 104 define the contour of passage 60 adjacent the ports and define a transition passage for the fan air to flow from the passage 60 into the passage 87 of the offtake ducts 44 and 46. The blocker doors 90 are in position to block the flow from the sub-passages of passage 60 that are in the quadrants remote from the ports 40 and 42.
In the forward flight mode as shown in FIG. 15, the rotary drum 32 is rotated 90 degrees to position ports 40 and 42 out of alignment with the offtake ducts 44 and 46. In this instance, the blocker doors 90 are placed in the quadrant that includes the offtakes 44 and 46 so that the core flow D flows axially through the rotary drum 32. The fan air portion E flows through the sub-passages of passage 60 and the remaining portion F flows through passage 56.
As is apparent from the foregoing the flow of the core stream and the flow of the fan stream in all modes of engine and aircraft operation are maintained separate. It will be appreciated that when in the STOVL mode of operation either the vane blockers 28 or the exhaust nozzle 30 are in the close position so as to divert the core stream. It is to be understood that in certain modes of operation it may be desired to proportion the core stream so that only a portion is diverted. This could easily be controlled by the controller 62 (FIG. 7) which would position the rotary drum and the exhaust nozzle or vane blockers to control the amount of flow being diverted.
FIGS. 16-18 exemplify another embodiment of this invention where coannular offtakes are utilized as opposed to the twin duct offtakes depicted in FIGS. 1-15. The schematic illustrations of FIGS. 16-18 show the rotating drum 110 having concentrically disposed shell 112 and liner 114 with a plurality of circumferentially spaced ports 116. The contoured inserts 118 support the liner to the shell 112 and both rotate together. The space between the liner 114 and shell 112 define the annular passage 122 and the inserts 118 form transition surfaces to guide the flow around the respective ports 116 so as to assure that the fan stream is maintained separate from the core stream.
The engine case 124 and liner 126 as shown in FIG. 16 are concentrically disposed and spaced to define the annular passage 128 and are supported by the ribs 130 extending axially through the case 124 and the inserts 130 contoured around the openings 132. As best seen in this Fig. the annular passage 126 is divided in sub-passages 134 and 136. Sub-passages 134 are axially aligned passages that extend straight through and sub-passages 136 adjacent each of the openings 132 lead the flow around the openings 132 into slots 138 formed on the aft side of the openings 132 and are in communication with the passage 140 formed between the annular offtake 142 and the offtake liner 144 parallel to and spaced therefrom.
In STOVL mode of operation the ports 116 align with the apertures 132 for diverting the core stream A from the rotary drum into the coannular offtakes 124 via the ports 116 and apertures 132. The blocker doors 148, similar in design to the blocker doors 90 depicted in FIGS. 7 and 8 block the sub-passages 134 leaving sub-passages 136 exposed to the fan air stream. Hence a portion of the fan air stream B is directed into sub-passage 136 and is transitioned into the passage 140 to maintain the coannular offtake 124 within the structural integrity of the material. The remaining portion of the fan air C flows through passage 122 axially through the rotary drum 110 to cool the downstream engine components. Similar to the operation of the twin duct offtake configuration the engine's exhaust gas discharging from the exhaust nozzles is completely or partially blocked off depending on the mode of aircraft operation.
In the forward flight or cruise aircraft mode of operation the rotary drum is rotated to place ports 116 out of alignment with the openings 132 and the core stream D flows axially through the rotary drum 110 to be discharged through the exhaust nozzle. In this mode of operation the blocker doors 148 block the flow in sub-passages 136 and expose sub-passages 134 so that the portion of the fan air E flows straight through the rotary drum 110 through sub-passages 134. The remaining portion of the fan air flows through the annular passage 122 to cool the downstream components of the engine.
What has been shown by this invention is a relatively simple structure requiring minimum number of components that divert the fan air flow and core flow separately while assuring that the fan air flow during STOVL mode of operation cools both the offtake ducts whether coannular ducts or twin ducts are utilized and the aft components of the engine.
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 flow diverting mechanism for the twin duct offtakes or coannular offtake for a turbo fan engine powering aircraft with either thrust reversing or short takeoff and vertical landing or both capabilities includes a rotary drum mounted between the turbine and afterburner sections and includes ports complementing the inlets in the offtakes to divert the core stream through the offtakes and passages to proportion the fan discharge air utilized for cooling purposes in the engine to cool the liner and walls of the offtakes and the engine components located downstream of the rotary drum while assuring separation of the core stream flow and fan air flow. | 5 |
This is a continuation-in-part of application Ser. No. 09/626,390, filed on Jul. 26, 2000, and which is now abandoned.
FIELD OF THE INVENTION
The present invention relates to clamping mechanisms for securing together multiple tubes together in a mutually parallel arrangement, and a method incorporated for use with such mechanism, and more particularly, provides a new and useful structure that can avoid incorporation of guide protrusions, external C-clamps, and the like and at the same time accommodate single-person installation.
BACKGROUND OF THE INVENTION
Most power plants use steam turbines to generate electricity. A simple steam turbine power plant consists of a boiler, a steam turbine, and a condenser. Water is heated in the boiler to form steam, which is then ducted to the turbine. The turbine converts the steam's thermal energy to rotational energy, which is used to power an electric generator. The steam exhausted form the turbine is condensed to water in the condenser, and returned to the boiler where it is again converted to steam. Steam power plants can be fueled by nuclear energy or by any conventional fuel that will supply sufficient heat to the boiler. As petroleum supplies dwindle and the environmental consequences of atomic energy use become increasingly evident, the use of coal-fired power plants will, no doubt, increase. Fuel-burning steam turbine power plants typically feature boilers having an array of metal boiler tubes therein. In order to maintain the tubes in an order arrangement and to prevent them from warping if hot spots occur, or if one or more of the boiler tubes springs a leak, it is common to clamp multiple the tubes in an essentially parallel arrangement. Heretofore, many different types of clamping mechanisms have been utilized. Typically, such clamping mechanisms are comprised of a pair of mating half-clamps, which incorporate guide protuberances and cooperating apertures which aid in bringing the tubes into a proximate, mutually parallel configuration. External C-clamps are sometimes provided to pull the half-clamps together, thereby forcing the tubes into the desired parallel configuration. Installation of such clamps often requires the effort of two or more workmen.
U.S. Pat. No. 5,083,372 to Polutnik, et al. discloses a now-common, self-aligning, boiler tube clamp having parallel mating half-clamps. The half-clamps are pulled together with bolts. U.S. Pat. No. 5,060,810 to Jones discloses a similar clamping device for holding load braces on a trailer or truck structure when not in use.
Boiler tubes and the clamps which hold them in parallel configurations are subjected to amazingly harsh environments. Both the tubes and the clamps are generally fabricated from stainless steel. The ranks of boiler tubes are generally positioned vertically within a boiler chamber that is at least several stories high. For coal-fired plants, pulverized coal is introduced into an air stream, ignited as it enters the top of the boiler chamber, and exhausted as ash, carbon dioxide, water vapor and other combustion gases at the bottom of the chamber. The coal dust and coal ash are abrasive, and over time, will erode unprotected materials in the boiler chamber. Those portions of the boiler tube clamp assemblies which project a flat surface perpendicular to the air stream become coated with ash and are, thus, protected against abrasion. However, portions of the clamp assemblies which are not coated, and which are directly exposed to the burning coal dust and coal ash will erode. Surfaces of welds, bolts and nuts which are exposed to the air stream are vulnerable. If welds bolts and nuts, which are used to hold the tube clamps together, project laterally from the sides of the clamps into the air stream, they will weaken from the constant erosion, and will eventually fail.
What is needed are boiler tube clamp assemblies which are generally immune from the erosive action of the coal dust and coal ash when placed within the air stream of a boiler chamber.
SUMMARY OF THE INVENTION
The present invention is an improved boiler tube clamp, which has greatly improved immunity to erosion caused by the continual blast of burning coal dust and coal ash in a boiler. Like the boiler tube clamp of Polutnik, et al., the new clamp includes a pair of mating half-clamps having multiple opposed recesses sized to snugly cradle boiler tubes of a given diameter. The half-clamps are brought together around a plurality of boiler tubes, and fastened together either with bolts or welds so as to maintain the tubes in a parallel configuration. Several embodiments of the improved clamp are disclosed. For each embodiment, at least one fastening means is protected from erosion caused by the continual blast of burning coal dust and coal ash. All embodiments feature weldable tabs on generally planar horizontal surfaces which are perpendicular to the flow of the burning coal dust and coal ash. Coal ash, which builds up on the horizontal surfaces, protects the welds from erosion.
A first embodiment of the new clamp mechanism includes a pair of non-matching half-clamps, one of which is equipped with a plurality of slots along the upper and lower surfaces thereof. The other half-clamp is equipped with tabs which mate with the slots of the other half-clamp when both halves are brought together by tightening the screw-type fasteners. The mating locations are readily accessible, thereby allowing a weld to be placed at the junction of each slot and its mating tab. When welds are applied to the new clamp, the clamping function is unaffected by vibration. The new clamp also differs from that of Polutnik, et al. in that provision for installation of a screw-type fastener is made between each adjacent pair of tube recesses. In order to reduce the number of personnel required to install the new clamp, one of the mating half-clamps is equipped with bolt head socket at each bolt insertion location, thereby eliminating the need to hold the bolt head with a wrench while tightening a threadably-attached nut.
A second embodiment of the new clamp is similar to the first embodiment thereof, with the exception that there are no bolt holes in the half-clamps, and no bolts are used to hold to two halves together. The half-clamps are drawn together using some other clamping means and welds are used to hold both half-clamps together.
A third embodiment of the new clamp includes a pair of matching half-clamps, each of which is equipped with a plurality of tabs along the upper surface thereof and a plurality of slots along the lower surface thereof. One half-clamp may be inverted and positioned opposite another so that the tabs of each mate with the slots of the opposing half-clamp. Rather than using a socket recesses on one of the half-clamps to retain the bolt heads of the clamping screw-type fasteners, the head of each bolt may be prevented from rotating by utilizing a locking clip beneath the head of each bolt. A ganged clip may secure all bolts installed in a half-clamp, or individual clips may be employed to lock each bolt to the half-clamp.
A fourth embodiment of the new clamp is similar to the third embodiment thereof, with the exception that there are no bolt holes in the half-clamps, and no bolts are used to hold to two halves together. The half-clamps are drawn together using some other clamping means and welds are used to hold both half-clamps together.
DESCRIPTION OF THE DRAWINGS
The present invention, both as to the organization and operation of the various embodiments, may best be understood by reference to the following drawings taken in connection with the description which follows, in which:
FIG. 1 is an isometric exploded view of a first embodiment of the multiple-tube clamp;
FIG. 2 is an isometric view of the clamp of FIG. 1, assembled in connection with multiple cylindrical tubes;
FIG. 3 is a cross-sectional view of the assembly of FIG. 2, taken through the plane ABCD, which passes through the longitudinal axes of the five bolts;
FIG. 4 is a cross-sectional exploded view of the assembly of FIG. 3;
FIG. 5 is an isometric exploded view of a second embodiment of the multiple-tube clamp;
FIG. 6 is an isometric view of the clamp of FIG. 5, assembled in connection with multiple cylindrical tubes;
FIG. 7 is a top plan view of the assembly of FIG. 6;
FIG. 8 is a top plan exploded view of the assembly of FIG. 7;
FIG. 9 is an isometric exploded view of a third embodiment of the multiple-tube clamp;
FIG. 10 is an isometric exploded view of a fourth embodiment of the multiple-tube clamp;
FIG. 11 is an isometric exploded view of a fifth embodiment of the multiple-tube clamp;
FIG. 12 is an isometric view of the clamp of FIG. 11, assembled in connection with multiple cylindrical tubes;
FIG. 13 is an isometric exploded view of a sixth embodiment of the multiple-tube clamp;
FIG. 14 is an isometric view of the clamp of FIG. 13, assembled in connection with multiple cylindrical tubes;
FIG. 15 is an isometric exploded view of a seventh embodiment of the multiple-tube clamp; and
FIG. 16 is an isometric view of the clamp of FIG. 15, assembled in connection with multiple cylindrical tubes.
DETAILED DESCRIPTION OF THE INVENTION
The new improved boiler tube clamp, which may be employed to clamp boiler tubes in an equal-spaced, parallel arrangement includes a pair of mating half-clamps having multiple opposed recesses sized to snugly cradle boiler tubes of a given diameter. The half-clamps are brought together around the boiler tubes and fastened together either with bolts or welds or both. The new clamp is disclosed as four primary embodiments, which will be described sequentially in reference to the attached drawings.
Referring now to FIG. 1, a first embodiment of the improved boiler tube clamp 100 includes first and second non-matching, elongated half-clamps 101 A and 101 B, respectively. Each half-clamp includes multiple, mutually spaced-apart, inwardly-curved, essentially hemi-cylindrical guides 102 , each adjacent pair of guides 102 on said first half-clamp 101 A being joined together by an integral medial portion 103 A, and each adjacent pair of guides 102 on said second half-clamp 101 B being joined together by an integral medial portion 103 B, each medial portion 103 A of said first half-clamp mating with a medial portion 103 B of said second half-clamp when said half-clamps 101 A and 101 B are brought together in a clamping configuration, thereby forming a series of axially-parallel, spaced-apart, hollow cylindrical guides 202 (see FIG. 2 ). Half-clamp 101 A is equipped with a plurality of slots 105 along the upper surface 106 U and lower surface 106 L thereof. The other half-clamp 101 B is equipped with tabs 107 along the upper surface 108 U and lower surface 108 L thereof, which mate with the slots 105 of half-clamp 101 A when both half-clamps ( 101 A and 101 B) are brought together in an assembled, clamping configuration. Each medial portion 103 A of half-clamp 101 A is equipped with a bolt-shank receiving bore 109 A, which aligns with the bore 109 B of a mating medial portion 103 B of half-clamp 101 B. A bolts 110 may be inserted in each aligned bore pairs 109 A/ 109 B. When a nut 111 is mated to each bolt 110 , the half-clamps 101 A and 101 B may be brought together in an assembled, clamping configuration. A washer 112 may be placed beneath each nut 111 . An mating junction 113 is formed along the perimeter of each slot 105 where it is adjacent a 107 . The mating junctions 113 are exposed and readily accessible, thereby allowing the placement of a weld at each junction 113 . When welds (see FIG. 2) are applied to the junctions 113 of the improved clamp 100 , the clamping function is unaffected by vibration.
Referring now to FIG. 2, the two half-clamps 101 A and 101 B of FIG. 1 have been brought together as a clamp assembly, 200 in combination with a series of boiler tubes 201 A- 201 G. The hemi-cylindrical guides 102 A and 102 B of assembled half-clamps 101 A and 101 B, respectively, form multiple cylindrical guides 202 , within each of which a boiler tube 201 A- 201 G is firmly clamped. The bolts 110 and nuts 111 may be employed to fasten both half-clamps 101 A and 101 B together. Once the two half-clamps 101 A and 101 B are brought together, a mating junction 203 is formed along the perimeter of each slot 105 where it is adjacent a tab 107 . The mating junctions 203 are exposed and readily accessible, thereby allowing the placement of a weld 204 at each junction 203 . In this drawing, a weld 204 has been placed on the mating junctions of each of the outer medial portion pairs 103 N/ 103 B and of the two middle medial portion pairs 103 A/ 103 B. When welds are applied to the junctions 203 of the improved clamp assembly 200 , the clamping function is unaffected by vibration.
Referring now to the cross-sectional view of FIG. 3, taken through the plane ABCD of FIG. 2, which passes through the axes of bolt receiving bores 109 A/ 109 B. In order to reduce the number of personnel required to install the improved boiler tube clamp 100 , the medial portions 103 B of half-clamp 101 B are equipped with a non-circular, bolt-head receiving socket 301 aligned to a bolt-shank receiving bore 109 B, thereby eliminating the need to hold the bolt head 302 with a wrench while tightening a threadably-attached nut 111 .
Referring now to FIG. 4, the assembly of FIG. 3 is shown in an exploded view. Tubes 201 A- 201 F are viewed parallel to their axes. The elements identified in this view have been heretofore described in reference to FIG. 1, 2 or 3 .
Referring now to FIG. 5, a second embodiment of the improved boiler tube clamp 500 is identical to the first embodiment clamp 100 , with the exception that there are no bolt shank receiving bores 109 A or 109 B in the medial portions 502 of each half clamp 501 A and 502 B. The half-clamps 501 A and 501 B are drawn together using some other clamping means (e.g., C-clamps) and welds are employed to hold the assembled half-clamps together.
Referring now to FIG. 6, the two half-clamps 501 A and 501 B of FIG. 5 have been brought together in an assembled configuration in combination with a series of boiler tubes 201 A- 201 F. A weld 114 has been placed at each mating junction 113 .
Referring now to FIG. 7, the top plan view of the assembly of FIG. 6 shows the boiler tubes 201 A- 201 F in an axially parallel and aligned configuration. Welds 114 are also visible in this view.
Referring now to FIG. 8, the assembly of FIG. 7 is shown prior to assembly in an exploded view. Of course, no welds are shown in this state of assembly.
Referring now to FIG. 9, a third embodiment of the improved clamp 900 includes a pair of matching half-clamps 901 , each of which is equipped with a plurality of tabs 107 along the upper surface 902 U thereof and a plurality of slots 105 along the lower surface 902 L thereof. One half-clamp 901 may be inverted and positioned opposite the other so that the tabs 107 of each mate with the slots 105 of the opposing half-clamp 901 . Because identical half-clamps 901 are employed in pairs, it is desirable to have a bolt-head receiving socket 301 on each medial portion 903 . It will be noted that a washer 904 larger in diameter than the bolt-head receiving socket 301 is placed beneath each nut 111 . The large washer 904 spans, or bridges the socket 301 so that the socket 301 does not interfere with the tightening of the nut 111 . Alternatively, a bolt-head locking clip (not shown) may be placed beneath the head of each bolt. The clips may either be ganged together or each may be shaped so as to lock the bolt head against the medial portion. Using either technique, both of which are common in the mechanical arts, the bolts 110 may be prevented from turning as the nuts 111 are tightened thereon.
Referring now to FIG. 10, a fourth embodiment of the improved clamp 1000 is similar to the third embodiment depicted in FIG. 9, with the exception that there are no bolt holes in the identical half-clamps 1001 , and no bolts are used to hold to two halves together. The half-clamps are drawn together using some other clamping means and welds are used to hold both half-clamps together. Welds (not shown in this Figure) are employed to physically join both half-clamps 1001 at mating junctions 113 formed between slots 105 and tabs 107 .
Referring now to FIG. 11, a fifth embodiment of the improved clamp includes first and second non-matching, elongated half-clamps 1101 A and 1101 B, respectively. Each half-clamp includes multiple, mutually spaced-apart, inwardly-curved, essentially hemi-cylindrical guides 1102 , each adjacent pair of guides 1102 on said first half-clamp 1101 A being joined together by an integral medial portion 1103 A, and each adjacent pair of guides 1102 on said second half-clamp 1101 B being joined together by an integral medial portion 1103 B, each medial portion 1103 A of said first half-clamp mating with a medial portion 1103 B of said second half-clamp when said half-clamps 1101 A and 1101 B are brought together in a clamping configuration, thereby forming a series of axially-parallel, spaced-apart, hollow cylindrical guides 1202 (see FIG. 2 ). Half-clamp 1101 A is equipped with a plurality of slots 1105 along the upper surface 1106 U and lower surface 1106 L thereof. The other half-clamp 1101 B is equipped with tabs 1107 along the upper surface 1108 U and lower surface 1108 L thereof, which mate with the slots 1105 of half-clamp 1101 A when both half-clamps ( 1101 A and 1101 B) are brought together in an assembled, clamping configuration. Each medial portion 1103 A of half-clamp 1101 A is equipped with a bolt-shank receiving bore 1109 A, which aligns with the threaded bore 1109 B of a mating medial portion 1103 B of half-clamp 1101 B. A bolt 1110 may be inserted through each bolt-shank receiving bore 1109 A in half-clamp 1101 B and secured in a threaded bore 1109 B of half-clamp 1101 B. It will be noted that each bolt 1110 is termed a stretch bolt. That is, the unthreaded part 1113 of the bolt shank 1114 is of reduced diameter, so that when the threaded part 1115 of the shank 1114 is torqued during tightening, the unthreaded part 1113 will stretch. This has a tendency to lock the bolt in the bore. This feature, coupled with a serrated head bearing surface (shown in FIG. 13) which bears against the seat 1116 of a receiving bore 1109 A, ensures that the bolt, when tightened to its specified torque rating, will not vibrate loose.
Referring now to FIG. 12, the two half-clamps 1101 A and 1101 B of FIG. 11 have been brought together in clamp assembly 1200 in combination with a series of boiler tubes 201 A- 201 G (see FIG. 2 of the original hand-drawn drawing figures). The hemi-cylindrical guides 1102 of assembled half-clamps 1101 A and 1101 B form multiple cylindrical guides 1201 , within each of which a boiler tube 201 Ak, 201 B, 201 C, 201 D, 201 E, 201 F or 201 G is firmly clamped. The bolts 1110 may be employed to fasten both half-clamps 1101 A and 1101 B together. A mating junction 203 is formed along the perimeter of each slot 105 where it is adjacent a tab 107 . The mating junctions 203 are exposed and readily accessible, thereby allowing the placement of a weld 204 at each junction 203 . When welds 204 are applied to multiple junctions 203 of the improved clamp 1100 , the half-clamps 1101 A and 1101 B become a single unit and will not separate under normal operational conditions. It will be noted that, as a large portion of each weld 204 in on a horizontal surface of the clamp, it will be largely unaffected by erosion caused by the blast of burning coal dust and coal ash against it when installed within a power plant boiler.
Referring now to FIG. 13, a sixth embodiment of the improved clamp 1300 includes a pair of matching half-clamps 1301 , each of which is equipped with a plurality of tabs 1302 along the upper surface 1303 U thereof and a plurality of slots 1304 along the lower surface 1303 L thereof. One half-clamp 1301 may be inverted and positioned opposite the other so that the tabs 1302 of each mate with the slots 1304 of the opposing half-clamp 1301 . Because identical half-clamps 1301 are employed in pairs, each medial portion 1305 is alternately equipped with either a bolt-shank receiving bore 1306 A or threaded bore 1306 B, so that when a pair of the half-clamps 1301 are brought together, a bolt 1105 may be inserted into every other medial portion 1305 of each half clamp 1301 . For this arrangement to be successful, an even number of medial portions 1305 and an odd number of tube guides 1307 are required. It will be noted that as with the fifth embodiment of the invention, stretch bolts having serrated head bearing surfaces 1308 are employed to lock the bolts in the bores 1306 A/ 1306 B when torqued to proper specifications.
Referring now to FIG. 14 the two half-clamps 1301 A and 1301 B of FIG. 13 have been brought together in a clamp assembly 1400 in combination with a series of boiler tubes 201 A- 201 G. The hemi-cylindrical guides 1307 of assembled half-clamps 1301 A and 1301 B form multiple cylindrical guides 1401 , within each of which a boiler tube 201 Ak, 201 B, 201 C, 201 D, 201 E, 201 F or 201 G may firmly clamped. A mating junction 203 is formed along the perimeter of each tab 107 where it is adjacent a slot 105 . The mating junctions 203 are exposed and readily accessible, thereby allowing the placement of a weld 204 at each junction 203 . When welds are applied to the junctions 203 of the improved clamp 1300 , the half-clamps 1301 A and 1301 B become a single unit and will not separate under normal operational conditions.
Referring now to FIG. 15, a seventh embodiment of the improved clamp 1500 includes a pair of matching half-clamps 1501 , each of which is equipped with a plurality of alternating tabs 1502 on the upper and lower surfaces 1503 U and 1503 L of the medial portions 1504 thereof. This embodiment is different from the others in that each bolt-shank receiving bore 1505 is equipped with a nut recess 1506 which can double as a bolt head recess. A serrated head head bear surface 1308 on each bolt 1110 is employed to lock each bolt in its respective bore 1505 . Each nut 111 , of course, is locked in place by the nut recess 1506 . The bolts may be inserted from either direction.
Referring now to FIG. 16, the two half-clamps 1501 of FIG. 15 have been brought together in an assembled configuration in combination with a series of boiler tubes 201 A- 201 F (see FIG. 2 of the original hand-drawn drawing figures). The hemi-cylindrical guides 1601 of assembled half-clamps 1501 form multiple cylindrical guides 1502 , within each of which a boiler tube 201 (see FIG. 2) may firmly clamped. A mating junction 1603 is formed along the perimeter of each tab 1502 where it is adjacent a slot 1504 . The mating junctions 1603 are exposed and readily accessible, thereby allowing the placement of a weld 1604 at each junction 1603 . When welds (identical to those in FIG. 1) are applied to the junctions 1603 of the improved clamp 1500 , the half-clamps 1501 become a single unit and will not separate under normal operational conditions.
Although only several embodiments of the invention have been heretofore described, it will be obvious to those having ordinary skill in the art that changes and modifications may be made thereto without departing from the scope and the spirit of the invention as hereinafter claimed. | A boiler tube clamp, for securing boiler tubes in an equal-spaced, parallel arrangement, includes a pair of mating half-clamps having multiple opposed recesses sized to snugly cradle boiler tubes of a given diameter. The half-clamps are brought together around the boiler tubes and either welded or bolted together, thereby aligning the tubes in the desired arrangement. The bolts and/or clamps used to secure together the mating half-clamps of each of the embodiments of the invention are unaffected by downward abrasive action that typically occurs in boilers. For welded-together half-clamps, the welds are on top and bottom surfaces where they are shielded from abrasive action. For bolted-together half-clamps, the bolts are protected from abrasive action by recessing the bolt heads and retaining nuts. | 5 |
BACKGROUND OF THE INVENTION
The invention relates to suspended ceiling construction and, in particular, to a device for stabilizing relatively long grid openings.
PRIOR ART
Suspended ceiling grid design has evolved to arrangements where the grid modules or openings are commonly 2 foot by 4 foot or 2 foot by 2 foot (or metric equivalents). Accordingly, the grid members are designed with a geometry and material content to withstand the forces present in these now common grid module sizes.
In recent times, there has developed a demand for larger panels than these common sizes. This presents a problem because the grid elements, typically tees, can bend and/or twist under the panel weight or other imposed loading. Deflection of a grid element for a given force is exponential with its unrestrained length and twisting is proportional to its length. It follows that a grid element having a standard construction but with an unusually long unrestrained length, can deflect and/or twist beyond normal limits. When a grid element deflects from its intended position, the associated edge of a panel can slip off the element. This results in an unsightly appearance or, worse, the panel can fall off the grid.
Stabilizer bars have been available to maintain a pair of grid elements in their desired positions. An example of a prior art stabilizer bar is disclosed in U.S. Pat. No. 4,064,671. A typical prior art stabilizer bar in a completed ceiling installation cannot be ordinarily relocated to a functional position after an underlying panel has been raised to gain access to the plenum above the ceiling. There is no practical way of reinstalling stabilizer bars where the adjacent panels on both sides of the removed panel are in place. Accordingly, there has existed a need for a stabilizer bar arrangement that can be reinstalled after the panel beneath it is raised for access and then reset in a ceiling grid module.
SUMMARY OF THE INVENTION
The invention provides a stabilizer bar for a suspended ceiling grid that is reinstallable after its removal for access to the plenum above the ceiling. The stabilizer bar, in accordance with the invention, is rigidly affixed to the rear side of the ceiling panel and is arranged to engage a pair of parallel spaced grid runners when the panel is lowered into place.
A hook structure at each end of the stabilizer bar is proportioned to laterally restrain an associated grid member. The hook structure engages opposite sides of a reinforcing bulb of a respective grid runner. As a result, the respective grid runner is restrained from excessive bowing and/or tilting which could otherwise result with an edge of an associated panel free to sag or drop from the grid.
In the disclosed embodiment, the stabilizer bar is provided with integral tabs for penetrating and locking onto the body or core of an associated acoustical panel. Alternatively, the stabilizer bar has provisions for being fixed with screws or like fasteners to a wood or other dense composite panel.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an isometric view of a stabilizer bar constructed in accordance with the invention;
FIG. 2 is a plan view of a blank or stamping from which the stabilizer bar of FIG. 1 is formed;
FIG. 3 is an end view of the stabilizer bar;
FIG. 4 is a fragmentary isometric view of the stabilizer bar showing the deployed positions of a stab tab, a capture tab, and a folded bulb hook;
FIG. 5 is an elevational view of the stabilizer bar fixed as an assembly on a ceiling panel with the assembly installed on a pair of parallel grid runners; and
FIG. 6 is a fragmentary isometric view of the stabilizer bar modified and fixed on a high density panel.
DESCRIPTION OF THE PREFERRED EMBODIMENT
A stabilizer bar 10 shown in FIG. 1 is an elongated sheet metal body formed with a right angle cross-section. The stabilizer bar 10 can be made of a suitable malleable metal such as, for example, 21 gauge hot dipped galvanized steel. The stabilizer bar, for example, can have nominal lengths of 24 inches, 30 inches, and 48 inches or metric industry substitutes for these dimensions depending on the application. The stabilizer bar 10 is symmetrical about its mid-length. The stabilizer bar 10 includes a horizontal leg 11 and a vertical leg 12 , both of which are generally planar allowing a plurality of stabilizer bars to be nested for shipping purposes. The horizontal leg 11 has a pair of integral stab tabs 16 stamped or otherwise cut into its body at locations spaced from the leg ends along a free or distal longitudinal edge 17 . With particular reference to FIG. 2 , showing the profile of the legs 11 and 12 , the tabs 16 are somewhat pointed adjacent the line of the distal edge 17 . A hole 18 in the leg 11 at the base of a tab 16 leaves two land areas 19 connecting the tab to the leg proper. The hole 18 forms a line of weakness 21 parallel to the length of the stabilizer bar 10 . At each end of the stabilizer bar 10 , the horizontal leg 11 is formed with an integral capture tab 23 . Preferably, the capture tab 23 , in the form of the stabilizer bar as it is shipped from the manufacturing site, has a proximal portion 24 in the plane of the horizontal leg 11 and a distal depending portion 25 in a plane at right angles to the plane of the horizontal leg. The distal portion 25 is in the form of a pair of truncated or blunted triangular barbs 26 .
A through slot 27 transverse to the length of the stabilizer bar 10 leaves a pair of spaced lands 28 joining the capture tab 23 to the horizontal leg proper and forms a transverse line of weakness 29 between the horizontal leg proper and the capture tab 23 . A plurality of through holes 32 are spaced along the length of the horizontal leg, preferably midway between the edge 17 and the vertical leg 12 .
As shown in FIG. 3 , the vertical leg 11 is stiffened at its upper edge by an integral offset formed by an oblique narrow band 33 and a vertical distal strip 34 . Each end of the vertical leg 12 includes a vertical slot 37 open at the bottom and forming an integral vertical depending hook 38 . A free end of the hook 38 has a beveled edge 39 leading to the slot 37 . A juncture of the hook 38 with the vertical leg proper is interrupted by a small through vertical slot 41 that leaves a pair of land areas 42 and forming a vertical line of weakness 43 in the juncture.
The selected length of the stabilizer bar will correspond to the nominal spacing of a pair of main tees on which the stabilizer bar 10 is ultimately mounted. One or two stabilizer bars 10 can be used on a ceiling panel, depending on the length of the panel. Ordinarily, where one is used, it is located at mid-length of the panel; when two are used on longer panels, they are located from an end of the panel at ⅓ and ⅔ of the panel length.
The stabilizer bar 10 can be fixed on the back side of an acoustical ceiling panel or tile of a low density type using the integral tabs 16 and 23 . The final position of a stabilizer bar on a panel is illustrated in FIG. 3 , but their mutual assembly is accomplished before they are mounted on the ceiling grid. First, the stab tabs 16 are manually bent down 90 degrees to a vertical orientation, typically by the person installing a ceiling panel 44 . The land areas 19 bend at the line of weakness 21 . Thereafter, the stabilizer bar 10 is laterally symmetrically located on the panel 44 so that the slots 37 are both outward of long edges 46 of the panel 44 as shown in FIG. 5 . Then, the stabilizer bar 10 is pressed downward to drive the stab tabs 16 into the core of the panel 44 until the lower face of the horizontal leg 11 abuts the backside of the panel 44 . Next, the capture tabs 23 are deployed by bending them so that the barbs 26 are driven into the vertical surfaces 46 of the respective edges of the panel 44 . The capture tab 23 hinges about the line 29 so that the proximal part 24 of the tab 23 can be folded tightly against the edge surface 46 while the barbs 26 are driven with a horizontal movement component into the core of the panel 44 .
With the stab tabs 16 and capture tabs 23 deployed as described, the stabilizer bar 10 is fixed on the panel 44 . The assembly of the panel 44 and stabilizer bar 10 or stabilizer bars is ordinarily installed on a grid by first manipulating the assembly through a grid opening from below much the same way an ordinary panel without a stabilizer bar is manipulated. The suspended ceiling grid is represented by a pair of parallel spaced grid runners or tees 51 illustrated in FIG. 5 . The grid runners 51 are spaced in parallel relation at, typically, the nominal dimensions recited above in the description of normally available stabilizer bars 10 . The panel and stabilizer bar assembly is aligned so that it overlies a grid module and is then lowered into place.
The beveled edges 39 on the hooks 38 afford a centering action to bring the panel and stabilizer bar assembly into lateral registration with the grid tees 51 . As the assembly is lowered, reinforcing bulbs 52 of the grid runners 51 enter respective slots 37 in the stabilizer bar vertical leg 12 . The width of a slot 37 is dimensioned with a moderately loose fit relative to the width of a reinforcing bulb 52 to allow the bulb to freely slide into the slot but to not allow appreciable lateral movement of the bulb. The vertical dimension of the slot 37 is large in comparison to the height of the bulb 52 , in a normal range of panel thickness, so that a clearance will exist between the stabilizer bar and the top of the bulb. The hook 38 can be manually bent towards the associated bulb 52 at the line 43 to reduce interference with installation or removal of a panel in the adjacent grid module.
With the panel 44 resting on flanges 53 of the grid runners 51 , the reinforcing bulbs 52 are constrained in both lateral directions by the sides of the respective slots 37 . Consequently, the grid runners 51 are restrained from significant lateral bowing and/or twisting about their longitudinal axii. Therefore, the risk that the edge of a panel 44 can slip off a flange 53 , deflected by the weight of a long panel or other force, is greatly reduced, if not eliminated.
The inventive stabilizer bar has the advantage of allowing the panel 44 to which it is fixed to be lifted for access to the plenum above the grid and permits it to be reinstalled in the same manner as it was initially installed.
The stabilizer bar can be modified by the technician installing it for use with wood or other dense core panels or tiles. A small reference notch 56 exists in the horizontal leg edge 17 adjacent each end of the leg 11 . A diagonal cut with a tin snips or the like is made from the notch 56 to the end of the horizontal leg 11 to sever the capture tab 23 from the stabilizer bar. The stab tabs 16 are not bent out of the plane of the horizontal leg 11 . As illustrated in FIG. 6 , the stabilizer bar 10 is located on the back of a dense panel substantially as described above. Short screws 57 are assembled in the holes 32 and driven into the panel core to fix the modified stabilizer bar to the panel.
It should be evident that this disclosure is by way of example and that various changes may be made by adding, modifying or eliminating details without departing from the fair scope of the teaching contained in this disclosure. The invention is therefore not limited to particular details of this disclosure except to the extent that the following claims are necessarily so limited. | An elongated stabilizer bar for maintaining a pair of grid runners in parallel upright positions to support a panel on respective grid runner support surfaces, the stabilizer bar having a horizontal leg and a vertical leg, the horizontal leg having self-penetrating tabs arranged to pierce and thereby grip a core of the panel to fix the stabilizer bar to the panel, a vertical leg having a vertical slot at each end, the slot having an open bottom, the slot having a horizontal width adapted to receive and confine an upper reinforcing bulb of a respective one of the pair of grid runners to thereby restrain the respective grid runner against excessive bowing and twisting deflection. | 4 |
FIELD OF THE INVENTION
This invention relates generally to devices to control fluid flow, and more particularly, to an automatic fluid flow control valve that maintains a constant rate of flow over a wide range of fluid pressure drops across the valve.
BACKGROUND OF THE INVENTION
Flow regulator valves are typically used to balance the flow rate of water to and from heating and cooling coils when several coils are supplied from one pump incorporating many branches in the flow circuit. For this reason, the valves are typically called balancing valves because they balance the flow rate of water to each coil, although they are often used to balance flow control rates for other applications. The valves are most often used to control the flow rates of fluids with viscosities similar to that of water to fixed flow rates with variations in pressure drop across the valves. Without a flow regulation valve, as the pressure drop across a fixed orifice is increased, the flow rate is increased accordingly.
Prior-an devices have been used to achieve flow regulation by employing a squat rubber "torpedo" (resilient diaphragm), as in U.S. Pat. No. 3,189,125 ("the '125 patent"). The torpedo is forced against a contoured orifice as the pressure drop increases across the valve. Increasing pressure drops across the device will progressively press the torpedo against the contoured orifice, causing the flow area between the torpedo and the contour to be reduced. The reduction in flow area is sufficient to restrict the flow to a more-or-less constant value even though the pressure drop across the flow area has increased (see FIG. 14 of the '125 patent). However, many of the existing balancing valves utilize ribs that are molded onto the torpedo to keep it concentrically centered in the flow path immediately upstream of the contoured orifice. See, e.g., U.S. Pat. Nos. 5,027,861; 4,986,312; 3,189,125 and 3,958,603. The fluid first flows around the front of the torpedo, then through the annular section between the walls of the flow passage and the torpedo. Next, the fluid is diverted into the flow section between the torpedo and the contoured orifice (the variable flow area section) then exits out the back of the contoured orifice.
A limitation to the prior-art control devices is that they require approximately 10 pounds per square inch of pressure drop to start to control the flow rate to a fixed value (within the flow tolerance of the device). An initial pressure drop of at least four pounds would be closer to the ideal low end of the range within which a valve should operate to regulate flow. Lower required pressure drops help to reduce the required pump size, which conserves energy costs and reduces the purchase price of the pump. A large portion of the pressure drop that occurs before the device controls the flow is caused by the restriction in the annular space between the torpedo and the flow line walls. The tight 90-degree bend that the fluid must take to enter the variable flow area also creates an unnecessary restriction.
The annular space could be increased and hence reduce the pressure losses by simply making the ribs that center the torpedo larger and increasing the inside diameter of the walls of the flow passage. The problem with this approach is that the longer ribs would be too flimsy to accurately center the torpedo over the contoured orifice.
Other prior art valves are constructed of rubber elements that bend to restrict flow. For example, U.S. Pat. No. 4,986,312 discloses a flow control device utilizing a rubber disk that bends as flow increases through its center. However, most of these devices are subject to excessive bending-beam creeping and, thus, inaccuracies over time.
The orifice contours are also not ideally conducive to small pressure drops across the valve. Also, during backflow conditions, such as when backflushing a system, the prior art valves may not allow fluid to freely pass in a reverse direction, or the torpedo may become dislodged.
SUMMARY OF THE INVENTION
The valve of the present invention provides improved centering of a rubber torpedo (diaphragm), compared to molded ears, that in turn improves accuracy of the flow control. The invention also includes other features, as explained below and in the detailed description of the preferred embodiment, to improve the accuracy of control especially at low pressure drops across the value.
In accordance with this invention, an apparatus to control fluid flow is disclosed. The apparatus includes a housing, a first orifice, a first diaphragm, and a first cage. The housing has two ends, an inlet end having an inlet opening and an outlet end having an outlet opening. The ends are arranged and configured to receive piping. The first orifice is disposed within the housing. The first orifice has an upstream end and a downstream end with a seat formed in the upstream end. In normal downstream flow the fluid flows over the seat and through the first orifice before exiting the outlet end of the housing. The first diaphragm is disposed within the housing adjacent and upstream of the seat of the first orifice. The first diaphragm has an upstream side, a downstream side, and sidewalls. The downstream side of the diaphragm is adjacent the seat such that a pressure drop across the diaphragm holds the downstream side of the diaphragm toward the seat. The first cage surrounds at least a portion of the sidewalls of the first diaphragm The first cage has ribs projecting toward and contacting the sidewalls of the first diaphragm to hold the first diaphragm away from the housing and to minimize the flow restriction between the housing and the sidewalls.
In the preferred embodiment of the invention the first cage further includes outer walls that abut against the interior of the housing, the ribs projecting inwardly from the outer walls of the first cage. The outer walls of the first cage form a "C" shape. The first cage is formed of flexible material such that the two ends of the C-shaped walls are compressible to:yard one another to reduce the overall outer size of the first cage. Preferably, the housing is a one-piece housing having an internal cross-sectional area, into which the first cage fits, larger than the cross-sectional area of either the inlet or the outlet openings. The first cage is insertable into the housing, and removable from the housing, by compression of the first cage to reduce its overall outer size such that it is slightly smaller than the size of the inlet opening.
In accordance with a particular preferred aspect of the invention, the first orifice seat includes at least one channel formed therein through which the fluid flows when entering the first orifice before exiting the housing. The first diaphragm regulates flow by moving within the channel when the pressure drop across the first diaphragm increases. Preferably, the channel includes first steeply sloped walls forming a "V" shape. The point of the "V" is in the downstream direction. The channel also includes gently sloped walls upstream of the first steeply sloped walls and second steeply sloped walls upstream of the gently sloped walls. In the preferred embodiment of the invention, at least two channels are formed in the seat of the first orifice. Each channel has first and second steeply sloped walls and gently sloped walls. The second steeply sloped walls of each channel form legs between the channels extending in an upstream direction. For a pressure drop of zero to approximately eight psi the downstream side of the first diaphragm only comes in contact with the upstream side of these legs. The first orifice further includes a sleeve on its downstream end. The first orifice is separable from the housing. The housing includes a first orifice shoulder upon which the first orifice sits, the sleeve extending beyond the first orifice shoulder of the housing in a downstream direction.
In another embodiment of the invention the first orifice is an integral portion of the housing, formed within the housing.
In accordance with another preferred aspect of this invention, the housing includes a first cage recess into which the first cage is placed. A spring is disposed within the first cage recess downstream of the first cage. The spring is arranged and configured such that the first cage and the first diaphragm, which is held within the first cage, are biased in an upstream direction. The first cage further includes means to hold the first diaphragm sidewalls from substantial downstream movement relative to the first cage. Preferably, the holding means include holding tabs attached to at least one of the ribs and a perimeter groove around the first diaphragm. The holding tabs project inwardly from the ribs and engage the perimeter groove.
In accordance with another preferred aspect of the invention, the first cage includes ribs projecting inwardly from each end of the C-shaped walls. Tabs extend from the inward ends of the ribs in a tangential direction to the center of diaphragm 24 and cage 26. The tabs are arranged and configured for ease of compression of the first cage for insertion and removal of the first cage from the inlet opening of the housing.
At least one of the cage ribs extends at least partially over the upstream side of the first diaphragm to prevent the first diaphragm from being moved substantially out of position during backflow conditions. Preferably, the first cage includes at least three ribs that extend at least partially over the upstream side of the first diaphragm. The three ribs have cleats projecting downstream from their extensions over the upstream side of the first diaphragm. The cleats contact the upstream side of the first diaphragm.
In accordance with an alternate embodiment of the invention, the first cage is an integral portion of the housing. The ribs project inwardly from the interior walls of the housing. In accordance with another alternate embodiment of the invention, a second orifice is disposed within the housing adjacent the first orifice. The second orifice has an upstream end and a downstream end with a seat formed in the upstream end. Fluid flows over the seat and through the second orifice before exiting the outlet end of the housing in normal flow. A second diaphragm is disposed within the housing adjacent and upstream of the seat of the second orifice. The second diaphragm has an upstream side, a downstream side, and sidewalls. The downstream side of the second diaphragm is opposite the seat such that a pressure drop across the second diaphragm holds the downstream side of the second diaphragm toward the seat. A second cage surrounding at least a portion of the sidewalls of the second diaphragm is also included. The cage has ribs projecting toward and contacting the sidewalls of the second diaphragm to hold the second diaphragm away from the housing and to minimize the flow restriction between the housing and the sidewalls. In accordance with one alternate embodiment, the first and second cages are integral portions of the housing. The ribs project from interior walls of the housing.
In accordance with another preferred aspect of the invention, the first diaphragm includes a conical portion on its downstream side. The point of the conical portion is directed downstream. The conical portion serves to direct the flow through the first orifice and toward the outlet opening after flowing over the seat. The upstream side of the first diaphragm is conical in the preferred embodiment.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing aspects and many of the attendant advantages of this invention will become more readily appreciated as the same becomes better understood by reference to the following detailed description, when taken in conjunction with the accompanying drawings, wherein:
FIG. 1 is an isometric view of the valve of the present invention with a portion of the inlet pipe and housing removed to illustrate the internal structure of the valve;
FIG. 2 is an isometric exploded view of the valve of the present invention with the housing cut laterally in its center;
FIG. 3A is a side view of the valve with the housing, inlet pipe, and outlet pipe in cross section, the flow conditions at low pressure drop across the valve being shown;
FIG. 3B is a view similar to that shown in FIG. 3A with a moderately high pressure drop across the valve;
FIG. 3C is a view similar to those shown in FIGS. 3A and 3B with a high pressure drop across the valve;
FIG. 4 is an illustration of an alternate embodiment of the valve shown with a portion of the inlet pipe and housing cutaway;
FIG. 5 is an exploded isometric view of an alternate embodiment of the invention with a spring;
FIG. 6 is a cross-sectional view of the embodiment shown in FIG. 5;
FIG. 7 is an exploded view of an alternate embodiment of the invention having the cage as an integral part of the housing;
FIG. 8 is an alternate embodiment of the invention showing four valves arranged in parallel fashion within the same housing;
FIG. 9 is a cross-sectional elevational view of an alternate embodiment of the invention showing two valve assemblies side by side;
FIG. 10 is a lateral crosscut of the same embodiment as that shown in FIG. 9; and
FIG. 11 is an isometric view of another alternate embodiment of the present invention with a portion of the inlet pipe and housing removed to illustrate the internal structure of the valve.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The preferred embodiment of a valve 10 of the present invention is illustrated in FIGS. 1 and 2. The valve includes a cylindrical housing 12 into which an inlet pipe 14 and an outlet pipe 16 are connected. The housing includes a housing inlet 18 that connects to inlet pipe 14 and a housing outlet 20 that connects to outlet pipe 16. The connections of pipes 14 and 16 to housing 12 may be by threaded engagement or any other conventional means. An orifice 22, a diaphragm 24, and a cage 26 are disposed within housing 12. Orifice 22 is comprised of a cylindrical body that rests on a shoulder 28 of housing 12 adjacent housing outlet 20. A sleeve 30 is attached to the downstream end (nearer housing outlet 20) of the body of orifice 22. The outer diameter of sleeve 30 is somewhat smaller than that of orifice 22 while the inner diameter is preferably equal to that of orifice 22 such that sleeve 30 provides a conduit through which the flow is channeled just before exiting housing 12. The function of sleeve 30 is to reduce the erosions/corrosion of housing 12 as the fluid exits orifice 22. The outer perimeter of the body of orifice 22 includes a groove within which an O-ring 32 is disposed. O-ring 32 seats tightly against the interior of housing 12 such that fluid is not allowed to circumvent orifice 22 around its outer walls. A contoured seat 34 is formed in the upstream end of orifice 22. In the preferred embodiment, seat 34 includes first steeply sloped walls 66 that form a V-shaped channel, gently sloped walls 68 on either side of first steeply sloped walls 66, followed by second steeply sloped walls 70, all combining to form a channel through which the fluid flows. Four such channels are formed around the top edge of orifice 22 evenly spaced such that four legs 56 project in an upstream direction and contact the downstream side of diaphragm 24. Because of the small top surface area of legs 56, the proper centering of diaphragm 24 by cage 26 is even more critical with this embodiment.
Diaphragm 24 comprises what may be termed a "rubber torpedo." Diaphragm 24 is preferably made of rubber but could alternatively be made of another elastomer. Diaphragm 24 has a circular cross section with parallel sidewalls, a conical upstream side, and a flat downstream side with a flow straightener cone 46 disposed in the middle of the downstream side. The diameter of diaphragm 24 is preferably approximately the same as, or just smaller than, that of orifice 22 for the purposes of fitting the largest control mechanism into single-piece housing 12.
Diaphragm 24 is held in place centrally over seat 34 of orifice 22 by cage 26. Cage 26 includes an outer wall 72 having a "C" shape. In the preferred embodiment, the C shape is approximately 240 degrees of a short circular cylinder. The 120 degrees that are removed, in other words the open section, in the preferred form of the cage allow the cage to be compressed together such that it has a smaller perimeter for insertion into housing 12. Cage 26 includes four cage ribs 38 that project radially inward from outer wall 72 at evenly spaced locations beginning at the ends of C-shaped outer wall 72. A larger or smaller number of ribs 38 could be used. The ribs could also alternatively be unevenly spaced. Optimally between three and six ribs 38 are used, preferably four. The main portions of cage ribs 38 extend inwardly enough to provide a slight interference fit with diaphragm 24 such that diaphragm 24 is held between cage ribs 38 on its sidewalls. Diaphragm 24 can slide in the axial direction and is not bonded to cage 26.
Cage ribs 38 also include rib extensions 40 that project further radially inward from the main portions of cage ribs 38 over the upstream side of diaphragm 24. Cleats 42 extend in a downstream direction from rib extensions 40. Cleats 42 press against the upstream surface of diaphragm 24 such that a biasing force in a downstream direction against seat 34 of orifice 22 is provided by the tendency of the rubber composition of diaphragm 24 to assume its original shape. The pressure of cleats 42 against diaphragm 24 in a downstream direction helps compensate for any minor slop or interference in machining of the interior of housing 12 or in any of the other component parts of valve 10. Cleats 42 also allow diaphragm 24 to move completely away from orifice seat 34 during backflushing operations where fluid is forced in a reverse direction through valve 10. Finally, cage 26 also includes cage compression tabs 44 that extend from cage ribs 38, which are disposed at the ends of outer wall 72. Cage compression tabs 44 aid in assembly and disassembly of valve 10 by providing a convenient place where cage 26 may be compressed into a smaller diameter shape such that cage 26 along with diaphragm 24 may be inserted or removed from housing 12.
Note that housing 12 in the preferred embodiment is a one-piece housing, such that all components within housing 12 that are not integral parts of housing 12 must be inserted therein to construct wave 10 (the use of a one-piece housing reduces the cost of valve 10). The axial tolerances of a cage recess 48, described below, relative to orifice 22 are widened when using the cage to achieve a slight compression of the diaphragm against the orifice at the lower pressure drops. The compression also helps stop the flow rate from creeping to lower values during low pressure drops. The reduction in flow with valve 10 having no clears 42 is a result of slight bending beam action and the initial compression of the top of seat 34. Stated another way, cleats 42 digging into diaphragm 24 allow diaphragm 24 to creep to the approximate shape that diaphragm 24 would have achieved over an approximate two day period at the lower pressure drops. All internal components are inserted through housing inlet 18. First, orifice 22 is placed within housing 12 and seated upon shoulder 28, O-ring 32 squeezing against the sides of housing 12 to form a seal. Diaphragm 24 is placed within cage 26 after which cage 26 and diaphragm 24 are compressed such that cage 26 has a small enough diameter to fit within housing inlet 18. This may be done by using a tool such as needle-nose pliers to compress cage 26 by applying pressure between ribs 38, which extend from the ends of outer wall 72. Cage compression tabs 44 assist by not allowing the tool to slip from tabs 38. Because diaphragm 24 is comprised of a flexible rubber material, it is compressed between ribs 38 as cage 26 is compressed. Cage 26 is also formed of a flexible material such as Delrin plastic. Once cage 26 with diaphragm 24 is in place, the compressive force on ribs 38 is removed such that cage 26 seats within cage recess 48 formed within housing 12. Cage recess 48 ensures that cage 26 maintains its proper position and orientation within housing 12 during normal and backflow conditions.
With the above-described construction, the valve operates by fluid flowing through inlet pipe 14 and housing inlet 18 to cage 26 and diaphragm 24. The fluid flows between ribs 38 and outer wall 72 around the sidewalls of diaphragm 24. The flow then proceeds over seat 34 and into orifice 22 to then exit through sleeve 30, housing outlet 20, and into outlet pipe 16. The details of the function of the valve during flow conditions are illustrated in FIGS. 3A through 3C. FIG. 3A illustrates a state of low pressure drop across the valve. In this state, diaphragm 24 is virtually undeformed such that the flow through valve 10 proceeds around diaphragm 24 between ribs 38 of cage 26 and through large channels formed between the bottom surface of diaphragm 24 and the upstream edge of seat 34. This large channel allows a large amount of flow such that, even at low pressure drops across the valve (typically down to 5 psid), accurate flow is maintained to outlet pipe 16. Small changes in the area of the channel are first accounted for by diaphragm 24 deforming over the relatively small top surface areas of legs 56. Before this deformation, value 10 acts as a fixed orifice device.
FIG. 3B illustrates a state of moderately high pressure drop across the valve corresponding to a high fluid pressure into housing inlet 18. As the fluid pressure increases, diaphragm 24 is squeezed into a new shape. In this state, the pressure drop across diaphragm 24 causes the bottom surface of diaphragm 24 to be pulled against seat 34 of orifice 22 such that the channels through which the flow may pass are much more restricted in area. The reduction in area of the channels is so proportioned to the increase in pressure that the net result is approximately the same fluid flow as existed before the pressure increase.
Finally, in FIG. 3C, a state of extremely high fluid inlet pressure is shown. In this state, diaphragm 24 is pulled not only into gently sloped walls 68, but also partially into first steeply sloped walls 66 such that the channel through which flow may proceed is quite small. Therefore, the high-pressure flow is restricted such that the same amount of flow proceeds through housing outlet 20 as in the situation described in both FIGS. 3A and 3B.
The above-described valve 10 construction results in a larger annular flow area around the side of diaphragm 24 than prior valves using molded rubber ribs to provide spacing. The ribs do not provide adequate spacing between the prior control member and the housing walls to minimize flow restriction. If ribs that extend further radially to provide a larger flow area were molded on diaphragm 24, they would have to be thicker in section than cage ribs 38 since rubber is far more flexible than is an injection-molded thermoplastic, such as would be used to construct cage 26. The increased rubber section would in turn reduce the annular area around diaphragm 24 so the rubber ribs would have to extend further radially than cage ribs 38 to attain the same annular flow area. Cage 26 with ribs 38 is preferred since rubber ribs may not provide adequate centering in some situations.
The design of valve 10 results in a reduction in flow restriction over existing valve designs. This reduction results from increased flow area around the sidewalls of diaphragm 24 that in turn allows a widening of the 90 degree bend that the fluid must make to enter orifice 22. These two factors result in a combined loss of restriction. The increased flow area provides less fluid velocity around the side of diaphragm 24, which allows the use of more economical materials such as ductile iron instead of brass for fresh water. Reducing the fluid velocity that the ductile iron is exposed to allows the ductile iron to keel:, its protective layer of magnate that would be continually washed away by erosion/corrosion if higher fluid velocities existed. Similarly, a brass body material may be used instead of a monel body for seawater use to attain additional savings when the fluid velocity is low enough (e.g., less than about five feet per second).
Since cage 26 can be economically molded out of corrosion-resistant and nonmetallic materials, valve 10 is adaptable to control the flow rate of corrosive fluids or fluids that require that no metal contact the fluid.
Even at minimal flow rates, cage 26 reduces the pressure loss around the side of diaphragm 24 and into orifice, seat 34. This reduction in pressure loss allows valve 10 to begin to control the flow at a lower pressure drop than would otherwise be possible, which in turn allows tile end user to specify a smaller pump, which in turn reduces the installation cost and the operating cost of the hydronic portion of a system (such as an air conditioning system).
Rib extensions 40, combined in the preferred embodiment with cleats 42, reduce the rotational movement of diaphragm 24 about an axis perpendicular to the longitudinal axis of valve 10 (end-over-end rotation). This reduction of rotational movement improves the accuracy of the flow control. Rib extensions 40 allow a high pressure drop to be applied to valve 10 in reverse flow without diaphragm 24 being swept out of housing 12. The configuration of the present invention also allows more water to pass at the same pressure drop in reverse flow compared to prior-art designs. This increased flow rate in reverse flow allows more complete flushing of hydronic heating and cooling systems.
Cleats 42, used in the preferred embodiment of the invention, add to this advantage by allowing diaphragm 24 to move longitudinally slightly upstream during backflow, the top surface of diaphragm 24 deflecting somewhat against cleats 42.
Cage 26 also provides a precise way of locating diaphragm 24 in the axial direction above orifice 22. This axial location is particularly important to improve the flow accuracy at lower pressure; drops across valve 10. If diaphragm 24 were inadvertently held off orifice seat 34 at lower pressure drops an out-of-tolerance high flow would exist until diaphragm 24 is pulled down onto orifice seat 34. This process would cause surges in the flow rate through valve 10 known as "hunting." On the other side of the spectrum, if diaphragm 24 were pressed onto orifice seat 34 too firmly, valve 10 would require a greater pressure drop to begin to control the flow to a specified tolerance. By purposely biasing diaphragm 24 onto orifice seat 34 with a controlled amount of force, the amount of creeping that diaphragm 24 experiences during the lower pressure drops may be reduced since a controlled set is applied. This creep reduction, in turn, holds the reduction in the flow rate, which may occur over time due to creeping, to a lower level.
Cleats 42 also help in this regard. Since the surface area of cleats 42 in contact with the top surface of diaphragm 24 is small, the slop or interference in the axial tolerances of housing 12, cage 26, and orifice 22 can be largely taken up with diaphragm 24 being slightly compressed into cleats 42. In other words, the milling of cage recess 48, cage 26, orifice seat 34, the bottom of orifice 24, and shoulder 28 does not have to be as exact. This will reduce manufacturing costs along with valve performance.
Legs 56 on orifice seat 34 are helpful at low pressure drops to allow diaphragm 24 to easily be pulled partially into the channel formed between seat 34 and diaphragm 24. The profile of seat 34 provides a contour with second steeply sloped walls 70 that are short and will not cause diaphragm 24 to "cork," while supporting the entire bottom surface of diaphragm 24 onto four legs 56 and, hence, providing greater sensitivity for the lower pressure drops. Concentrating the support for the entire area of diaphragm 24 onto the small tops of four legs 56 increases the sensitivity of the device at the lower pressure drops. As the pressure is increased, diaphragm 24 contacts most of seat 34.
FIG. 4 illustrates an alternate embodiment of the invention with several minor changes in the components of valve 10. First, sleeve 30 has been removed such that orifice 22 is simply a cylindrical member with seat 34 on the upstream side and a fiat edge that rides against shoulder 28 on the downstream side. Seat 34 has itself been changed, as well, from the preferred embodiment described above. Seat 34 in this embodiment does not include legs 56 formed by second steeply sloped walls 70. This may be a desirable configuration if only high-pressure drops across the valve are anticipated in normal use. Legs 56 may also not be needed in only low pressure ranges are to be used. The advantage of legs 56 is realized principally when large variations in pressure are anticipated. Cleats 42 have been removed in this embodiment such that rib extensions 40 seat against the upstream side of diaphragm 24.
Referring now to FIGS. 5 and 6, another alternate embodiment of the invention will now be described. The principal structural change in this embodiment is a spring 54 that is disposed within cage recess 48 on the downstream side of cage 26, cage recess 48 being longer so as to permit both spring 54 and cage 26 to be disposed therein. The purpose of spring 54 is to compensate for the hysteresis in the rubber at the lower pressure drops (i.e., five to 15 psid). In this range the percent of error in the flow rate is effected most by hysteresis. Spring 54 functions to bias cage 26 with diaphragm 24 disposed therein in a direction away from orifice 22. In this manner, valve 10 can more accurately compensate for low pressure drops across diaphragm 24 and provide a larger channel through which the fluid may flow over seat 34. Once the pressure drop is high enough, spring 54 will be compressed such that diaphragm 24 seats solidly against seat 34 and begins to deform within it to further restrict flow.
To ensure that diaphragm 24 stays within cage 26, holding tabs 50 and a perimeter groove 52 are used holding tabs 50 are connected to ribs 38 of cage 26 and extend generally perpendicular to ribs 38 in directions conforming to the shape of diaphragm 24. Holding tabs 50 fit within perimeter groove 52, which is formed within the sidewalls of diaphragm 24. Due to the engagement of holding tabs 50 within perimeter groove 52, diaphragm 24 is held within cage 26 while still permitting deformation of the lower surface of diaphragm 24 into seat 34. Diaphragm 24 is allowed to move in an axial direction in relation to orifice 22 by cage 26 sliding in relation to housing 12. Spring 54 surrounds the upstream portion of orifice 22 but does not contact orifice 22 such that flow over seat 34 is not obstructed. In this embodiment, housing 12 may be either one piece or two pieces. If a one-piece housing is used, spring 54 may be inserted by tightly winding its coils within their elastic range such that its diameter is reduced. Once placed within cage recess 48, spring 54 may be released to assume its normal shape such that its diameter expands into cage recess 48.
Referring now to FIG. 7, another alternate embodiment will be described. This embodiment includes cage 26 and orifice 22 being integral parts of housing 12. Outer wall 72, shown in FIG. 1, is essentially nonexistent in the embodiment illustrated in FIG. 7, unless viewed as being an integral part of the interior walls of housing 12. Cage ribs 38 are formed protruding from the walls of housing 12 in radially inward directions. Housing 12 is a two-piece housing such that diaphragm 24 may be inserted therein.
An alternate form of orifice 22 is also shown in FIG. 7. The form of seat 34 is simply a design choice based on the desired flow conditions and range of allowable pressure drops through valve 10. Orifice 22, shown in FIG. 7, includes two sets of first steeply sloped walls forming two V shapes with gently sloped walls 68 connecting the two V shapes. Alternatively, any of the previously discussed shapes of orifice seat 34 may be employed. Orifice 22 is also an integral part of housing 12, on the outlet side of housing 12. Orifice 22 is cast as part of housing 12 after which seat 34 is milled into the upstream end as desired.
Referring now to FIG. 8, another alternate embodiment will be described. This embodiment is simply an extension of the embodiment described above in connection with FIG. 7. Like the embodiment described above, cage ribs 38 are formed as an integral part of housing 12. However, this embodiment employs four such sets of cage ribs 38 in parallel with four diaphragms 24 and four orifices 22. Instead of threadably engaging the two halves of housing 12, bolts 58 and nuts 60 are used to couple the two halves together. Housing inlet 18 increases in diameter as it nears the internal components of valve 10 and housing outlet 20 does the same as it nears the internal components of valve 10. Thus, space is provided such that four sets of internal components may be used in parallel fashion to allow four times the flow through valve 10. An inlet divider wall 62 provides the structural support to carry cages 26 with diaphragms 24 engaged therein. An outlet divider wall 64 holds orifices 22 in their proper orientations. Outlet divider wall 62 includes shoulders 28 upon which orifices 22 sit, O-rings 32 engaging within outlet divider wall 64 such that flow cannot proceed around the outer surfaces of orifices 22 but must go through the central channels of orifices 22 to exit housing outlet 20.
With the arrangement of the valves in parallel as shown in FIG. 8, four times the flow of a single valve assembly is allowed to exit housing outlet 20. Obviously, other numbers of valve assemblies could be combined to accomplish a desired amount of outlet flow. Of course, the requisite amount of inlet flow must be provided that is greater with a greater number of valve assemblies such that the same pressures are attained.
FIGS. 9 and 10 illustrate still another embodiment of the present invention in which a single-piece housing 12 is used to hold two valve assemblies side by side. Each valve assembly includes cage 26, which has outer walls 72 that may be compressed to fit within housing inlet 18 to be placed in its proper orientation. The two internal valve assemblies are oriented side by side with cages 26 having their open ends facing one another such that they nest compactly together in a figure-eight shape, as shown in FIG. 10.
The "C" shaped outer walls 72 provide for denser packing than a cage with a complete perimeter (denser also than a complete bore to house a diaphragm with longer radially extending ears). This denser packing facilitates more economical housing designs by reducing the material cost. The open "C" also allows valve housing designers to take advantage of casting techniques such as "lost foam" or "lost wax" to cast what would have to be a bolted- or screwed-together assembly of two or three components into one piece for the valves 10 that have multiple diaphragms 24 in parallel. A cage without an open section would be difficult to retain in a one-piece design since a retaining plate is normally needed to keep the diaphragms and cages in their respective bores. Such a retaining plate could not be inserted through a bore smaller than the diameter of the plate.
The open C-shaped cage 26 is more forgiving for the tolerance of the bore that it must seat against than is a complete perimeter cage. If the bore is smaller than the diameter of cage 26, the open section of cage 26 will shrink to conform to the out-of-tolerance diameter. The result of this shrinking gap in the cage perimeter causes cage ribs 38 to squeeze into diaphragm 24, which in turn has little or no effect on the accuracy of valve 10. Of course this advantage is also realized in the single valve embodiment as well as the multiple valve embodiments.
Finally, referring to FIG. 11, another alternate embodiment of the present invention will be described. In this embodiment, the function of cage ribs 38 is embodied in diaphragm ears 74 Diaphragm ears 74 project outwardly from the sidewalls of diaphragm 24 and include horns 76 that extend upstream of the sidewalls. Diaphragm ears 74 are made of the same material as diaphragm 24b, or alternatively, they may be made of a different material. For example, a stiffer material may be desirable. Diaphragm ears 74 space the sidewalls of diaphragm 24b away from cage recess 48 to allow an enlarged flow area, as described above, around diaphragm 24b. The remainder of valve 10 in this embodiment is similar to that described above. Horns 76 projecting from ears 74 provide greater flow passage around the front of diaphragm 24, hence reducing the pressure loss and allowing smaller rubber ears 74 than would otherwise be required.
While the preferred embodiment of the invention has been illustrated and described, along with several alternate embodiments, it will be appreciated that various changes can be made therein without departing from the spirit and scope of the invention. For example, different materials may be used, alternate numbers of internal valve assemblies may be nested together, or other changes may be made to meet the constraints of a particular use. The above detailed description is not meant to limit the invention to those embodiments described, but to be exemplary of the invention through a description of the current preferred forms of carrying out the invention.
Because of the above and numerous other variations and modifications that will occur to those skilled in the art, the following claims should not be limited to the embodiments illustrated and discussed herein. | An apparatus to control fluid flow to an approximate fixed rate is disclosed. The apparatus includes a housing (12), an orifice (22), a diaphragm (24), and a cage (26). The housing has two ends, an inlet end (18) having an inlet opening and an outlet end (20) having an outlet opening. The ends are arranged and configured to receive piping (14 and 16). The orifice is disposed within the housing. The orifice has an upstream end and a downstream end with a seat (34) formed in the upstream end. The fluid flows over the seat and through the orifice before exiting the outlet end of the housing in normal flow. The diaphragm is disposed within the housing adjacent and upstream of the seat of the orifice. The diaphragm has an upstream side, a downstream side, and sidewalls. The downstream side of the diaphragm is opposite the seat such that a pressure drop across the diaphragm pulls the downstream side of the diaphragm toward the seat. The cage surrounds at least a portion of the sidewalls of the diaphragm. The cage has ribs (38) projecting toward and contacting the sidewalls of the diaphragm to hold the diaphragm away from the housing and to allow reduced flow restriction between the housing and the sidewalls. | 5 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a method of performing a desired operation in one conduit of a system having a pair of conduits and a connecting nipple providing communication between the conduits. More particularly this invention relates to a method of utilizing pump down tools to perform a desired operation in one tubing string of a well at a point axially spaced below from the connecting nipple when the upper locomotive piston of the pump down tool cannot be pumped past the circulating nipple to the work location.
2. The Prior Art
A well is equipped for pump down operations by providing two strings of tubing and a circulating nipple for fluid communication from one string of tubing to the other. Performing an operation, such as setting a tool, in the first string of tubing above the circulating nipple can be accomplished by pumping down a pump down piston locomotive and work tool in the first string of tubing and circulating fluid through the circulating nipple and up the second string of tubing. In this manner, no matter what the bottomhole pressure is, enough force can always be applied through the locomotive piston to the work tool to perform the desired operation. The pump down tools are removed from the well by pumping fluid down the second string of tubing and circulating fluid up through the first string of tubing.
Problems have arisen in the use of pump down equipment when it is desired to perform an operation below the circulating nipple in one of the tubing strings. To provide a means for removing the pump down equipment once the operation is performed the locomotive transport pistons must remain above the circulating nipple so that reverse circulation will be able to lift the equipment out of the tubing string. Extending from the locomotive pistons to the running tool is a stem. The stem may be a sucker rod. The stem is long enough so that the locomotive pistons can remain above the circulating nipple and the running tool can be run down to the desired work location. Sometimes a high differential pressure across the transport pistons is required to apply enough force to the work tool to perform the desired operation. Applying such force downward through the locomotive transport pistons causes the stem to buckle or corkscrew in the tubing. Thus the stem does not efficiently transmit force from the locomotive transport piston to the running tool. With the inefficient transmission of forces from the locomotive piston to the running tool, the operator is uncertain whether or not the desired operation has been properly performed below the circulating nipple.
OBJECTS OF THE INVENTION
It is the object of this invention to provide a method of utilizing pump down tools to insure an adequate transmission of forces to a running tool on one side of a circulating nipple when the locomotive, transport piston remains on the other side of the circulating nipple.
It is a further object of this invention to provide a method of utilizing pump down tools to enable fluid pressure to be exerted directly on a running tool on one side of a circulating nipple even though the locomotive, transport piston remains on the other side of the circulating nipple.
It is an additional object of this invention to provide a method of utilizing pump down tools, as in the preceding object, wherein the fluid pressure applied to the running tool may be effectively controllably released so that the pumpd down tool may be removed from the well.
Another object is to provide a method for utilizing pump down tools having an interconnected upper transport piston and lower force applying piston in which pressure may be applied through the lower piston and in which the effective area of the lower piston may be reduced to permit reverse circulation of the tool from a point intermediate the two pistons at the time of beginning reverse circulation.
These and other objects and features of advantage of this invention will become apparent from the drawings, the claims and the detailed description which follows.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings wherein like numerals indicate like parts, and wherein an illustrative embodiment of this invention is shown,
FIG. 1 is a schematic view, partially in section, showing an initial phase of running a pump down tool down a well in accordance with this invention;
FIG. 2 is another schematic view, partially in section, depicting a pump down tool after it has been further run down a well in accordance with this invention;
FIG. 3 is another schematic view, partially in section showing a pump down tool landing a tool in a well in accordance with this invention;
FIG. 4 is still another schematic view, partially in section, depicting a pump down tool being removed from the well after a tool has been landed in accordance with this invention;
FIG. 5 is a side view, partially in section and partially in elevation, of one of the set of ported, bypass pistons in a tubing that is utilized with a pump down tool in accordance with this invention; and
FIG. 6 is a side view, partially in section and partially in elevation of a standing valve in a nipple that has been set utilizing the pump down tool and method of this invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The invention may be utilized in any system having a pair of conduits which are interconnected to provide for circulation in both directions. For convenience the invention will be disclosed as it applies to a petroleum well.
A well equipped for pump down operations has a pair of conduits, a communicating means between the conduits and some surface equipment. The pair of conduits is normally provided by a tubing string 10 and an auxiliary tubing 12. The tubing string 10 provides for production and the circulating tubing 12 provides for control. Of course the well could be equipped with only one string of tubing. The pair of conduits would then be provided by the string of tubing and the annulus between the string and the well casing. In the embodiment shown, the two strings 10 and 12 have been run in the well casing 14. The communicating means for providing fluid circulation between the two conduits may be a nipple 16 which is connected to the two conduits and has a circulating port between the conduits. When the well is equipped with a pair of tubing strings, the circulating nipple may be what is commonly called an H-member. When the well has only one tubing string the circulating nipple is a ported nipple. The surface equipment (not shown) includes a hydraulic pump to pump fluid in the conduits, a fluid storage tank, a manifold to control fluid volume and pressure, an instrument panel, and loops above the wellhead. The surface equipment employed may be as desired.
As shown in FIGS. 1 through 4, a tubing string 10 often extends in both directions from the performed nipple 16. Various operations are preformed at a location axially spaced from the circulating nipple 16 in the tubing string 10 while for reasons to be hereinafter explained a pump down transport piston remains on the opposite side of the circulating nipple 16. These operations include shifting a sleeve in the tubing, opening a valve, closing a valve, setting a tool or retrieving a tool. With an appropriate running tool, the pump down tool, utilized in the manner hereinafter described, can perform a desired operation at a location axially spaced from the circulating nipple 16 and yet it will be possible to remove the pump down tool from the tubing 10.
The pump down tool may include two spaced piston means, connecting means for connecting the pistons together and a bypass valve means associated with one piston. Preferably each piston means is a set of pistons.
One set of pistons 18 will be the transport, or locomotive pistons. The set of transport pistons 18 has piston cups 20 that point in a first direction and piston 22 that point in a second direction. The piston cups 20 and 22 create an effective seal with the wall of the tubing 10. Fluid pumped in a first direction in the tubing 10 will seep past piston cups 20 and will engage piston cups 22. The engagement of the fluid with piston cups 22 of the transport pistons 18 provides a locomotive force to move the pump down tool in a first direction in the tubing 10. Likewise, fluid pumped in a second direction in the tubing will seep past piston cups 22, will engage piston cups 20 and will provide a locomotive force to move the pump down tool in a second direction in the tubing. Any design of pump down piston may be utilized as long as it is capable of responding to applied fluid pressure in either direction to provide locomotion for the pump down tool in either direction. If desired a series of transport pistons 18 may be provided and the pistons run in tandem to obtain additional thrust for operating the pump down tool.
The other set of pistons 24, the set associated with the bypass valve means is a ported bypass set of pistons. The bypass set of pistons 24 has piston cups 26 that point in the same second direction as piston cups 22. When fluid pressure is applied in tubing 10 in a first direction, if the bypass valve means is closed, the fluid engages piston cups 26 and the ported bypass set of pistons 24 is a force transmission means. The force is transmitted in the first direction. A series of ported bypass pistons 24 may be provided and the pistons 24 run in tandem to obtain additional force, if desired.
Connecting the set of transport, locomotive pistons 18 with the set of ported bypass pistons 24 is a connecting means 28. The connecting means 28 may be a stem comprising a series of connecting reach rods joined together. If the pump down tool does not have to be circulated through a small radius (3 to 5 feet) curve in the tubing, the connecting rods can be joined together by a pin and box connection. If the pump down tool is circulated through a small radius curve of tubing, the connecting rods are joined together by ball joints. The length of the connecting rods is such that they can be circulated through the smallest radius curve of tubing in the tubing strings. Where ball joints are used they are preferably slightly smaller in diameter than the inner diameter of the tubing to maintain the rods in alignment. The stem connecting means maintains the spaced relationship between the transport, locomotive pistons 18 and the ported bypass pistons 24. The length of the stem connecting means 28 is such that the transport, locomotive pistons 18 can remain on one side of the circulating nipple 16 while the ported bypass pistons 24 are run past the circulating nipple 16 to the work location.
Also connected to the ported bypass set of pistons 24 is a running tool 29. The running tool 29 is designed to perform the desired operation in the tubing string 10. In the drawings, the illustrated running tool is being utilized to set a tool 30.
Referring now to FIG. 5 there is depicted the detailed construction of one of a set of pistons. The piston, as depicted, may be utilized as the ported bypass piston 24 while modified version may be utilized as the transport, locomotive piston 18.
Forming the body of the piston is a mandrel 32. Surrounding the mandrel 32 is a piston element 34. The cups 36 of the piston element 34 are capable of engaging the internal wall of the tubing string 10 so that the pump down tool may be pumped in at least one direction through the tubing string 10. The piston cups 36 of the piston depicted in FIG. 5 are pointed upward so that the piston could be pumped downward in the tubing string 10. However, it is to be understood that the piston element 34 could simply be reversed, and then the piston could be pumped upward in the tubing string 10. Since the piston may be pumped through a small radius curve in the tubing string, the means for connecting the piston to other devices in the pump down tool is capable of undergoing universal pivotal movement. Another design feature of the connecting means, to facilitate the makeup of the pump down tool out in the field, is that male threaded connections face upwards while female threaded connections face downward.
Ball joints are provided at each end of the piston to permit articulation. At either extremity of the mandrel 32 there are means 38 for threadably attaching an end connector to the mandrel 32. The piston element 34 is confined on the mandrel 32 between a downward facing shoulder 40 of the upper end connector 42 and an upward facing shoulder 44 of the lower end connector 46. Before the upper end connector 42 is threaded onto mandrel 32 a stem ball connector 48 is inserted into the upper end connector 42 with the stem extension 48a extending upward through the end connector 42. The upwardly extending stem extension 48a has threads 50 to provide the upward facing male threaded connecting means desired for field operations. The stem ball connector 48 also has a lower ball portion 48b which is confined in an internal housing of the upper end connector 42. The confinement of the ball portion 48b within the housing of the upper end connector 42 with the stem extension 48a extending through a circular opening in the upper end connector 42 permits universal pivotal movement of any device or connection 52 that may be threaded onto the stem ball connector 48 relative to the set of pistons.
Before the lower end connector 46 is threaded onto mandrel 32 a ball connector 53 is inserted into the lower end conductor 46. The ball connector 54 has internal, female threads 56 to provide the downward facing female threaded connecting means desired for field operations. A rod connector 58 with an upward facing male threaded end 58a is threaded into the ball connector 54. When the lower end connector 46 is threaded onto the mandrel 32, the ball connector 54 is confined in an internal housing of the lower end connector 46. With the rod connector 58 extending through a circular opening in the lower end connector 46, and device that is attached to the rod connector 58 may undergo limited universal pivotal movement with respect to the piston.
In accordance with this invention bypass valve means are provided in the bypass piston which is closed when the connecting rod is in compression and open when the rod is in tension. The balls 48b and 54 and the end connectors 42 and 46 provide a portion of the bypass valve means associated with the bypass pistons. The bypass valve means is designed so that when the valve is open the cross sectional area of the pistons is greatly reduced. If two sets of pistons were connected together and placed in a tubing 10 and if each set of pistons had the piston element arranged so that the cups 36 were facing each other, and if fluid under pressure was being injected into the tubing 10 between the sets of pistons, and if one set of pistons had the bypass valve means open and the other set of pistons had no bypass valve means even though the fluid pressure applied to each set of pistons would be equal, the reduction in area to the one set of pistons caused by the open bypass valve means would result in the force being applied to that set of pistons being less than the force applied to the other set of pistons. The connected pistons would move in reaction to the net force applied to the other set of pistons. In the set of pistons depicted in FIG. 5, the bypass valve means is provided by having at least one bypass port 60 in both the upper end connector 42 and in the lower end connector 46 and by having a bore 62 extend through mandrel 32. The ball portion 48b of the ball stem connector 48 is slidable, axially within the housing of the upper end connector 42 between an annular downward facing shoulder 64 of the end connector 42 and an annular upward facing shoulder 66 of the mandrel 32. Likewise, the ball connector 54 is slidable axially within the housing of the lower end connector 46 between an annular upward facing shoulder 68 of the end connector 46 and an annular downward facing shoulder 70 of the mandrel 32. When the ball portion 48b is seated on annular shoulder 66 of mandrel 32 and when the ball connection 54 is seated on annular shoulder 70 of mandrel 32 the bypass ports 60 are closed as is the bore 62 of mandrel 32. Thus seating the balls, which may be done by placing the stem ball connection 48 and the rod connection 58 in compression, will close the bypass valve means. The upper locomotive pistons 18 are identical with the lower pistons except that a plug (not shown) is received in threads 72 in mandrel 32 to close the bore through the mandrel. The ports 60 may also be omitted.
When the pump down tool that will be utilized to perform a desired operation in accordance with this invention is made up sets of pistons, as described above, with a plug valve may be utilized as the set of transport locomotive pistons 18. As has been mentioned, the piston element 34 will be placed on the mandrel 32 so that the cups 36 are pointed in the desired direction. For the bypass unloader set of pistons, the set of pistons, as described above, without a plug valve is utilized.
Although any desired operation in the well tubing may be performed utilizing the pump down tool above described, FIGS. 1 through 4 schematically show the landing of a standing valve 30 in a no-go landing nipple 74 in the tubing 10. FIG. 6 illustrates the landed standing valve. For a detailed description of the operation of the running tool 29 which is utilized to set the lock mandrel 76 of the standing valve 30 reference is made to U.S. Pat. application Ser. No. 405,084 filed Oct. 10, 1973, the disclosure of said application being hereby incorporated by reference for all purposes. In practicing the method of this invention, the aforedescribed pump down tool with the set of transport pistons 18, the set of bypass pistons 24, the connecting means 28 maintaining the transport pistons 18 in spaced relation to the bypass pistons 24 and the bypass valve means is utilized to perform an operation in a well conduit in a well equipped for pump down operations at a location axially spaced from the circulating nipple 16. When the pump down tool is in position to perform the desired operation, the reach rod connecting means 28 extends from the running tool at the work location at a point axially spaced from the circulating nipple 16 below the nipple 16, to the transport pistons on the opposite side of the circulating nipple 16 above the nipple 16.
Referring now to FIGS. 1 through 4 the method of utilizing the pump down tool will be described. The well has a pair of conduits, and the pump down tool is made up to be run in one of the conduits in which it is desired to perform an operation. The pump down tool is inserted in the one circuit and fluid is pumped in a first direction in the conduit to move the pump down tool through the conduit in a first direction. In FIGS. 1 and 2 the pump down tool is being pumped down the production tubing 10. The fluid pressure of fluid pumped in a first direction to move the pump down tool in a first direction is greater than the pressure in a second direction of other fluids that may be in the one conduit. These other fluids may be associated with the well production. These production fluids create downhole pressure and retard the downward movement of the pump down tool. In FIGS. 1, 2 and 3 the downhole pressure would be exerted upward through tubing string 10 against the tool 30 at the lower end of the pump down tool.
In FIG. 3 the pump down tool is illustrated after having been pumped in a first direction, which in the drawing would be downward, with the running tool 29 in position to perform the desired operation at a point axially spaced from the communicating means between the well conduits. The pistons bridge the communicating means with the transport pistons 18 being on one side and the bypass pistons 24 being on the other side at the work location with the running tool. The connecting means 28 maintains the spaced relationship between the pairs of pistons. The illustrated work location is the landing nipple 74 in production tubing 10 below circulating nipple 16. The standing valve 30 is shown, in FIG. 3, in a position to be landed in the landing nipple 74. The running tool 29 and the bypass pistons 24 are in position to perform the operation of landing the standing valve 30 in the landing nipple 74. They are thus illustrated as being below the circulating nipple 16. The transport pistons 18 are on the opposite side of the circulating nipple 16 above the nipple 16. The reach rod connecting means 28 maintain the spaced relation between the pair of pistons and extend from the transport pistons 18 to the bypass pistons 24.
With the pump down tool in position, the desired operation can be performed. While the operation is beign performed, the bypass valve means associated with the bypass piston 24 is closed. The bypass valve means is closed by the application of fluid pressure in a first, (as illustrated, downward) direction to place the connecting means 28 in compression. With the connecting means 29 in compression, the ball portion 48b of the ball stem connector 48 seats an annular shoulder 66 of the mandrel 32 and the ball connector 54 seats on the annular shoulder 70 of the mandrel 32. The seating of the balls blocks bypass ports 60 and closes bore 62 to close the bypass valve means.
To perform the desired operation, fluid pressure is applied in the pair of well conduits in a first direction simultaneously. In the well system illustrated in FIG. 3, fluid pressure would be applied in a downward direction in the production tubing 10 and in a downward direction in the circulating tubing 12. The application of fluid pressure in the second conduit, e.g., the circulating tubing 12, provides a column of fluid between the transport pistons 18 and the bypass pistons 24. The fluid pressure is adjusted to maintain the bypass valve means closed. Since the bypass valve means is closed when the connecting means 28 is in compression, the fluid pressure in the one conduit where the operation is being performed, e.g., the production tubing 10, is at least as great as the fluid pressure in the other, second conduit, e.g., the circulating tubing 12. Preferably the fluid pressures in both conduits are equal. With the fluid pressures in the conduits equal, the forces exerted on the transport pistons 18 would equalize out since they would be equal and opposite so that the net result would be that zero force would be transmitted across the transport pistons 18. However the column of fluid between the transport pistons 18 and the bypass pistons 24 would exert a force in a first direction, the illustrated direction is downward, on the bypass pistons 24. The force exerted on and through the bypass pistons 24 is sufficient to perform the desired operation. If the pressure applied in the one conduit, e.g., the production string 10, is greater than the pressure applied in the other conduit, e.g., the circulating string, then a net force in a first direction would be transmitted across the transport pistons 18. This force would be transmitted through the column of fluids between the transport pistons 18 and the bypass pistons 24 and through the bypass pistons 24 to contribute to the performance of the operation. The illustrated running tool 29 will land standing valve 30 in landing nipple 74 in the manner described in the aforementioned patent application. If needed a suitable probe may be carried by the running tool to maintain the standing valve member off its seat until the running tool releases the standing valve.
After the desired operation has been performed, the pump down tool can be removed from the work location of the well conduit. To remove the pump down tool, a net force in a second direction is applied to the transport pistons 24. A resultant force in a second direction across the transport pistons may be obtained by relieving the pressure in the one well conduit until it is less than the pressure in the other well conduit. In the sequence illustrated in FIG. 4 this would be done by relieving the applied fluid pressure in production tubing 10, while fluid pressure is continued to be applied in the circulating tubing 12. With the pressure of the column of fluids between the transport pistons 18 and the bypass pistons 24 being greater than the pressure of the fluids on the other side of the transport pistons 18, the connecting means 28 is placed in tension, the ball connector 48 and the ball connector 54 go off seat and the bypass valve means opens. The opening of the bypass valve means effectively reduces the cross sectional area of the bypass pistons 24. The cross sectional area of the transport piston 18 is not reduced. The pumping of fluid in a first direction in the second conduit maintains a column of fluid under pressure between the transport pistons 18 and the bypass pistons 24. Because of the difference in effective cross sectional area of the sets of pistons, the fluid pressure exerted on the transport pistons 18 provides a greater force in a second direction than the fluid pressure exerted on the bypass pistons 24 provides in a first direction. As illustrated in FIG. 4, fluid pumped down the circulating tubing 12 will enter the production tubing 10 through circulating nipple 16, will apply a force in an upward direction to the transport pistons 18 while flowing through the bypass pistons 24 and will lift the pump down tool out of the production tubing 10. Once the entire pump down tool has been lifted above the circulating nipple 16, continued pumping of fluid down the circulating tubing 12 will continue the lifting of the pump down tool from the tubing in the conventional manner.
From the foregoing description it can be seen that the objects of this invention have been obtained. A pump down tool, and a method of utilizing a pump down tool has been provided whereby a desired operation in a well conduit of a well equipped for pump down operations at a location axially spaced from a communicating means between conduits can be efficiently performed through the application of fluid pressure directly to the running tool and yet the pump down tool can be removed from the work location.
The foregoing disclosure and description of the invention are illustrative and explanatory thereof and various changes in the process, or in the size, shape and materials, as well as changes in the details of the illustrated construction may be made within the scope of the appended claims without departing from the spirit of the invention. | A pumpable tool and method of utilizing the tool to perform an operation at a point axially spaced from a circulating means between a pair of conduits. The tool includes a pair of pistons one of which is associated with a bypass valve. The operation is performed by applying fluid pressure in both conduits with the bypass valve closed. The tool can be circulated out of one of the conduits when the bypass valve is open. This abstract is neither intended to define the invention of the application which, of course, is measured by the claims, nor is it intended to be limiting as to the scope of the invention in any way. | 4 |
FIELD OF INVENTION
The present invention relates to a new class of compounds for use as active principals for topical treatment of skin conditions, to compositions containing these compounds and to methods of treating skin conditions using these compounds and compositions. Compounds of the class include those of Formula (I): ##STR2## wherein, R 4 is (CR 5 R 6 --CR 7 R 8 --X 1 ) n --CR 9 R 10 --C(═X 2 ) X 3 R 11 ; n is an integer from 1 to 18; R 1 , R 2 , R 3 , R 5 , R 6 , R 7 , R 8 , R 9 , R 10 and R 11 are hydrogen or non-hydrogen substituents, with preferred non-hydrogen substituents including alkyls, alkenyls, oxa-alkyls, aralkyls and aryls; and X, X 1 , X 2 , X 3 , Y and Z are independently, O, NH or S, with preferred compounds including those in which X, X 1 , X 2 , X 3 , Y and Z are each oxygen and R 1 , R 2 , R 3 , R 5 , R 6 , R 7 , R 8 , R 9 , R 10 and R 11 are each hydrogen.
BACKGROUND OF THE RELATED ART
Dermal use of all carbon backbone, alpha hydroxyacids is described in U.S. Pat. No. B1 5,091,171, and cosmetic compositions using 2-hydroxyalkenoic acid are known such as described in U.S. Pat. No. 5,108,751. Such compounds must have an unsubstituted alpha hydoxy group on their all carbon backbone, chemical structure, and are purportedly used for beneficial effects to skin. The trend, however, is away from such alpha hydroxyacids as their use necessitates low operational pH ranges which for the most common forms such as glycolic and lactic acids have been known to cause skin irritations.
Topical formulations comprised of straight, all carbon backbone, dicarboxylic acids have been proposed to replace the fashionable alpha hydroxyacids. For example, U.S. Pat. Nos. 4,292,326, 4,386,104 and 5,385,943 claim that dicarboxylic acids having 7 to 13 carbon atoms could be used for various skin indications. Similarly, U.S. Pat. No. 4,885,282 states that a 4 to 18 carbon dicarboxylic acid compound is useful for skin disorders.
The problem with use of these dicarboxylic acids is their inherent insolubility in aqueous solutions which make up the bulk of cosmetic delivery systems. Such all carbon backbone, dicarboxylic acids are solids at ambient temperatures, are extremely difficult to work with, and if a solution is ever achieved, the result is an aesthetically unpleasant mixture unsuitable for cosmetic use.
There is a need in the art for a class of compounds that can be used as mild, exfoliating actives for topical treatment of skin.
There is also a need in the art for a mild, exfoliating topical composition which contains a water soluble compound that is amenable for manufacturing aesthetically acceptable cosmetic or dermatologic products.
OBJECTS OF THE INVENTION
It is an object of the present invention to provide a topical composition with multiple skin care benefits.
Another object of the present invention is to provide a class of water soluble compounds that are amenable for manufacturing aesthetically acceptable, mild, exfoliating compositions for topical use.
A further object of the present invention is to provide a new, dermatologic and cosmetic use for oxa diacids and related compounds. These and other objects will become evident from the disclosure provided below.
SUMMARY OF INVENTION
The active compounds used in the treatment methods and the compositions of this invention are compounds of Formula (I): ##STR3## wherein, R 4 is (CR 5 R 6 --CR 7 R 8 --X 1 ) n --CR 9 R 10 --C(═X 2 )X 3 R 11 ; n is an integer from 1 to 18, preferably from 2 to 12; R 1 , R 2 , R 3 , R 5 , R 6 , R 7 , R 8 , R 9 , R 10 and R 11 are independently, hydrogen or non-hydrogen substituents.
Preferred non-hydrogen substituents include alkyls, alkenyls, oxa-alkyls, aralkyls and aryls. Examples of non-hydrogen substituents include methyl, ethyl, propyl, isopropyl, butyl, isobutyl, hexyl, heptyl, octyl, nonyl, dodecanyl, methoxy, ethoxy, propoxy, butoxy, cyclohexenyl, hydroxymethyl, hydroxyethyl, hydroxypropyl, cyclobutyl and cyclohexanyl.
X, X 1 , X 2 , X 3 , Y and Z are independently, O, NH, or S. Preferred are those compounds in which X, X 1 , X 2 , X 3 , Y and Z are all oxygen. Most preferred are those compounds in which X, X1, X 2 , X 3 , Y and Z are each oxygen, and R 1 , R 2 , R 3 , R 5 , R 6 , R 7 , R 8 , R 9 , R 10 and R 11 are each hydrogen.
As defined herein, all compounds of the class identified by Formula (I) above will collectively, be referred to as "oxa diacids" and/or "oxa compounds" regardless of whether any or all of X, X 1 , X 2 , X 3 , Y and Z are, independently, oxygens, sulfurs or amino groups.
The methods of treatment and the topical compositions of the present invention can further comprise mixtures of two or more compounds of Formula (I).
The present invention provides topical compositions comprising compounds of Formula (I), methods of treating skin conditions using compounds of Formula (I), and methods of treating skin conditions using compositions comprising compounds of Formula (I) and a suitable topical vehicle.
DETAILED DESCRIPTION OF THE INVENTION
The present invention includes the surprising discovery that the class of compounds of Formula (I) can be used as active principals in topical applications to treat various skin conditions attributed to, accompanied by or exacerbated by abnormal desquamation including dry skin, ichthyosis, palmar and plantar hyperkeratoses, dandruff, lichen simplex chronicus, Dariers disease, keratoses, lentigines, age spots, melasmas, blemished skin, acne, psoriasis, eczema, pruritis, inflammatory dermatoses, striae distensae (i.e. stretch marks), warts and calluses.
The compounds are unexpectedly and surprisingly found to be useful as active agents in topical preparations for treating signs of dermatological aging, both photoaging and intrinsic aging, including skin wrinkles such as fine wrinkling in the eye area or "crows feet," or fine wrinkles around the mouth area, irregular pigmentation, sallowness, loss of skin resilience and elasticity.
The present compounds of Formula (I) and topical compositions containing them are also useful for treating disorders associated with the nails, cuticles and hair such as ingrown hair, folliculitis and Pseudofolliculitis barbae. It has been discovered that the present compounds soften hair and promotes the elimination of hair ingrowths, and are particularly useful for shaving.
Exemplary compounds of Formula (I) for the methods of treatment and the topical compositions of the present invention include 3,6-dioxaoctadioic acid (HOOC--CH 2 --O--CH 2 --CH 2 --O--CH 2 --COOH); 3,6,9-trioxaundecanedioic acid (HOOC--CH 2 --O--CH 2 --CH 2 --O--CH 2 --CH 2 --O--CH 2 --COOH); 3,6,9,12-tetraoxatetradecanedioic acid (HOOC--CH 2 --O--CH 2 --CH 2 --O--CH 2 --CH 2 --O--CH 2 --CH 2 --O--CH 2 --COOH); 3,6,9,12,15-pentaoxaheptadecanedioic acid (HOOC--CH 2 --O--CH 2 --CH 2 --O--CH 2 --CH 2 --O--CH 2 --CH 2 --O--CH 2 --CH 2 --O--CH 2 --COOH); 2-methyl-3,6,9-trioxaundecanedioic acid (HOOC--CH 2 --O--CH 2 CH 2 --O--CH 2 --CH 2 --O--CH (CH 3 )--COOH); 2-ethyl-3,6,9,12-tetraoxatetradecanedioic acid (HOOC--CH 2 --O--CH 2 --CH 2 --O--CH 2 CH 2 --O--CH 2 --CH 2 --O--CH(C 2 H 5 )--COOH); 2-phenyl-3,6,9-trioxaundecanedioic acid (HOOC--CH(Ar)--O--CH 2 --CH 2 --O--CH 2 --CH 2 --O--CH 2 --COOH); 3,6,9-trioxaundecanedioic acid diethyl ester (H 2 C 2 --OOC--CH 2 --O--CH 2 --CH 2 --O--CH 2 CH 2 --O--CH 2 --COO--C 2 H 5 ); 3,6,9-triaminoundecanedioic acid (HOOC--CH 2 --NH--CH 2 --CH 2 --NH--CH 2 --CH 2 --NH--CH 2 --COOH); 3,6,9,12-tetraminotetradecanedioic acid (HOOC--CH 2 --NH--CH 2 --CH 2 --NH--CH 2 --CH 2 --NH--CH 2 --CH 2 --NH--CH 2 --COOH); 3-amino-6,9-dioxaundecanedioic acid (HOOC--CH 2 --NH--CH 2 --CH 2 --O--CH 2 --CH 2 O--CH 2 --COOH); 3,6-diamino-9-oxaundecanedioic acid (HOOC--CH 2 --NH--CH 2 --CH 2 --NH--CH 2 --CH 2 --O--CH 2 --COOH); 3,6,9-trithioundecanedioic acid (HOOC--CH 2 --S--CH 2 --CH 2 --S--CH 2 --CH 2 --S--CH 2 --COOH); 3,6-dithio-9,12-dioxatetradecanedioic acid (HOOC--CH 2 --S--CH 2 --CH 2 --S--CH 2 --CH 2 --O--CH 2 --CH 2 --O--CH 2 --COOH); 3-amino-6,9-dioxaundecanedioic acid monoamide (HOOC--CH 2 NH--CH 2 --CH 2 --O--CH 2 --CH 2 --O--CH 2 --CO--NH 2 ); 3-amino-6,9-dioxaundecanedioic acid diamide (H 2 N-OC--CH 2 --NH--CH 2 CH 2 --O--CH 2 --CH 2 --O--CH 2 --CONH 2 ); 3,6,9-trioxaundecanedioic acid monoamide (HOOC--CH 2 --O--CH 2 --CH 2 --O--CH 2 --CH 2 --O--CH 2 --CONH 2 ); 3,6,9-trioxaundecanedioic acid diamide (H 2 N-OC--CH 2 --O--CH 2 --CH 2 --O--CH 2 --CH 2 --O--CH 2 --CONH 2 ); 2,10-dimethyl-3,6,9-trioxaundecanedioic acid (HOOC--CH--(CH 3 )--O--CH 2 --CH 2 --O--CH 2 --CH 2 --O--CH(CH 3 )--COOH); and 2,10-dimethyl-3,9-dithio-6-oxaundecanedioic acid (HOOC--CH(CH 3 )--S--CH 2 CH 2 --O--CH 2 --CH 2 --S--CH(CH 3 )--COOH). The methods and compositions of the present invention can also advantageously comprise two or more different compounds of Formula (I).
Compounds within this class are described as intermediates in making curing agents and hardeners for epoxy resins in U.S. Pat. Nos. 5,017,675 and 5,319,004, both assigned to Hoechst AG. German Published Application No. DE-A-2936123 describes the preparation of such epoxy resin intermediate compounds. Such compounds are also commercially available from Hoechst AG.
Other compounds in the class can also be prepared from commercially available polamines, polyols and polythiols via routine chemical reactions well known to those skilled in the art such as amidations, catalytic oxidations, esterifica-tions and other well known organic chemistry synthetic protocols such as described in organic chemistry textbooks including March, Advanced Organic Chemistry: Reactions, Mechanisms, and Structure, 3rd ed., John Wiley Interscience (1985) and Carey et al., Advanced Organic Chemistry, 3rd ed., Parts A and B, Plenum Press, New York (1990).
The oxa compounds can be incorporated into the compositions as free acids or as corresponding salts derived by neutralization with organic or inorganic bases such as triethanolamine, arginine, lysine, potassium hydroxide, sodium hydroxide, lithium hydroxide, ammonium hydroxide or their like. The pH of the oxa diacid composition can also be adjusted by adding water soluble salts formed by strong bases (e.g. KOH, NaOH, NH 4 OH) and weak acids (e.g. phosphoric acid, acetic acid, lactic acid, carbonic acid). Examples of such salts include potassium biphosphate, sodium phosphate, sodium acetate, sodium lactate and the like. Other methods of adjusting the pH of the topical compositions of the present invention are well known to those skilled in the art.
The oxa compounds used in the methods of treatment and the topical compositions of this invention can also be used in the form of derivatives that are converted back to the acidic form by action of hydrolytic enzymes in the skin such as glycosidases, phosphatases, esterases and amidases. Examples of suitable derivatives of oxa diacids include their esters with aliphatic alcohols or with carbohydrates, amides, lactones and anhydrides.
As used herein, "topical application" means spreading or laying directly onto the surface of skin; a "topical composition" means a composition intended to be directly layed onto or spread on the surface of skin; an "effective amount" means an amount of a compound or a composition sufficient to induce a positive change (e.g. normalization of desquamation) in the skin condition to be treated such as those attributed to, accompanied or exacerbated by abnormal desquamation; and a "physiologically acceptable vehicle" or a "suitable topical vehicle" mean drugs, cosmetics, medicaments or inert ingredients which the terms describe that are suitable for use in direct contact with human tissues without undue toxicity.
The present invention includes methods by which these compounds can be used to address the aforementioned skin conditions. Such methods include topically applying an effective amount of one or more compounds of Formula (I) to the affected skin areas normally once or twice daily. Such methods also include topically applying a composition containing an effective amount of one or more compounds of Formula (I) in a physiologically acceptable vehicle to the affected skin areas, normally once or twice daily. The methods of the present invention include the topical application of the compounds of Formula (I) in concentrations of up to 100%, when such compounds are a liquid at ambient temperature (e.g. 3,6,9-trioxaundecanedioic acid), such as when using the oxa compounds for skin peels or for softening hair.
When used in combination with a physiologically acceptable vehicle to form a topical composition, the effective amount of the compounds of Formula (I) can be within the range from about 0.1% to about 95%. Both the effective amount and the frequency of application will vary depending on the particular skin condition treated, the age and physical condition of the person under treatment, the severity of the condition, the duration of treatment, the nature of concurrent treatments, the specific compound or compositions employed, the particular vehicle utilized to deliver the compound or compositions, and like factors within the knowledge and expertise of those skilled in the art.
It has also been discovered that the efficacy of these compounds in treating skin conditions can be affected by the pH of the composition. It is desirable to maintain the pH in the acid range pH<7.0, preferably pH<5.0, most preferably in the pH range between 3.5 and 4.0.
The compounds of Formula (I) used in the methods of treatment and topical compositions of this invention are structurally distinct from other known compounds which have been used for skin conditions such as alpha hydroxyacids and dicarboxylic acids. When compared to alpha hydroxyacid formulations, the present invention delivers a class of compounds which have clear advantages such as superior mildness for skin. Formulations with alpha hydroxyacids such as glycolic and lactic acids cause substantial discomfort in some individuals and symptoms of severe skin irritation in others, upon facial application. For instance, a formulation containing 4.0% glycolic acid at pH 3.7 produced a skin irritation (PII) score of 0.23 when tested on 20 panelists. In contrast, a composition containing 10% of 3,6,9-trioxaundecanedioic acid at pH 3.7 produced a PII score of only 0.13 (see Example 2, below).
Compounds which manifest a PII score of less than or equal to 0.15 are considered non-irritating; those exhibiting PII scores between 0.15 and 0.3 are considered moderately irritating; and those compounds which elicit a PII score of more than 3.0 from tested panelists are considered serious irritants. The PII scoring takes into consideration such factors as the number of panelists displaying irritation symptoms versus the total number of panelists in the test.
While being significantly gentler to skin than the glycolic acid formulation, the oxa diacid compositions are highly effective in normalizing the desquamation of the upper stratum corneum which is the mode of activity that is prerequisite for alleviating the skin conditions listed hereinabove.
The advantages of oxa compounds over dicarboxylic acids include better water solubility and superior stratum corneum desquamatory activity. Oxa diacids easily dissolve in water to concentrations of at least 20 to 30% by weight and, therefore, allow a much wider range of composition flexibility. Straight, all carbon backbone, dicarboxylic acids of moderate to long chain length are virtually insoluble in water or, for that matter, in any other aesthetically acceptable vehicle. This severely limits the choice of delivery vehicles for the dicarboxylic acids. Desquamatory activity of all carbon backbone dicarboxylic acids is also questionable. For example, it is known that formulations containing 5% and 10% dodecanedioic acid do not produce any normalizing effect on stratum corneum desquamation beyond that of its vehicle alone.
The oxa compounds of the present invention can be used alone or in combinations with other cosmetic and pharmaceutical actives and excipients. The oxa diacids can be readily used in compositions containing other cosmetic and pharmaceutical agents such as antifungals, vitamins, sunscreens, retinoids, antiallergenic agents, depigmenting agents, antiinflammatory agents, anesthetics, surfactants, moisturizers, exfolients, emulsifiers, stabilizers, preservatives, antiseptics, emollients, thickeners, lubricants, humectants, chelating agents, fragrances, colorants and skin penetration enhancers. Use of the oxa compounds in combination with any one of several of the above classes of actives will provide additional dermatological and/or cosmetic benefits unattainable when the above actives are used without the oxa compounds of this invention.
The composition may also contain emulsifiers that can be cationic, anionic, non-ionic or amphoteric, or a combination thereof. Non-ionic emulsifiers are preferred. Exemplary nonionic emulsifiers are commercially available sorbitans, alkoxylated fatty alcohols and alkyl polyglycosides. Anionic emulsifiers may include soaps, alkyl sulfates, monoalkyl and dialkyl phosphates, alkyl sulphonates and acyl isethionates. Other suitable emulsifiers can be found in McCutcheon, Detergents and Emulsifiers, North American Edition, pp. 317-324 (1986), the contents of which are incorporated herein by reference.
If the present compositions need preservation, suitable preservatives include alkanols, especially ethanol and benzyl alcohol, parabens, sorbates, diazolidinyl urea, and isothiazolinones.
Examples of thickening agents suitable for use with the present oxa diacids include xanthan gum, xanthan gum brine tolerant, hydroxypropyl cellulose, hydroxyethyl cellulose, carbopol and gum acacia, Sepigel 305 (available from Seppic Co., France), vee-gum or magnesium aluminum silicate. The oxa diacids are also compatible with and their utility can be enhanced by humectants, for example urea, PCA, amino acids, certain polyols and other compounds with hygroscopic properties.
The compounds of this invention can be combined with most conventional emollients such as mineral oil, petrolatum, paraffin, ceresin, ozokerite, microcrystraline wax, perhydrosqualene, dimethyl polysiloxanes, methylphenyl polysiloxanes, siliconeglycol copolymers, triglyceride esters, acetylated monoglycerides, ethoxylated glycerides, alkyl esters of fatty acids, fatty acids and alcohols, lanolin and lanolin derivatives, polyhydric alcohol esters, sterols, beeswax derivatives, polyhydric alcohols and polyethers, and amides of fatty acids. Other suitable emollients can be found in Sagarin, Cosmetics, Science and Technology, 2nd Ed., vol. 1, pp. 32-43 (1972), the contents of which are incorporated by reference herein.
Another beneficial use of oxa diacids is in topical compositions alongside keratolytic agents such as salicylic acid and benzoyl peroxide, and skin lightening agents such as kojic acid, benzoquinone, licorice derivatives, ascorbic acid and its derivatives (e.g. magnesium ascorbyl phosphate), glycerhetinic acid and its derivatives. The oxa diacids can also be used readily with organic and inorganic sunscreens such as titanium dioxide, zinc oxide, benzylidene camphor, anthranilates (e.g. methyl, menthyl, phenyl, benzyl, phenylethyl, linalyl, terpinyl, cyclohexenyl and cycloheptenyl esters, and o-amino-benzoates), salicylates (amyl, phenyl, benzyl, menthyl, glyceryl, octyl, dipropyleneglycol ester and cholesteryl salicylate), cinnamic acid derivatives (menthyl, octyl, 2-ethylhexyl, benzyl, alphaphenyl cinnamonitrile, and butyl cinnamoyl pyruvate), dihydroxycinnamic acid derivates (umbelliferone, methylumbelliferone, methylacetoumbelliferone), trihydroxycinnamic acid derivatives (esculetin, methyl esculetin, daphnetin, and the glucosides, esculin and daphrun), naphtholsulphonates (salts of 2-napthol-3,6-disulfonic acid and of 2-naphthol-6,8-disulfonic acids), dihydroxynaphthoic acid and its salts, ortho- and para- hydroxybiphenyldisulfonates, safe coumarine derivatives, diazoles (e.g. 2-acetyl-3-benzothiazoles), quinoline derivatives (salts of 8-hydroxyquinoline, 2-phenylquionoline), quinine salts, uric and voiluric acids, tannic acid and its derivatives, dioxybenzone, benzoresorcinol, 2,2',4,4'-tetra-hydroxybenzophenone, etocrylene. Of these, the cinnamic acid derivatives are preferred.
The utility of the oxa diacids can be further enhanced by their co-formulation with (i) retinoids such as, by way of example, retinol, retinoic acid, retinyl palmitate, retinyl propionate, retinyl acetate, isotretinoin as well as synthetic retinoid mimics; (ii) hormonal compounds such as, by way of example, estriol, estradiol, estrone or conjugated estrogens; (iii) alpha-hydroxyacids or polyhydroxy alpha-hydroxy acids such as glycolic acid, lactic acid, tartaric acid, gulonic acid and other carboxylic acids and their monomeric, polymeric, cyclic or acyclic derivatives having a free or a substituted hydroxy- , thiol- , selenyl- or a non-basic amine group in the alpha-position relative to the carboxyl group; (iv) with alpha-keto acids, such as, by way of example, pyruvic acid, 2-oxapropanoic acid, 2-oxabutanoic acid, 2-oxapentanoic acid, and the like.
Oxa diacids are also compatible with and can be utilized for additional benefits in topical forumulations alongside:
(i) vitamins, enzyme co-factors such as vitamin B6 (pyrodoxine-HCl), vitamin B12 (cyanocobalamin), vitamin D 3 (cholecalcipherol), 1,25-dihydroxy vitamin D3, vitamin B1 (thiamine), vitamin B2 (riboflavin), vitamins K n , vitamin E (tocopherol), tocopheryl acetate, tocopheryl hemisuccinate, tocopheryl ascorbyl phosphate, tocopheryl linoleate, tocotrienols and their derivatives, nicotinic acid and its esters, pantothenic acid and its esters, panthenol, folic acid and its derivatives, choline, carnitine and substances without formal vitamin status or "pseudo-vitamins" such as vitamin F or cis,cis-linoleic acid, vitamin M or pteroylglutamic acid, vitamins B10 and B11, vitamin T also known under such names as "sesame seed factor", termitin, penicin, insectine, hypomycin and mycoine, vitamin L or anthranilic acid, vitamin L2 or adenylthiomethylpentose, myoinositol or cis-1,2,3,5-trans-4-6-cyclohexanehexol and its esters, especially phytic acid, laetrile or 1-mandelo-nitrile-beta-glucuronic acid, amygdalin, vitamin B15 or pangamic acid, vitamin B13 or orotic acid, vitamin H3 or procaine hydrochloride, vitamin U or methylsulfonium salts of methionine, and pyrroloquionoline quinone;
(ii) effective amounts of antifungal agents such as clotrimazole, ketoconazole, miconazole, naftifine, tolnaftate, amphotericin B, nystatin, 5-fluorocytosine, griseofulvin, haloprogin, of which tolnaftate, haloprogin and miconazole are most preferred;
(iii) self-tanning agents such as dihydroxyacetone and lawsone, of which the former one is most preferred;
(iv) anti-mycobacterial agents, such as erythromycin, tetracyclin and related compounds, especially doxycyclin and methacyclin, cephalosporins, penicillins, phenazines, especially clofazimine, rifamycins, especially rifampin, sulfones, especially 4,4' diaminodiphenyl sulfone, pyrazineamide, thiosemicarbazones, especially benzaldehyde thiosemicarbazone, thioureas, especially 4,4-disubstituted diphenylthioureas, viomycin, macrolide, aminoglycoside and peptide compounds selected from the group consisting of novobiocin, vancomycin, oleandomycin, paromomycin, leucomycins, fortimycin, colistin, crycloserine, dactinomycin, bicyclomycin, amphomycin with macrolide molecules preferred over the polypeptide compounds, quinolone derivatives, especially nalidixic acid, oxolinic acid, norfloxacin, ciprofloxacin and flumequine, and other compounds which interfere with bacterial cell wall synthesis, membrane function, RNA metabolism, purine, pyrimidine and protein synthesis, respiration or phosphorylation;
(v) topical analgesics, such as lidocaine, benzocaine, butamben, butacaine, dimethisoquin, diperodon, dyclonine, pramoxine, tetracaine, chlorobutanol, clove oil, eugenol, of which benzocaine and lidocaine are most preferred;
(vi) lipidic compounds essential for the skin's barrier function such as ceramides, essential fatty acids and their esters, especially glycerides, ω-hydroxy fatty acids and their esters derived with alkanols through carboxylic hydroxyl or with other fatty acids at the omega-hydroxyl, the latter type being most preferred, with phospholipids, cholesterol and its esters, such as cholesteryl hemisuccinate and cholesteryl phospate of which cholesterol phospate and essential fatty acids are most preferred, phytosterols, cholestanol and its derivatives. The lipidic compounds can be added to a topical composition either as singular molecular entities or as a complex mixture of lipids derived from either synthetic, animal or plant sources;
(vii) antiallergenic agents and H1 and/or H2 antihistamines such as diphenylhydramine, clemizole, antazoline, thenaldine, phenyltoloxamine citrate, doxyl amine and its salts, diphenylpyraline, medrylamine, clemastine, pheniramine and its halogenated derivatives and salts, especially pehniramine maleate, buclizine, triprolidine and its salts, phenothiazines and related analogs, especially fenethazine hydrochloride and parathiazine hydrochloride, debenzazepines, especially, trapane, other tricyclic antiallergenics such as ketotifene, dithiadene and 3-thienylsulfide of thiadene, H2-receptor blockers, especially burimamide, metiamide and cimetidien, cromolic acid and its salts, khellin, kiethylcarbamazine, piriprost;
(viii) topical anti-inflammatory agents that can reduce inflammation at a concentration from about 0.025% to 10%, preferably, 0.5-1%, with the concentration of the anti-inflammatory adjusted up or down depending upon the potency of the utilized agents. Examples of steroidal anti-inflammatories that can be used with oxa diacids in practicing this invention include hydrocortisone, hydroxytriamcilone, alpha-methyl dexamethasone, dexamethasone phosphate, beclamethasone dipropionate, clobetasol valerate, desonide, desoxymethasone, desoxycorticosterone acetate, dexamethasone, dichlorisone, di-florasone diacetate, diflucortolone and its derivatives, fluadrenolone, flucrolone acetonide, fluocinonide, flucortine butyl ester, fluocortolone, fluprednidine, acetate, flurandrenolone, halcinonide, hydrocortisone acetate, hydrocortisone butyrate, methylprednisolone, triamcinolone acetonide, medrysone, amcinafide, betamethasone and its esters, chloroprednisone, chloroprednisone acetate, clocortelone, clescinolone, dichlorisone, difluprednate, flucloronide, flunisolide, fluoromethalone, fluperolone, fluprednisolone, hydrocortisone valerate, hydrocortisone cyclopentylpropionate, hydrocortamate, meprednisone, paramethasone, prednisolone, prednisone, and mixtures thereof, with the most preferred being prednisolone and hydrocortisone; and
(ix) non-steroidal anti-inflammatories can also be employed such as described in Rainsford, Antiinflammatory and Anti-Rheumatic Drugs, Vols. I-III, CRC Press, Boca Raton, Fla. (1985), and specific examples of suitable NSAID's include enolic acids, oxicams (e.g. piroxicam, isoxicam), fenamic acid derivatives, meclofenamic acid derivatives (e.g. sodium meclofenamate), flufenamic acid derivatives such as N-(α,α,α-trifluoro-m-tolyl) anthranilic acid), mefenamic acid derivatives (e.g. N-(2,3-xyl-yl) anthranilic acid), propionic acid esters such as ibuprofen, naproxen, benoxaprofen, flubiprofen, ketoprofen, suprofen, of which ibuprofen is most preferred, pyrazolidinediones such as feprazone, trimethasone, oxyphenbutazone, sulfinpyrazone, phenylbutazone, of which phenylbutazone is most preferred, the acetic acid derivatives, such as diclofenac, fenclofenac, indomethacin, sulindac, tolmetin, isozepac, furofenac, clidanac, zomepirac, acematricin, of which indomethacin is most preferred, salicylic acid derivatives, such as asprin, safaprin, disalacid, benorylate, trisilate, of which aspirin and disalacid are most preferred.
The compositions of the invention may also include safe anti-inflammatory products of natural origin shown to possess anti-inflammatory activity such as aloe vera extracts, extracts from genus Rubis (Rubia Cordifolia), extracts from genus Commiphom (Commiphora Mukul), willow bark, matricarria flowers, arnica flower, comfrey root, fenugreek seed and the like known to those skilled in the art.
The composition of the invention can also contain antioxidants with phenolic hydroxy functions such as gallic acid derivataives (e.g. propyl gallate), bio-flavonoids (e.g. quercetin, rutin, daidzein, genistein), ferrulic acid derivatives (e.g. ethyl ferrulate, sodium ferrulate), 6-hydroxy-2,5,7,tetramethylchroman-2-carboxylic acid. The compositions may also contain effective concentrations of water soluble antioxidants such as, by way of example, uric acid, reductic acid, tannic acid, rosmarinic acid and catechins. Also of benefit is a coformulation of oxa diacids with nitric oxide synthase inhibitors as a way of reducing skin redness, vasodilation and inflammatory reactions, especially in response to electromagnetic and ionizing radiation or to the action of chemically or biochemically aggresive compounds. The nitric oxide synthase inhibitors can be added at concentrations from about 0.05% to 10%, most preferably from 1% to 3%, and selected from the group consisting of guanidine derivatives, especially monoaminoguianidine and methylguanidine, L-arginine derivatives, especially N G -nitro-L-arginine and its esters, N G -monomethyl-L-arginine, 2-iminopipperidines and other 2-iminoazaheterocycles.
The inventive composition may also include about 0.025% to 5%, with 0.5-2% preferred and with 0.5-1% most preferred, of those compounds that are known to be electron spin-traps such as nitrones, N-tert-butylnitrone and α- 4-pyridyl 1-oxide!-N-tertbutyl nitrone or other compounds known to form free radicals with half-life time of more than 1 min.
Other possible antioxidants that the composition may contain are those which have one or more thiol functions (--SH) in either reduced or non-reduced form such as glutathione, lipoic acid, thioglycolic acid, thiolactic acid, thioglycerol and cysteine. The levels of sulfhydryl antioxidants should not exceed 0.5% for cosmetic uses of the composition but may be higher for pharmaceutical uses as dictated by the considerations of efficacy. The composition may also include inorganic antioxidants such as sulfites, bisulfites, metabisulfite or other inorganic salts and acids containing sulfur in oxidation state +4. The preferred level of inorganic sulfur-containing antioxidants is about 0.01-0.5% with the most preferred level between about 0.1% and 0.4% by weight.
The oxa diacids can also be used in compositions that contain insect repellents such as aliphatic, cyclic or aromatic amides, citronella oil, terpineol, cineole, neem oil and terephthalic acid and its esters. Other suitable insect repellents can be found in Technical Bulletin No. 1549 from the U.S. Department of Agriculture or in their Agricultural Handbook Nos. 69, 340 and 461.
The oxa diacids are suitable for topical compositions that contain skin cooling compounds such as, by way of example, menthol, menthyl glycerol, assymetical carbonates, thiocarbonates and urethanes, N-substituted carboxamides, ureas or phosphine oxides such as described in J. Cosmet. Chem., vol. 29, p. 185 (1978), menthyl lactate, and menthone glycerine acetal.
The compositions of the present invention can be made as lotions. A basic lotion would contain an effective amount of an oxa diacid, up to 95% of water, up to 20% of an emollient and up to 10% of an emulsifier. Such lotions may be preserved with up to 5% of a preservative and contain up to 2-3% of a fragrance, and up to 5% of a dye or a pigment. The composition of the invention can also be formulated as a cream. A basic cream would normally include an effective amount of an oxa diacid, up to about 30% of an emollient, up to about 90% of water and up to about 20% of an emulsifier.
While such lotions or creams can be made via conventional homogenization methods known to those skilled in the art, it is also possible to make such lotions and creams via a process of microfluidization which involves co-mixing the aqueous phase and the oil phase of such creams and lotions in a high-pressure homogenizer which reduces the emulsion particle size dramatically to about 1/400th the size of those in creams and lotions prepared without applying high pressure. Microfluidization allows one to prepare elegant stable creams and lotions containing effective amounts of an oxa diacid without the use of traditional emulsifiers and surfactants.
The oxa diacids can also be formulated in the form of micro-emulsions. A micro-emulsion system would typically contain an effective amount of oxa diacid, up to 18% of a hydrocarbon; up to 40% of an oil; up to 25% of a fatty alcohol; up to 30% of an nonionic surfactant; and up to 30% of water.
The oxa diacids are suitable and convenient for use in topical products formulated in the form of oil-in-water or water-in-oil emulsion, gels, lotions, ointments, sticks, sprays, tapes, patches, as multiphase emulsion compositions, such as water-in-oil-in-water type as disclosed in U.S. Pat. No. 4,254,105, incorporated herein by reference. The compositions of the invention can also be formulated as triple emulsions of the oil-in-water-silicone fluid type as disclosed in U.S. Pat. No. 4,960,764 incorporated herein by reference.
The compositions of the invention can also be made as a liposomal formulation, for example, according to the methods described in Mezei, J. Pharmaceut. Pharmacol., vol. 34, pp. 473-474 (1982) or modification thereof. In such compositions, droplets of the oxa diacid solution can be entrapped inside the liposomal vesicles and then incorporated into the final formula with the shell of the liposome being a phospholipid but which can be replaced with other suitable lipids (e.g. skin lipids). The liposomes can then be added to any of the carrier systems described above according, for example, to the preparation modes, uses and compositions of topical liposomes as described in Mezei, Topics in Pharmaceutical Sciences, Breimer et al. Eds., pp. 345-358, Elsevier Science Publishers BV, New York (1985), incorporated herein by reference, or according to the reverse-phase evaporation method described in Szoka et al., Proc. Nat. Acad. Sciences, vol. 75, pp. 4194-4198 (1978), and also in Diploses et al., J. Soc. Cosmetic Chemists, vol. 43, pp. 93-100 (1992), all incorporated herein by reference.
Solutions of oxa diacids can also be entrapped in polymeric vesicles with a shell consisting of a suitable polymeric material such as gelatin, cross-linked gelatin, polyamide, poylacrylates and the like. These vesicles can then be incorporated into any composition according to the disclosures herein.
The general activity and mildness to skin of the present oxa diacids in a topical composition can also be enhanced by neutralization to pH 3.5 to 8.0, most preferably from pH 3.7 to 5.6, with one or more amphoteric and pseudoamphoteric compounds selected from a list containing, but not limited to, glycine, alanine, valine, serine, theronine, methionine, leucine, asparagine, histidine, glutamic acid, glutamine, lysine, cystine, cystein, tryptophan, serine, phenylalanine, citrulline, creatine, proline, 3- or 4-hydroxyproline, 5-hydroxylysine, ornithine and its derivatives, 3-aminopropanoic acid and other aminocarboxylic acids, canavanine, canaline, homoarginine, betaine, taurine, aminoaldonic acids and aminosugars, aminouronic acid, aminoaldaric acid, deacetylated hyaluronic acid, hyalobiuronic acid, chondrosine, desulfated heparin, neuraminic or sialic acid, thyroxine, di-iodotyrosine, methionine sulfone, glycylglycine, deacetylated chondroitin, DL-sphinngosine, sphingomyelin, L-(erythro) sphingosine, ophidine, glucagon, homocarnosine, aminopipecolic acid, phosphytidyl serine, cocoamphoglycine, phospha-tidyl ethanolamine, cysteinesulfinic acid, glutathione, aluminum oxide, zinc oxide or other amphoteric inorganic oxides, polyamidoamines, polyamidoamines-based dendrimers, sodium hydroxymethylglycinate and polyethylene amine.
The utility and mildness of the present oxa diacids in a topical composition can also be enhanced by certain chelating agents incorporated into the composition at levels from about 0.01% to about 25% by weight, more preferably from about 0.5% to 10%, and most preferably from about 1% to about 5%. Suitable examples of chelating agents include those that have a high affinity for zinc, calcium, magnesium, iron and/or copper ions, such as ethylene-diamine-tetra-acetic acid, (ethylenedioxy)-diethylene-dinitrilo-tetra-acetic acid, salicylaldoxime, quinolinol, diaminocyclohexane-tetra-acetic acid, diethylene-triaminopenta-acetic acid, dimethylglyoxime, benzoin oxime, triethylenetetramine, desferrioxamine or mixtures thereof.
The following examples are illustrative of the present invention and are not intended to limit the invention thereby.
EXAMPLES
The compositions of the present invention are generally made into lotions, creams or gels for topical application.
Example 1
Preparation of Oxa diacid Topical Compositions
In a suitable vessel, water, glycerin, propylene glycol Na 2 EDTA and trioxaundecanoic acid are added and mixed together. Ammonium hydroxide is added to the vessel in increments to adjust pH to the desired range. This pH-adjusted phase is then heated to 170°-175° F. Hydroxyethyl cellulose is next added with agitation until uniform to complete phase A.
For the lotion and cream, phase B is added to a suitable, second vessel, combined and heated to 170°-175° F. Phase B is then added to phase A with sufficient mixing, again at 170°-175° F. The batch is then cooled to 120° F. Phase C is added to the batch and mixed until uniform.
______________________________________Phase GEL LOTION CREAM______________________________________(A) water Q.S. Q.S. Q.S. glycerin 5.00 3.00 5.00 propylene glycol 3.00 3.00 3.00 disodium-EDTA 0.10 0.10 0.10 3,6,9-trioxa- undecanoic acid 10.00 10.00 10.00 hydroxyethyl cellulose 0.50 0.30 0.50 ammonium to pH to pH to pH hydroxide (30%) 3.7-3.9 3.7-3.9 3.7-3.9(B) octyl palmitate -- 3.00 5.00 myristyl myristate -- 3.00 5.00 glyceryl -- 1.50 3.00 monostearate cetearyl alcohol -- 3.00 5.00 & Ceteareth-20 methyl paraben -- 0.20 0.20(C) imidazolidilyl urea 0.30 0.30 0.30______________________________________ All numbers are expressed as percentages of total weight of composition except for pH ranges and Q.S. for balance with water.
Those skilled in the art will readily perceive possible vehicles other than lotions, creams or gels, after having the benefit of this disclosure.
Microscopic normalization of desquamation of the stratum corneum or macroscopic exfoliation of the epidermis are the modes of activity that are prerequisite for alleviating the skin conditions for which the present oxa diacid compounds and compositions are intended. The following example demonstrates, inter alia, the superior stratum corneum desquamatory activity provided by the present oxa diacid compositions.
Example 2
Exfoliation Patch Test for Desquamatory Activity
In general, the exfoliation patch test procedure involves a 24-hour occlusive patching to a skin site. Skin gradings are conducted immediately and 24 hours after removal of the patch. The test focuses primarily on product effects on the stratum corneum and mainly on exfoliation.
A corneocyte removing activity sampling (a "CRAS") is taken following the visual grading at 24 hours after removal of the patch. A CRAS score is a quantitative measure of corneocyte desquamation and its calculation is based on the amount of corneocytes removed with each sampling.
A series of studies were conducted, the first of which showed that in a 1-day exfoliation CRAS assay, a 10 wt % 3,6,9-trioxaundecanedioic acid composition at pH 3.7 had superior exfoliating activity as compared to a formulation which contained 4 wt % glycolic acid at pH 3.8. This study examined the exfoliation properties of 10 wt % oxa diacid at low and high pH, and 5 wt % oxa diacid at low pH. The 4 wt % glycolic acid was included as a frame of reference. Table 1, below, provides a complete data summary as well as material identification.
TABLE 1______________________________________ pH CRAS______________________________________5 wt % oxa diacid 3.7 2.5810 wt % oxa diacid 3.7 2.9310 wt % oxa diacid 5.4 2.684 wt % glycolic acid 3.8 2.80______________________________________
No significant irritation was observed with any of the samples. In all of the various comparisons, the 10% oxa diacid low pH sample was consistently better and exhibited meaningful exfoliation activity.
The next study in the series re-confirmed that a composition with 10 wt % of 3,6,9-trioxaundecanedioic acid has exfoliating activity better than that of a 4 wt % glycolic acid formulation At the same time, the 3,6,9-trioxaundecanedioic acid composition was also milder to the skin than the glycolic acid. It is to be noted that on a molar basis, the concentration of "acid" in a 10% 3,6,9-trioxaundecanedioic acid composition is less than in a 4% glycolic acid formula. Coupled with the clinical results presented herein, this indicates that the intrinsic exfoliating activity of 3,6,9-trioxaundecanedioic acid is significantly higher than that of glycolic acid.
The second study was performed to confirm the results observed earleir with the 10 wt % oxa diacid compositions at pH 3.7. Table 2, below, provides a data summary and material identification for the second study.
TABLE 2______________________________________ Previous pH PII CRAS CRAS______________________________________10% oxa diacid 3.7 0.13 3.23 2.9310% oxa diacid 3.74 0.18 3.33 --4% glycolic acid 3.7 0.23 3.05 2.80______________________________________
No significant irritation was observed with any of the sampled participants, but use of the oxa diacids did show lower irritation index (PII) scores compared to both the glycolic acid and vehicle. The results confirmed what was observed in the prior exfoliation assay.
Example 3
Cream for Hyperpigmented Spots
This example illustrates a cream which can be prepared and used to reduce appearance of hyper-pigmentation spots on the skin of hands.
______________________________________ w/w %______________________________________isopropyl myristate 3.0polyethylene glycol (1000) monostearate 5.0palmitic acid 10.03,6,9,12-tetraoxatetradecanedioic acid 10.0glycerine 3.0polyethylene glycol (300) monostearate 5.0methyl paraben 0.2magnesium ascorbyl phosphate 2.0water 60.0perfume & color to 100.0triethanolamine to pH 4.0______________________________________ All numbers are expressed as percentages of total weight of composition except for the reference to pH.
Example 4
Cream for Dry Skin, Ichthyosis and Hyperkeratoses
This example illustrates a silicone cream that can be prepared and used to treat dry skin, ichthyosis and hyperkeratoses according to the present invention.
______________________________________ w/w %______________________________________Phase A 2.0laurylmethicone copolyol 2.0mineral oil 1.0lanolin 1.5sunflower or soybean oil 10.0cyclomethicone 6.0oil soluble rosmary extract 2.0Phase Bsodium iodide 2.03,6,9-trioxaundecandioic acid 9.03,6,9,12,15-pentaoxaheptadecanedioic acid 1.0sodium hydroxymethyl glycinate 0.5demineralized water to 100.0sodium biphosphate to pH 3.8______________________________________ All numbers are expressed as percentages of total weight of composition except for the reference to pH.
Example 5
Silicone Gel
This example illustrates a water-in-silicone gel composition.
______________________________________ w/w %______________________________________Phase Adimethiconol 10.0dimethicone copolyol 10.0cyclomethicone 5.0Phase B3,6,9-trioxaundecanedioic acid 8.0glycerine 20.0demineralized water to 100.0triethanolamine to pH 4.0______________________________________ All numbers are expressed as percentages of total weight of composition except for the reference to pH.
Example 6
Cream for Acne, Skin Blemishes and Age Spots
This example illustrates a face cream than can be used to treat acne, skin blemished and age spots.
______________________________________ w/w %______________________________________Phase Aoleic acid 1.0stearic acid 17.0polyoxyethylene (20 propylene glycol monostrearate 10.0retinol 0.1Phase Bglycerine 5.02-pyrollidone-5-carboxylic acid 5.03,6,9-trioxaundecanedioic acid 7.53,6,9,12-tetraoxatetradecanedioic acid 2.5lactic acid 3.0demineralized water to 100.00ammonium hydroxide to pH 4.2______________________________________ All numbers are expressed as percentages of total weight of composition except for the reference to pH.
Various modifications and alterations to the present invention may be appreciated based on a review of this disclosure. These changes and additions are intended to be within the scope and spirit of this invention as defined by the following claims. | Described are the use of compounds of Formula (I), depicted below, as active principals for treating skin conditions, compositions containing these compounds, and methods of treating skin conditions using these compounds and compositions. ##STR1## wherein, R 4 is (CR 5 R 6 --CR 7 R 8 --X 1 ) n --CR 9 R 10 --C(═X 2 )X 3 R 11 , with n being an integer from 1 to 18; R 1 , R 2 , R 3 , R 5 , R 6 , R 7 , R 8 , R 9 , R 10 and R 11 are independently, hydrogen or non-hydrogen substituents; and X, X 1 , X 2 , X 3 , Y and Z are independently, O, NH or S. | 2 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a handicraft clip suitably used for handicraft work such as patchwork.
[0003] 2. Description of the Related Art
[0004] In the field of handicraft works such as patchwork, a technique so called “puff quilt” is known as one of the methods that provide excellent ornamental effects. For example, U.S. Pat. No. 5,899,160 discloses a conventional puff quilt square maker and a method for fabricating a puff quilt square. Generally, the puff quilt is performed with a plurality of square-shaped quilting materials (puffs). The puff is made through superposing a pleated cloth over a base cloth and sewing these cloths together, which allows forming various design patterns depending on the pleating form, and also stuffing padding in between the cloths, to thereby form a three-dimensionally swollen shape. To practically form the puff, for example, two pieces of square cloths that are different in size are prepared. Each of the four sides of the larger cloth is pleated so as to make the size thereof the same with the smaller cloth, and the pleats are temporarily fixed with marking pins. Then the two cloths are laid on each other and a sewing margin is defined so as to sew the perimeter of the stacked cloths. In the case where the puff is to be stuffed with padding, for example a portion of the perimeter is left open for inserting the padding therethrough, instead of sewing the entire perimeter, and then the cloths are turned inside out through the opening, after which the padding is stuffed and the opening is sewn to close. The puff thus made up obtains a shape swelling toward the upper side, as shown in FIG. 11 . The puff quilt is made up by combining a plurality of such puffs and sewing the edges together, or sewing the puffs onto another base cloth.
[0005] When performing the patchwork with the puff quilt, a large number of puffs are often employed according to the design. In this case, it is so difficult to make pleats of the same size and same form on all of the large number of puffs.
SUMMARY OF THE INVENTION
[0006] The present invention has been proposed in the foregoing circumstances. It is therefore an object of the present invention to provide a handicraft clip that facilitates, when making a pleated quilt material such as a puff, efficient forming of pleats in generally the same size.
[0007] According to the present invention, there is provided a handicraft clip for forming a pleat in a cloth. The clip comprises: a base plate including a first portion and a second portion of a predetermined width, the first portion having a basal end portion, the second portion being integral with the first portion and having a distal end portion; and a fastening plate including a first portion and a second portion, the first portion of the fastening plate having a basal end portion, the second portion of the fastening plate being integral with the first portion of the fastening plate and having a distal end portion, the fastening plate being pivotally connected, at the basal end portion thereof, to the basal end portion of the base plate. The base plate and the fastening plate are foldable to face each other in a manner such that the first portions of the respective plates are superposed on each other, and that the second portions of the respective plates are superposed on each other. The second portion of the fastening plate is formed with a slit extending from the distal end portion of the fastening plate toward the basal end portion of the fastening plate.
[0008] Preferably, the slit formed in the fastening plate may be located at a widthwise center of the second portion of the base plate when base plate and the fastening plate are superposed on each other.
[0009] Preferably, the second portion of the base plate may be formed with a slit extending from the distal end portion of the base plate toward the basal end portion of the base plate.
[0010] Preferably, the slit formed in the base plate may be located at a widthwise center of the second portion of the base plate.
[0011] Preferably, the handicraft clip of the present invention may further comprise a lock for keeping the base plate and the fastening plate superposed on each other.
[0012] Preferably, the lock may include a through-hole and a protrusion to be fitted into the through-hole. The through-hole may be formed in one of the first portions of the respective plates, while the protrusion on the other of the first portions of the respective plates.
[0013] Preferably, the protrusion may be fitted in the through-hole in a manner such that an end portion of the protrusion sticks out beyond an end portion of the through-hole.
[0014] Preferably, the second portions of the respective plates may have cloth holding surfaces brought into facing relation when these second portions are superposed on each other, where each of the cloth holding surfaces is formed with an elongated projection extending widthwise of the second portions.
[0015] Other features and advantages of the present invention will become more apparent through the following detailed description given with reference to the -accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] FIG. 1 is a plan view showing a handicraft clip according to the present invention;
[0017] FIG. 2 is a sectional view taken along a line II-II in FIG. 1 ;
[0018] FIG. 3 is a plan view showing the handicraft clip of FIG. 1 , with the fastening plate superposed over the base plate;
[0019] FIG. 4 is a sectional view taken along a line IV-IV in FIG. 3 ;
[0020] FIG. 5 is a perspective view for explaining a procedure in using the handicraft clip shown in FIG. 1 ;
[0021] FIG. 6 is a perspective view for explaining the procedure in using the handicraft clip shown in FIG. 1 ;
[0022] FIG. 7 is a schematic view showing in section the handicraft clip shown in FIG. 1 forming a pleat on a cloth;
[0023] FIG. 8A is a front-side, schematic view for illustrating the procedure of use of the handicraft clip shown in FIG. 1 ;
[0024] FIG. 8B is a back-side, schematic view for illustrating the procedure of use of the handicraft clip shown in FIG. 1 ;
[0025] FIG. 9 is a plan view for explaining a procedure of use of the handicraft clip shown in FIG. 1 ;
[0026] FIG. 10 is a plan view for explaining a procedure of use of the handicraft clip shown in FIG. 1 ;
[0027] FIG. 11 is a perspective view showing a quilt material made up by the handicraft clip shown in FIG. 1 ; and
[0028] FIG. 12 is a schematic cross-sectional view showing the handicraft clip shown in FIG. 1 forming a pleat on a cloth in another manner.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0029] Preferred embodiments of the present invention will be described with reference to the accompanying drawings.
[0030] FIG. 1 is a plan view showing a handicraft clip according to the present invention. FIG. 2 is a cross-sectional view taken along a line II-II in FIG. 1 . As shown in FIG. 1 , the handicraft clip Al according to this embodiment, including a base plate 1 , a fastening plate 2 , and a lock or locking means L (see FIG. 4 ), is integrally formed as a single unit made of a synthetic resin (such as polypropylene) having an appropriate strength. The handicraft clip A 1 serves to form a pleat on the perimeter of a cloth, when making a quilt material such as a puff.
[0031] The base plate 1 includes a thin base portion 11 of a predetermined thickness, and a clip element 12 extending from the base portion 11 . The base portion 11 is of a shape stretched widthwise thereof (left and right direction in FIG. 1 ), so as to enable the user to easily hold the portion in his or her hand. The base portion 11 is formed with a generally elliptical through-hole 13 , located in a central region and penetrating throughout the thickness of the base portion. As is apparent from FIG. 2 , the inner wall of the through-hole 13 includes an engaging stepped portion 131 formed at a lower portion thereof, along the entire inner circumferential surface of the through-hole.
[0032] The clip element 12 extends from an edge portion of the base portion 11 toward a distal end, and has a predetermined width and length. The clip element 12 is formed with three slits 121 to 123 of a predetermined width, extending from the distal end portion toward the base portion 11 . In this embodiment, the slit 121 is located at the widthwise center of the clip element 12 , and the slits 122 , 123 are spaced from the central slit 121 by the same distance. Also as shown in FIGS. 1 and 2 , the clip element 12 is formed with a plurality of elongated projections 124 , 125 extending widthwise on the upper and lower surfaces of the element 12 , provided for preventing slippage of the cloth.
[0033] The fastening plate 2 includes a main plate 21 and a clip element 22 extending from the main plate 21 . The main plate 21 is generally the same in thickness as the base portion 11 of the base plate 1 , and connected to the basal end portion of the base portion 11 via a joint portion 3 having a reduced thickness and extending in the widthwise direction along the basal end portion. Such configuration permits the fastening plate 2 to pivot about the joint portion 3 toward or away from the base plate 1 . The main plate 21 includes a generally elliptical protrusion 23 formed substantially in a central region thereof. The protrusion 23 is made slightly smaller than the through-hole 13 of the base plate 1 in a plan view, so as to be fitted into the through-hole 13 when the fastening plate 2 is folded onto the base plate 1 . Thus, as shown in FIGS. 3 and 4 , the fastening plate 2 can be folded upon the base plate 1 such that the main plate 21 and the base portion 11 , as well as the clip element 22 and the clip element 12 , are respectively superposed over each other. The height of the protrusion 23 is made greater than the thickness of the base portion 11 . Accordingly, when the protrusion 23 is fitted into the through-hole 13 , the end portion of the protrusion 23 sticks out beyond the lower end portion of the through-hole 13 . The protrusion 23 includes an engaging stepped portion 231 projecting from the upper end portion thereof, along the entire outer circumferential surface thereof.
[0034] The clip element 22 extends from an end portion of the main plate 21 toward a distal end portion, and has a predetermined width and length. The clip element 22 is made smaller in width than the clip element 12 of the base plate 1 , and substantially the same in length as the clip element 12 . The clip element 22 includes a slit 221 of a predetermined width extending from the distal end portion thereof toward the main plate 21 . The slit 221 is located at the widthwise center of the clip element 22 . Here, the widthwise center of the clip element 22 coincides with the widthwise center of the clip element 12 . Thus, as shown in FIG. 3 , once the clip element 22 is superposed over the clip element 12 , the slit 221 of the clip element 22 is located at the center of the clip element 12 , and communicates with the slit 121 . Also as shown in FIG. 1 , the clip element 22 includes a plurality of elongated projections 222 extending widthwise on the upper surface thereof, provided for preventing slippage of the cloth.
[0035] The lock L serves to keep the fastening plate 2 superposed over the base plate 1 , and includes the engaging stepped portion 131 formed along the inner circumferential surface of the through-hole 13 of the base plate 1 , and the engaging stepped portion 231 formed along the outer circumferential surface of the protrusion 23 of the fastening plate 2 , which constitute the operative portion of the lock L. When the fastening plate 2 is superposed over the base plate 1 , the protrusion 23 is introduced into the through-hole 13 . Upon pressing the fastening plate 2 against the base plate 1 with a predetermined or a greater force, the engaging stepped portion 231 is elastically deformed slightly so as to pass through the inner circumferential surface of the through-hole 13 , to be thereby engaged with the engaging stepped portion 131 . Such action causes the main plate 21 of the fastening plate 2 to be completely superposed over the base portion 11 of the base plate 1 , such that the fastening plate 2 is inhibited from moving away from the base plate 1 .
[0036] Now, a method of making up a puff with the handicraft clip A 1 thus configured will be described referring to FIGS. 5 to 10 . The following refers to the case of making a basic puff utilizing four pieces of handicraft clips A 1 .
[0037] To start with, two pieces of square cloths of different sizes are cut out, to form the puff. The larger cloth (hereinafter, top cloth C 1 ) is used to form pleats, to be finally located on the upper face of the puff. The small cloth (hereinafter, base cloth C 2 ) is to be superposed over the top cloth C 1 with the pleats formed, to be thereby sewn together.
[0038] When cutting out the top cloth C 1 and the base cloth C 2 , employing a template (not shown) facilitates efficiently performing the job. The template may be two square frames of the same dimensions as the top cloth C 1 base cloth C 2 respectively. In this case, putting markings on the back of the cloth along the perimeter of the respective templates, and cutting the cloth along the markings leads to preparation of the top cloths C 1 and the base cloths C 2 in uniform dimensions. Regarding the template for the base cloth C 2 , it is convenient to provide a stitch line along the inner perimeter of the frame.
[0039] The handicraft clip Al is now employed to form the pleats. The top cloth C 1 is folded in half face to face, and the edge portion of the cloth on the respective sides of the folded point is inserted into the left and right slit 122 , 123 of the base plate 1 as shown in FIG. 5 , and the end portions of the folded cloth are put together and lifted upward. Then as shown in FIG. 6 , the fastening plate 2 is lifted and folded onto the base plate 1 . At this step, the edge portion of the top cloth C 1 now folded in double is introduced into the slit 221 of the fastening plate 2 . Upon pressing the back of the protrusion 23 on the fastening plate 2 against the base plate 1 , the engaging stepped portion 231 of the protrusion 23 is engaged with the engaging stepped portion 131 of the through-hole 13 , thereby actuating the lock L. At this stage, a pleat is formed on the top cloth C 1 by the handicraft clip Al, as shown in FIG. 7 . Another handicraft clip A 1 is then applied to the opposite side of the top cloth C 1 in the same way, to thereby form the pleat. Then to the remaining two sides of the top cloth C 1 also, the handicraft clip Al is likewise attached. FIGS. 8A and 8B are schematic plan views showing the top cloth C 1 to which the four pieces of handicraft clips A 1 are attached, and FIG. 8A shows the front side and 8 B the back side.
[0040] Then the top cloth C 1 and the base cloth C 2 are sewn together. As shown in FIG. 9 , the top cloth C 1 and the base cloth C 2 are stacked face to face, and the sewing margin is fixed with a marking pin N as shown in FIG. 10 . On the base cloth C 2 , for example a stitch line M is marked, so that the base cloth C 2 and the top cloth C 1 are sewn together along the stitch line M over a predetermined region. In this embodiment, a position designated by (1) in FIG. 10 is the starting point of the stitch, and (2) designates the finishing point. The region between the starting point (1) and the finishing point (2) is an unsewn region (opening 01 ). Regarding the stitch method, for example a back stitch may be employed at the starting point and the finishing point, and a running stitch may be employed in the remaining portion. The sewing may be performed either with a sewing machine or by hand. Upon completing the sewing process, the four handicraft clips A 1 are removed and a surplus portion of the sewing margin is cut off.
[0041] Then the cloths sewn together is turned inside out through the opening O 1 , and padding is introduced therethrough. Finally, the opening O 1 is sewn to close. That is how a padded puff P as shown in FIG. 11 can be obtained.
[0042] As may be understood from FIG. 7 , when forming a pleat with the handicraft clip A 1 according two this embodiment, the clip element 12 of the base plate 1 serves to determine a first folding position, and the slit 221 of the fastening plate 2 serves to determine a second folding position. Thus, the handicraft clip A 1 permits sequentially and efficiently forming pleats of substantially the same size. Also, the slits 122 , 123 on the left and right side of the base plate facilitate forming the first folding position.
[0043] The handicraft clip A 1 also includes the lock L. This device serves to maintain the pleated portion of the top cloth C 1 in the state of being held between the clip elements 11 , 12 . Accordingly, the handicraft clip A 1 can be prevented from accidentally coming off from the top cloth Cl.
[0044] Further, in the handicraft clip A 1 , simply superposing the fastening plate 2 over the base plate 1 causes the engaging stepped portions 131 , 231 to be mutually engaged, thereby actuating the lock L. Such arrangement enhances the usefulness of the handicraft clip A 1 .
[0045] In the handicraft clip A 1 , the clip elements 11 , 12 each include a plurality of projections 124 , 125 , 222 . These projections serve to restrict a relative positional shift between the clip element 11 , 12 and the top cloth C 1 held therebetween.
[0046] In the handicraft clip A 1 , to use the lock L, the protrusion 23 is inserted into the through-hole 13 until the end portion of the protrusion 23 protrudes beyond the end of the through-hole 13 . Thereafter, the user can easily release the lock L simply by pushing the button-shaped end portion of the protrusion 23 back into the through-hole 13 with the thumb, for example.
[0047] The base plate 1 of the handicraft clip A 1 includes the plurality of slits 121 to 123 . Such configuration allows forming pleats of a plurality of different types according to how the top cloth C 1 is inserted through the slits 121 to 123 . FIG. 12 illustrates a different pleating pattern of the top cloth C 1 formed around the clip elements 12 , 22 , so as to make a puff of a different design from that of the foregoing basic shape. In this case, a pleat folded back in an S-shape is formed, which provides a puff of a different design from that of the basic shape.
[0048] The present invention being thus described, it is obvious that the same may be varied in many ways. Such variations are not to be regarded as a departure from the spirit and scope of the present invention, and all such modifications as would be obvious to those skilled in the art are intended to be included within the scope of the following claims. | A handicraft clip is provided for forming a pleat in a cloth. The clip includes a relatively wide base plate and a narrower fastening plate connected to the base plate via a connecting hinge portion having a reduced thickness for allowing pivotal movement of the fastening plate relative to the base plate. The base plate is formed with a generally elliptical through-hole, while the fastening plate is provided with a locking protrusion to be fitted into the through-hole of the base plate when the base plate and the fastening plate are superposed on each other. The fastening plate includes a cloth holding portion of -a generally constant width. The cloth holding portion is formed with a slit for insertion of a cloth. The slit extends from the distal end of the cloth holding portion toward the locking protrusion. | 3 |
TECHNICAL FIELD OF INVENTION
[0001] The present invention relates to ambient mist technology. In particular, the present invention relates to tools that employ ambient mist technology in combating fire, smoke and airborne pollutants.
BACKGROUND OF INVENTION
[0002] Fires destroy lives, homes, memories and property each year, costing millions of dollars in damages. Conventional nozzles used in firefighting tools require a high-pressure water source and copious amounts of water. Furthermore, the high pressure of water used in these nozzles often causes extensive structural and water damage to remaining property and possessions. Furthermore, these high-pressure nozzles often create a back draft during the course of use.
[0003] As a means of circumventing the damaging effect of high-pressure water nozzles, mist-generating nozzles have been used as an alternative means to fight fires.
[0004] Conventional mist nozzles are made of stainless steel, and are often used in grocery stores to spray cold water mist over fresh vegetables. However, these are quite expensive. Other conventional mist nozzles include nozzles used for oil furnaces. However, these rust quickly when used with water. The mist nozzles used in the present invention are relatively inexpensive, made of milled pure brass (so as to prevent the onset of rust), and are quite rugged and durable. The mist head of the present invention can withstand high temperatures caused by fires, without sustaining any damage.
[0005] U.S. Pat. No. 4,697,740 discloses a mist generating nozzle that has a cylindrical bearing member in which a plurality of distribution slots are formed. A cylindrical sleeve member is concentrically disposed about the bearing member, with an annular chamber defined therebetween. The sleeve member has a plurality of orifices communicating with the annular chamber and which extend transversely with respect to the radius of the sleeve member for imparting rotational motion to the sleeve member in response to the discharge of water through the orifices. The centrifugal force acting on the water discharged through the orifices particulates the water droplets into a fine mist or fog, in a substantially spiral pattern around the nozzle. This particular design requires a high-pressure water input, and releases water at a high pressure rate of up to 100 gallons per minute (gpm). Therefore, a relatively high volume of water is consumed, while damage from high-pressure output still occurs.
[0006] U.S. Pat. No. 4,700,894 discloses a firefighting nozzle forming a generally sphere-like water spray pattern. The nozzle includes a coupler for coupling the nozzle to a water delivery hose. The nozzle also includes a plurality of rings for forming a spray-like pattern.
[0007] U.S. Pat. No. 4,736,801 discloses a fire extinguisher that has an elongated manifold for discharging fire in a chimney. The extinguisher is surrounded by a protective cage. The extinguisher comprises a bore, which is connected externally to a standard water supply line. The bore connects internally to a series of lateral channels, each of which connects to a small mist nozzle. The manifold has a pointed end, which penetrates ignited creosote at the base of chimney.
[0008] U.S. Pat. No. 5,253,716 discloses a fog-producing firefighting tool that has a nozzle which includes a plurality of apertures oriented so that when pressurized fluid flows through each aperture, the liquid impacts at an angle of 90 degrees with another stream of liquid to atomize the liquid and create the fog. Moreover, the firefighting tool consists of a plurality of members that are coupled with locking devices.
[0009] U.S. Pat. No. 6,173,909 discloses a portable fire extinguishing nozzle arrangement that has a nozzle head provided with fire extinguishing nozzles that may be connected to a supply pipe. A plurality of the nozzles are mutually spaced apart at the front side of the nozzle head. The head contains valve combinations which allow for the nozzles to be selectively supplied with fluid.
[0010] U.S. Pat. No. 6,398,136 discloses a fire-fighting tool that incorporates a twist-lock mechanism whereby various nozzles can be interchanged. The fluid aperture angles can be configured to produce a mist in various directions. A key feature is the water streams that exit through the apertures, impinge on other streams emanating from other apertures.
[0011] As noted, many of the prior art devices are complex, requiring a plurality of parts, either within the head, or as part of the overall assembly. Additionally, many of these prior art devices require water output from the mist nozzles to intersect, and thus, form water droplets.
[0012] There is a need for a simple, durable fire extinguishing tool that uses relatively inexpensive, durable, low-pressure mist nozzles, and can operate on low-pressure water input. The low-pressure input results in a relatively low volume of consumption, while the low-pressure output minimizes water and property damage that occurs when conventional high-pressure hoses are used. The firefighting tools should be durable, and should withstand the high temperatures associated with fires. In addition, to minimize the complexity of design, the mist nozzles used in the tool should be configured in a simple manner that does not require the emerging streams to intersect with each other.
SUMMARY OF INVENTION
[0013] The invention in its general form will first be described, and then its implementation will be detailed hereafter. These embodiments are intended to demonstrate the principle of the invention, and the manner of its implementation.
[0014] Disclosed herein is an ambient mist head that comprises a plurality of mist nozzles attached to a head. The mist nozzles are arranged spatially on the head at various angles. The number of mist nozzles, the spatial arrangement and the angular placement of the mist nozzles can vary, depending on the area of coverage required. The angular placement of the mist nozzles on the head is effected so that the mist stream emerging from one mist nozzle does not impinge on a mist stream emerging from another mist nozzle. The angular placement of the mist nozzles thereby provides a maximal amount of mist production, and minimizes the occurrence of streams of water droplets.
[0015] In one aspect of the present invention, there is provided an ambient mist head comprising: a head body with: an inlet for a fluid source; a plurality of outlets; and a cavity within the head body connecting the inlet to the outlets; a plurality of low-pressure mist nozzles equal in number to the outlets; with each mist nozzle attached to the head body at an outlet; wherein a fluid stream exiting from one mist nozzle does not intersect a fluid stream exiting from any another mist nozzle.
[0016] In another aspect of the present invention, there is provided an ambient mist head for extinguishing a fire comprising: a) a head body having an inlet for a fluid source; five outlets; and a cavity within the head body connecting the inlet to the five outlets; and b) five low-pressure mist nozzles attached to the head body at each of the outlets; wherein four of the five low-pressure mist nozzles are attached on a bevelled surface of the head body, and the fifth mist nozzle is attached centrally on a planar surface of the head body, the planar surface adjacent to the bevelled surface.
[0017] In a further aspect of the present invention, there is provided a firefighting tool comprising: a) a wand having a handle; a water stoppage device located at a first extremity of the wand; and b) an ambient mist head for extinguishing a fire connected to the wand at a second extremity, wherein an external supply line is connected to the wand at the first extremity, and the ambient mist comprising a) a head body having an inlet for a fluid source; five outlets; and a cavity within the head body connecting the inlet to the five outlets; and b) five low-pressure mist nozzles attached to the head body at each of the outlets, with four of the five low-pressure mist nozzles are attached on a bevelled surface of the head body, and the fifth mist nozzle is attached centrally on a planar surface of the head body, the planar surface adjacent to the bevelled surface.
[0018] In yet another aspect of the present invention, there is provided an ambient mist head for extinguishing a chimney fire comprising: a) a head body having an inlet for a fluid source; four outlets; and a cavity within the head body connecting the inlet to the four outlets; and b) four low-pressure mist nozzles attached on an external surface of the head body at each of the outlets.
[0019] In yet another aspect of the present invention, there is provided a chimney fire extinguishing tool comprising the ambient mist head for extinguishing a chimney fire; a water stoppage device located upstream from the ambient mist head; and a supply line attached to the inlet.
[0020] In yet another aspect of the present invention, there is provided an ambient mist head for use in a sprinkler system, the ambient mist head comprising: a) a head body having an inlet for a fluid source at a first extremity; four outlets at a second extremity; and a cavity within the head body connecting the inlet to the four outlets; b) four low-pressure mist nozzles attached to the body at each of the outlets; wherein the four low-pressure mist nozzles are attached on a bevelled surface of the head body.
[0021] In yet another aspect of the present invention, there is provided a sprinkler system comprising the ambient mist head for use in a sprinkler system attached to piping; and a water stoppage device located upstream from the mist head.
[0022] The mist pattern produced by the device of the present invention can be used to fight four classes of fires, without the occurrence of back draft. Conventional nozzles used in firefighting tools often create a back draft during the course of use. Unlike conventional firefighting materials, the fine mist particles produced by the device of the present invention do not cause damage to the surroundings. For example, conventional nozzles produce dense fog at 175 gallons per minute (gpm) which blows out the fire and, in most cases, causes extensive damage due to the high pressure of the extinguishing material. In contrast, the mist head of the present invention produces a mist output at a lower rate, preferably 6-40 gpm, more preferably 8-12 gpm, thereby preventing damage to the surroundings.
[0023] In addition, the mist produced by the device of the present invention can remove smoke particles, carcinogens and other airborne pollutants.
[0024] In contrast to conventional mist nozzles that are made of expensive materials (such as steel), and are prone to rust, the mist nozzles used in the present invention are relatively inexpensive, made of milled pure brass (so as to prevent the onset of rust), and are quite rugged and durable. The mist head of the present invention can withstand high temperatures caused by fires, without sustaining any damage.
[0025] The mist nozzles are engineered and milled so as to provide a mist when in use with water.
[0026] Each mist nozzle has a rate of flow (i.e. number of gallons per minute of vapour produced) preferably in the range of about 2 to 6 gpm, more preferably from 2 to 4 gpm. The mist nozzle is preferably made of milled pure brass, so as to avoid sparks or rust. The mist nozzles tips in the present invention provide an ambient mist with minimal water supply and/or low water pressure. In addition, the mist head is custom milled, and preferably made from anodized aluminum, and more preferably, made from brass. As such, the mist nozzles and head are very durable.
[0027] Each mist nozzle is threaded and/or screwed into the head. A threaded hole is preferably drilled into the head for each mist nozzle. The threaded hole may be angled into the head, depending on the required angular placement of the mist nozzle
[0028] The various components (except the shut off valve) of each tool are also custom milled. The mist nozzles, head and other components are very durable.
[0029] Water enters the mist head via a supply line which is attached to the mist head. The supply line is preferably ½ inch or ¾ inch.
[0030] Wherever ranges of values are referenced within this specification, sub-ranges therein are intended to be included within the scope of the invention unless otherwise indicated. Where characteristics are attributed to one or another variant of the invention, unless otherwise indicated, such characteristics are intended to apply to all other variants of the invention where such characteristics are appropriate or compatible with such other variants.
[0031] The foregoing summarizes the principal features of the invention and some of its optional aspects. The invention may be further understood by the detailed description which follows.
BRIEF DESCRIPTION OF DRAWINGS
[0032] FIGS. 1 a , 1 b and 1 c respectively illustrate a side view, a front view and a perspective view of an embodiment of the present invention.
[0033] FIGS. 2 a and 2 b respectively illustrate a side view and a perspective view of a firefighting tool of the present invention using the ambient mist head shown in FIGS. 1 a - 1 c.
[0034] FIGS. 3 a - 3 c respectively illustrate a side view, a front view and a perspective view of a second embodiment of the present invention.
[0035] FIGS. 4 a - 4 c respectively illustrate a side view, a front view and a perspective view of a third embodiment of the present invention.
[0036] FIGS. 5 a - 5 d respectively illustrate a side view (closed position); end view (closed position), side view (open position) and end view (open position) of a plunger device used to activate a sprinkler using the mist head of FIGS. 4 a - 4 c.
DETAILED DESCRIPTION
[0037] The following is given by way of illustration only and is not to be considered limitative of this invention. Many apparent variations are possible without departing from scope thereof.
Firefighting Tool
[0038] An ambient mist head ( 10 ) used in a firefighting tool is shown in FIGS. 1 a - 1 c . The ambient mist head ( 10 ) is shown in perspective form in FIG. 1 c ; side view in FIG. 1 a and end view in FIG. 1 b . The ambient mist head ( 10 ) has five mist nozzle tips ( 25 , 30 ): one ( 25 ) at each corner of the body ( 20 ), and one central nozzle tip ( 30 ) at the center of the body ( 20 ). A threaded hole is preferably drilled into the body ( 20 ) for each mist nozzle ( 25 , 30 ). The threaded hole may be angled into the head, depending on the required angular placement of the mist nozzle. As seen in FIG. 1 a , the corner nozzle tips ( 25 ) tips are set at an angle of 45° from the vertical of the head ( 20 ), while the central nozzle tip ( 30 ) is perpendicular to the horizontal plane of the mist head. As shown in FIG. 1 b , each corner tip ( 25 ) is set 90° from each other. Each mist nozzle ( 25 , 30 ) is threaded and/or screwed into the body ( 25 ). Each corner nozzle tip has an output of preferably 2 gpm, while the central nozzle tip has an output of preferably 4 gpm.
[0039] FIG. 1 a illustrates a side view of the head body ( 20 ), which comprises inner walls ( 35 ) and a threaded opening or inlet ( 40 ). The diameter of the threaded opening ( 40 ) is preferably ¾ inch, in order to connect to a standard ¾ inch supply line. Alternatively, the diameter of the threaded opening ( 40 ) can be ½ inch to connect to a standard ½ inch supply line. When connected to an external water source, water flows into the inlet defined by the inner walls ( 35 ) and exits through each mist nozzle ( 25 , 30 ). In the present embodiment, the height ( 50 ) of the body ( 20 ) is about 1.45 inches; the full length ( 55 ) is about 1.9 inches; the length of the angular portion ( 60 ) of the body ( 20 ) is about ½ inch. The other dimensions are as follows: the height of the central portion ( 65 ) of the body ( 20 ) is about 0.45 inches, while the distance ( 70 ) at which each corner nozzle ( 25 ) is placed from the end of the body ( 20 ) is about 0.25 inches. The number of mist nozzles (five), and their placement is found to provide the most effective coverage when used as part of the firefighting tool described below.
[0040] A firefighting tool ( 100 ) that uses the ambient mist head ( 10 ) of FIGS. 1-3 , is shown in FIGS. 2 a and 2 c . The tool consists of the ambient mist head ( 10 ), connected to a wand ( 110 ). A handle ( 120 ) is attached to the wand ( 110 ) for ease of carrying the tool. The wand has a diameter that is equal to that of the ambient mist head ( 10 ), which is preferably ¾ inch. At the other extremity of the wand ( 110 ) is an on/off valve ( 130 ) which controls the water flow through the wand ( 110 ). The valve ( 130 ) is preferably of the ball-type variety.
[0041] The wand ( 110 ) and handle ( 120 ) are milled and made of a lightweight material which is fireproof, and does not become excessively hot. In one test, the firefighting tool was placed in 1200° F. heat, with no damage sustained by the tool. The handle and wand are preferably made of anodized aluminum. The tool can be easily and quickly assembled by attaching the wand ( 110 ) to the mist head ( 10 ). This equipment can be installed as a fixed system or used as a piece of lightweight, portable firefighting equipment.
[0042] The firefighting tool ( 100 ) can be attached to a portable pressurized water source (not shown) using a conventional hose or supply line (not shown). At a fire, the valve ( 130 ) is turned on so that water fills the tool ( 100 ), and enters the ambient mist head ( 10 ), building up pressure. As the pressure increases, the nozzle tips ( 25 , 30 ) atomize the water into a fine mist, which puts out the fire. Once the fire is extinguished, the valve ( 130 ) is turned off.
[0043] The firefighting tool ( 10 ) can operate effectively with low or ambient water pressure. In one experimental test, the firefighting tool was shown to operate effectively using water at a pressure of about 60 psi, although the tool will primarily operate at conventional water pressures of 100 psi-120 psi.
[0044] The mist produced by the firefighting tool does not blow the fire as conventional nozzles do. While not being limited to any particular theory, it is thought that the mist particles extinguish fire by greatly reducing access to surrounding oxygen; i.e. the low-pressure mist smothers the fire. Furthermore, there is no back draft produced by the firefighting tool.
[0045] The fire fighting tool that uses the ambient mist head of the present invention contains, controls and extinguishes fire, in conditions from the earlier incipient fire start to larger, free-burning fires. It can be used to fight fires originating from (but not limited to) materials such as paper or wood, flammable liquids, up to and including live electrical equipment. The firefighting tool is able to extinguish fires from low volumes to large volumes. In particular, it is effective in fighting fires that are Class A, B and C.
Chimney Tool
[0046] A second embodiment of the present invention is shown in FIGS. 3 a - 3 c . The ambient mist head ( 150 ) is shown in perspective form in FIG. 3 c ; side view in FIG. 3 a and end view in FIG. 3 b . The ambient mist head ( 150 ) comprises a head body ( 160 ) with four mist nozzles ( 165 ), spaced equidistantly in a horizontal plane around the external surface of the body ( 160 ). As shown in FIG. 3 c , the head body ( 160 ) is preferably cylindrical, although other shapes are contemplated, such as a rectangular block. The spray tips ( 165 ) are 90° from each other.
[0047] According to FIG. 3 a , the body ( 160 ) consists of inner walls ( 170 ) which define an orifice through which water flows into through the threaded opening ( 175 ); it then exits via the four mist nozzles ( 165 ). The diameter of the orifice is preferably ¾ inches, in order to match standard ¾ inch supply lines. Alternatively, the inlet can preferably have a diameter of ½ inches, in order to match standard ½ inch supply lines. The remaining dimensions are as follows: body length ( 180 ) is about 1.75 inches, while distance ( 185 ) between the center of each mist nozzle ( 165 ) and the end of the body ( 20 ) is about 0.45 inches.
[0048] The mist head ( 150 ) is attached directly to a hose line (not shown) in order to a form a chimney tool that can be used to extinguish chimney fires. The chimney tool preferably has no handle, and is directly attached to a hose line. The chimney tool further includes a water stoppage device located upstream from the mist head ( 150 ); this device is used to stop the inflow of water. When there is a fire, the stoppage device is opened, thereby allowing water to enter the body ( 160 ). As the pressure in the body ( 160 ) builds up, the nozzle tips ( 165 ) atomize the water into a fine mist, which extinguishes the fire. The chimney tool is used by lowering the device down a chimney while water is supplied, thereby creating an ambient mist as the chimney tool is lowered. The ambient mist extinguishes the fire quickly with little or no water damage caused to the flute. Once the fire is extinguished, the system will need to be turned off, drained and reset.
Sprinkler Tool
[0049] FIGS. 4 a - 4 c illustrate a third embodiment of the present invention. The ambient mist head ( 200 ) is shown in perspective form in FIG. 4 c ; side view in FIG. 4 a and end view in FIG. 4 b.
[0050] The ambient mist head ( 200 ) shown in FIGS. 4 a - 4 c can be used in a sprinkler systems. The head body ( 220 ) has four mist nozzle tips ( 225 ): one ( 225 ) at each corner of the body ( 220 ). As seen in FIG. 4 a , the corner nozzle tips ( 225 ) tips are set at an angle of 45° from a vertical plane of the head ( 220 ). As shown in FIG. 4 b , each corner tip ( 225 ) is set 90° from each other. Each corner nozzle tip has an output of preferably 2 gpm. The total output of the mist head ( 200 ) is preferably 8 gpm.
[0051] FIG. 4 a illustrates a side view of the head body ( 220 ), which comprises inner walls ( 235 ) and a threaded opening ( 240 ). The diameter of the threaded opening ( 240 ) is preferably ¾ inch. When connected to an external water source, water flows through the orifice defined by the inner walls ( 235 ) and eventually through each mist nozzle ( 225 ). In the present embodiment, the height ( 250 ) of the body ( 220 ) is about 1.45 inches; the full length ( 255 ) is about 1.9 inches; the length of the angular portion ( 260 ) of the body ( 220 ) is about ½ inch. The other dimensions are as follows: the height of the central portion ( 265 ) of the body ( 220 ) is about 0.45 inches, while the distance ( 270 ) at which each corner nozzle ( 225 ) is placed from the end of the body ( 220 ) is about 0.25 inches. The number of mist nozzles (four), and their placement is found to provide the most effective coverage when used as part of the firefighting tool described below.
[0052] In FIG. 4 b , a front view of sprinkler mist head of FIG. 4 a is shown, with the four mist nozzles ( 225 ) spaced equidistant along the circumferential surface of the cylindrical head ( 220 ).
[0053] The sprinkler system further includes a water stoppage device located upstream from the mist head ( 200 ); this device is used to stop the inflow of water. When there is a fire, the stoppage device is opened, thereby allowing water to enter the body ( 220 ). As the pressure in the body ( 220 ) builds up, the nozzle tips ( 225 ) atomize the water into a fine mist, which extinguishes the fire. Once the fire is extinguished, the system will need to be turned off, drained and reset.
[0054] When the sprinkler tool is activated, a fine mist is produced from the four nozzle tips, which quickly extinguishes the fire. Unlike conventional sprinkler systems, the mist does not cause extensive water damage to the surrounding. A sprinkler of the present invention extinguishes normal combustibles, electrical fires, flammable liquids and gases, with minimal damage. The sprinkler system of the present invention extinguishes Class A, B and C fires.
[0055] Furthermore, the sprinkler tool can be placed at any height (e.g. ceiling, floor, or in between the ceiling and floor). It can also be placed in a corner, with nozzle tips of the mist head pointing away from the walls. As such, it can operate on a fire from any angle of a room. The activation of the sprinkler tool can be accomplished by a number of standard activation means. Each of these activation means can be installed onto existing sprinkler systems; i.e. each activation means can retrofit onto existing sprinkler systems.
[0056] FIGS. 5 a - 5 d respectively illustrate a side view (closed position); end view (closed position), side view (open position) and end view (open position) of a plunger device used to activate the sprinkler of the present invention. This design is independent of the number or style of heads further downstream from the device.
[0057] In a front view of the closed position, as shown in FIG. 5 a , the plunger device uses a stopper ( 72 ), preferably made of rubber, to stay the flow of water and seal the pipe ( 84 ). Standard ‘T’ and ‘L’ pipe fittings ( 86 , 88 ) are used in the pipe construction. As can be seen from FIG. 5 b , the pipe assembly is offset ( 95 ) from back to front. The end of the pipe assembly connects to a mist head ( 90 ) of the present invention. In FIGS. 5 a - 5 d , the mist head ( 90 ) is similar to that shown in FIGS. 4 a - 4 c . A connecting rod ( 74 ) is used to give the stopper a great travel distance. A frangible bulb ( 76 ) is held in place by a bulb cap ( 82 ). In its closed position the stopper/rod ( 72 , 74 ) device will be held in place by a standard frangible bulb ( 76 ). In the closed position the frangible bulb ( 76 ) is kept dry and open to the heat.
[0058] FIG. 5 c illustrates what happens when there is a fire. The frangible bulb ( 76 ) breaks, allowing the connecting rod ( 74 ) to pass through the bulb cap ( 82 ). This allows the stopper ( 72 ) to drop, which allows the water to flow to the sprinkler mist head ( 90 ). The assembly is now in the open position, as shown in FIGS. 5 c and 5 d . Water pressure will push the stopper ( 72 ) downstream and the connecting rod ( 74 ) will guide the stopper. As seen in an end view of the assembly in FIG. 5 d , the offset pipe assembly ( 95 ) allows the connecting rod ( 74 ) to drop freely.
[0059] This system does not require gravity to work; it can therefore be installed at any angle required. When the stopper ( 72 ) comes to its resting place, it will seal off the hole in the bulb cap ( 82 ), stopping unwanted leaks. The pipe downstream from the stopper is to be offset to allow the connecting rod ( 74 ) to travel its full range of motion. The water can now rush in to the mist head ( 90 ), thereby activating a fine mist. After the fire has been suppressed, the device can be reset by pushing the stopper ( 72 ) back in place and installing a new frangible bulb ( 76 ) in the bulb cap ( 82 ).
[0060] Another activation means is a butterfly device. A design that incorporates the butterfly device is independent of the number or style of heads further downstream from the device.
[0061] The butterfly device uses a circular plate with a grommet, preferably made of rubber, to stay the flow of water. The plate rotates around an offset bar so that when it is released, it will spin to the heavier side. The device is held closed by a lever on the outside of the housing resting on a standard frangible bulb. The frangible bulb is held in place by a sleeve and is resting on a small bar. When there is a fire, the frangible bulb breaks. This will allow the circular plate to move freely. Water pressure will be greater on the larger side of the circular plate and force the plate to spin around the bar. As water starts flowing, the circular plate will stop in a position parallel to the flow of water.
[0062] This system does not require gravity to work, so can be installed at any angle required. After the fire has been suppressed, the device can be reset by turning the lever back to its closed position and inserting a new frangible bulb into the sleeve.
[0063] Another activation means is a slider device; this design is independent of the number or style of heads further downstream from the device.
[0064] The slider device uses a plate, preferably rubberized, to stay the flow of water. The housing of the slider is to be made out of a high heat resistant material. A standard frangible bulb is held in place by a collar at the end of the slider and another collar built into the housing. In its closed position the slider device will be held closed by the frangible bulb. In the closed position the frangible bulb is kept dry and open to the heat.
[0065] When there is a fire, the frangible bulb breaks. The spring will provide the initial force to move the slider. As water starts flowing, the angled tail of the slider will assist in moving the slider into its open position. The housing will guide the slider perpendicular to the water flow. In its open position, the tail of the slider will seal the housing, stopping unwanted leaks.
[0066] This system does not require gravity to work, so can be installed at any angle required. After the fire has been suppressed, the device can be reset by opening the housing from the end, forcing the slider back into its closed position and installing a new frangible bulb between the collars. | Disclosed herein is an ambient mist head for extinguishing fires that comprises a plurality of mist nozzles attached to a head. The mist nozzles are arranged spatially on the head at various angles. The number of mist nozzles, the spatial arrangement and the angular placement of the mist nozzles can vary, depending on the area of coverage required. The angular placement of the mist nozzles on the head is effected so that the mist stream emerging from one mist nozzle does not impinge on a mist stream emerging from another mist nozzle. The angular placement of the mist nozzles thereby provides a maximal amount of mist production, and minimizes the occurrence of streams of water droplets. | 0 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims the priority, under 35 U.S.C. §119, of German application DE 10 2008 038 902.1, filed Aug. 13, 2008; the prior application is herewith incorporated by reference in its entirety.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to a container for receiving objects container for receiving objects. The container has a lower part with an opening and a receiving space for objects that is accessible via the opening and an upper part that can be connected to the lower part via at least one connecting region. The at least one connecting region is configured such that the receiving space is tightly closed, in particular is closed in a germ-free manner. The container further has means for releasing the connection between the upper part and lower part. The invention further relates to a container with an upper part that can be connected to the lower part via at least one connecting region, wherein the connection between the upper part and lower part is designed in such a manner that the receiving space is tightly closed and an opening in the upper part, which opening is provided or can be provided with a filter.
[0004] The present invention furthermore relates to a method for producing a connection between a lower part and an upper part of a container for receiving objects, such as described herein.
[0005] Containers of this type are known and are composed, for example, of transparent plastic, glass or other transparent materials. In one specific application, orchids are grown in at least partially transparent containers of this type. In particular, the containers are used for the meristem cultures of orchids. Autoclaved nutrient media are placed into such containers, which have been sterilized prior to use. Plant parts are transplanted in turn onto the nutrient media under sterile laboratory conditions, or the nutrient media are impregnated with other cell cultures. Only a sterile environment and the sterile containers can ensure that the highly sensitive orchid cultures can grow. In the prior art, the containers for sterile cell cultures are generally not completely tight. For example, the upper part and lower part have encircling edges which are connected to each other. The edges are connected to each other, for example, in such a manner that gas can be exchanged between the receiving space and environment via the connecting region of the edges.
[0006] A disadvantage of the un-tight containers known from the prior art is that, during the storage or transportation of the container, the nutrient media may be infected by pests, such as viruses, bacteria, fungal spores or, in particular, mites. The infected containers are then unusable for further use. Damage due to such infections, in particular due to mites, can inflict heavy economic losses on the laboratories.
[0007] A container of the type mentioned first above is described in German published patent application DE 32 18 532 A1. A film is welded or adhesively bonded as a cover onto the Petri dish described therein for cultivating bacteria and small fungi, thus producing a tight connection between the lower part and cover. The cover has a tab which is arranged outside the welding region and on which a user can pull in such a manner that the cover is removed as a whole from the lower part.
[0008] A disadvantage of this prior art is that the cover, once it has been torn off, can no longer be placed onto the lower part in such a manner that it seals the receiving space in the lower part such that it is at least dust-tight and secure from the surroundings. Furthermore, the cover also cannot effectively cover the lower part before being welded on, and therefore the lower parts cannot be filled in large numbers with nutrient medium before the nutrient medium is provided with the plant parts to be grown.
[0009] A container of the type mentioned second above is described in German utility model DE 20 2007 002 121 U1. The lower part and the upper part of the container described therein have edges which engage around each other and which are not absolutely tight. An opening which is provided with a filter and is intended for the exchange of air and water vapor is provided in the upper part.
[0010] A disadvantage of that prior art is that absolute tightness between the lower part and cover is not ensured. Furthermore, an uncontrolled exchange of gas with the environment may occur.
SUMMARY OF THE INVENTION
[0011] It is accordingly an object of the invention to provide a container and a method for producing a connection between a lower part and an upper part of a container, which overcomes the above-mentioned disadvantages of the heretofore-known devices and methods of this general type and which provides for a container of the type mentioned above that is better suited to growing plants. Furthermore, a method of the type mentioned at the beginning is to be specified, with which the upper part and lower part of a container can be connected more effectively to each other.
[0012] With the foregoing and other objects in view there is provided, in accordance with the invention, a container for receiving objects, comprising:
[0013] a lower part formed with a receiving space for objects and an opening for accessing the receiving space;
[0014] an upper part to be connected to the lower part via at least one connecting region, the at least one connecting region being configured to tightly close off the receiving space; and
[0015] means for releasing a connection between the upper part and the lower part, the releasing means being disposed between the opening and the at least one connecting region.
[0016] In other words, the means for releasing the connection are arranged between the opening and the at least one connecting region. As a result, the connection of the lower part and upper part can be released without the upper part being removed from the lower part. Even after the upper part is removed, it can be placed again onto the lower part and can seal the receiving space at least in a dust-tight manner and securely from the surroundings.
[0017] Both the upper part and the lower part can have an at least partially encircling edge, wherein the edges of the upper part and lower part are at least partially in contact with each other in the connected state. In particular the connection here between the upper part and lower part can be realized by connecting the edges to each other. The edges, for example which rest on each other, can be, for example, welded to each other in an encircling manner.
[0018] The at least one connecting region can be arranged on one of the edges or on both edges of the upper part and lower part. For example, the at least one connecting region can be at least partially encircling together with one of the edges or both edges. In particular, in this case, the at least one connecting region can have a length of more than 20 cm, in particular of more than 40 cm, preferably a length of between 50 cm and 55 cm, in the encircling direction or circumferential direction. Such large connecting regions permit the germ-free closure of containers having a comparatively large area.
[0019] The connection between the upper part and lower part can be designed, for example, as a welding connection, in particular as an ultrasonic or laser welding connection, as a hot embossed connection or as an adhesive bonded connection. Such connections permit a germ-free closing of the receiving space using simple means. Pests are prevented as a result from penetrating through the connecting region into the receiving space.
[0020] It is possible for the upper part and/or the lower part to be designed as plastic parts, in particular injection molded parts or deep-drawn parts, or as parts made of other transparent materials. The upper part and/or the lower part can be preferably at least partially or in sections of antimicrobial design or act in an antimicrobial manner. Additional protection against infestation with pests is achieved by the upper part and/or the lower part of the container being at least partially or in sections of antimicrobial design or acting in an antimicrobial manner.
[0021] The means for releasing the connection between the upper part and lower part can comprise a predetermined breaking region on the lower part or on the upper part, the predetermined breaking region being arranged between the opening and the at least one connecting region. In this case, the predetermined breaking region can comprise at least one, preferably two, at least partially encircling grooves. In this manner, a specific weakening which can ensure that the connection is released can be achieved in a simple and reliable manner.
[0022] Furthermore, the means for releasing the connection between the upper part and lower part can comprise at least one tear-open tab which is arranged adjacent to the at least one predetermined breaking region, in particular between the two grooves, on the lower part or on the upper part. Such a tear-open tab constitutes a simple and highly functional means for releasing the connection.
[0023] In this case, the at least one tear-open tab can project away perpendicularly from the lower part or the upper part and in particular is of angled design in cross section, such as, for example, is of L-shaped or V-shaped design. This enables a punctiform tearing open of a predetermined breaking line.
[0024] Furthermore, the upper part and/or the lower part can have an opening which is provided or can be provided with a filter. The receiving space can exchange gas with the environment through the opening. The filter can be designed in such a manner that, although gas can be exchanged through the filter, pests cannot penetrate therethrough. Under some circumstances, the filter can also be of antimicrobial design.
[0025] With the above and other objects in view there is also provided, in accordance with the invention, a container for receiving objects, comprising
a lower part formed with a receiving space for objects and an opening for accessing the receiving space; an upper part which can be connected to the lower part via at least one connecting region, wherein a connection between the upper part and the lower part is configured to tightly close off the receiving space; and the upper part having an opening formed therein configured to receive a filter; and the lower part having an opening formed therein configured to receive a filter.
[0030] According to this embodiment of the invention, the lower part likewise has an opening which is provided or can be provided with a filter. For example, in the use position, the opening can be arranged in one of the side walls at a distance from the upper edge of the lower part. This makes it possible to ensure that harmful gasses, such as, for example, CO 2 , can escape from the container through the opening. In a preferred embodiment, the opening in the lower part is arranged in a side wall of the lower part at a spacing distance from an upper edge of the lower part.
[0031] A container according to the invention is suitable in particular for receiving and/or growing plants, in particular orchids, or for receiving cell, fungal, virus or bacteria cultures in the sphere of human biology, veterinary biology or plant propagation.
[0032] With the above and other objects in view there is further provided, in accordance with the invention, a method for producing a connection between a lower part and an upper part of a container for receiving objects, the lower part having a receiving space for objects and an opening for access to the receiving space, and wherein the upper part can be connected to the lower part via at least one connecting region to tightly close the receiving space. The method is characterized in that the upper part is welded to the lower part in the at least one connecting region. The preferred process includes an ultrasound welding step.
[0033] In other words, the upper part is welded to the lower part in the at least one connecting region, in particular is welded by ultrasound. In particular, the ultrasonic welding permits a high cycle rate for the connection of lower parts and upper parts.
[0034] In this case, for the welding use can be made of an ultrasonic sonotrode which has a plurality of segments, at least sections of which are spaced apart from one another. Such an ultrasonic sonotrode also permits the welding of upper parts and lower parts with long connecting regions in a single working step, and therefore the connection can be realized cost-effectively.
[0035] Other features which are considered as characteristic for the invention are set forth in the appended claims.
[0036] Although the invention is illustrated and described herein as embodied in a container and method for producing a connection between a lower part and an upper part of a container, it is nevertheless not intended to be limited to the details shown, since various modifications and structural changes may be made therein without departing from the spirit of the invention and within the scope and range of equivalents of the claims.
[0037] The construction and method of operation of the invention, however, together with additional objects and advantages thereof will be best understood from the following description of specific embodiments when read in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING
[0038] FIG. 1 shows a perspective view from below of an upper part of a first embodiment of a container according to the invention;
[0039] FIG. 2 shows a perspective view from above of a lower part of a first embodiment of a container according to the invention;
[0040] FIG. 3 shows an end view of the lower part according to FIG. 2 ;
[0041] FIG. 4 shows a view of a detail of the lower part according to FIG. 2 corresponding to the section indicated by IV in FIG. 3 ;
[0042] FIG. 5 shows a sectional view of part of the interconnected edges of the upper part and lower part of the first embodiment;
[0043] FIG. 6 shows a side view of a lower part of a second embodiment of a container according to the invention;
[0044] FIG. 7 shows a top view of the lower part according to FIG. 6 ;
[0045] FIG. 8 shows a section through two lower parts stacked one inside another according to FIG. 6 ;
[0046] FIG. 9 shows a view of a detail according to the arrow IX in FIG. 8 ;
[0047] FIG. 10 shows a view of a detail according to the arrow X in FIG. 9 ;
[0048] FIG. 11 shows a sectional view according to the arrows XI-XI in FIG. 7 ;
[0049] FIG. 12 shows a sectional view according to the arrows XII-XII in FIG. 7 ;
[0050] FIG. 13 shows a perspective view of an upper part of a second embodiment of a container according to the invention;
[0051] FIG. 14 shows a view of a detail according to the arrow XIV in FIG. 13 ;
[0052] FIG. 15 shows a view of a detail according to the arrow XV in FIG. 13 ;
[0053] FIG. 16 shows a top view of the upper part according to FIG. 13 ;
[0054] FIG. 17 shows a sectional view according to the arrows XVII-XVII in FIG. 16 ;
[0055] FIG. 18 shows a sectional view according to the arrows XVIII-XVIII in FIG. 16 ;
[0056] FIG. 19 shows a schematic sectional view according to the arrows XIX-XIX in FIG. 16 , a second upper part which is inserted into the upper part apparent from FIG. 16 additionally being depicted for clarification purposes;
[0057] FIG. 20 shows a perspective view of a sonotrode for carrying out the method according to the invention;
[0058] FIG. 21 shows a perspective view from below of a lower part according to FIG. 6 ;
[0059] FIG. 22 shows a view of a detail according to the arrow XXII in FIG. 21 .
DETAILED DESCRIPTION OF THE INVENTION
[0060] Referring now to the figures of the drawing in detail and first, particularly, to FIG. 1 thereof, there is shown an upper part 1 , designed as a lid or a cover, of a container according to the invention. The upper part 1 is composed of plastic and is, for example, an injection molded part. The upper part 1 has a cover surface 2 and an edge 3 which surrounds the latter and extends parallel thereto.
[0061] An opening 4 which, during use, can be closed with a filter (not depicted) is provided in the cover surface 2 . In this case, the connection between the filter and the upper part 1 can be designed as a welding connection, in particular as an ultrasonic or laser welding connection, as a hot embossed connection or as an adhesively bonded connection. Furthermore, an IML (in mold labeling) connection is also suitable. In this case, the filter is placed directly into the injection molding die for producing the upper part 1 and is cast with the injection molded part.
[0062] The filter can be designed as a membrane and in particular can be produced by stretching a unilayer.
[0063] The opening 4 is surrounded by projections 21 arranged in a star shape. Said projections 21 can prevent a leaf of a plant growing in the container from resting flat on the opening 4 and thereby closing the latter. The projections 21 end at a distance from the edge of the opening 4 . This produces a bearing surface for a counter punch when pressing the filter onto the upper part 1 from the outside.
[0064] A handle 19 which serves as a grasping means and can be grasped with a pair of tweezers is provided on the edge 3 . Said grasping means and the resultantly enabled use of a pair of tweezers prevent edge regions of the lower part 5 (described in more detail below) and/or of the upper part 1 being infected by hand contact when the upper part 1 is placed on before the welding operation. Furthermore, the handle 19 can prevent a user's thumb from penetrating the sterile region during the opening of the cover.
[0065] FIG. 2 and FIG. 3 show the lower part 5 of a container according to the invention. The lower part 5 is composed of plastic and is, for example, an injection molded part. The lower part 5 comprises a base 6 and side walls 7 which surround a receiving space 8 . An encircling edge 9 which extends parallel to the base 6 is arranged on the upper end of the side walls 7 . The lower part 5 is open at the top, thereby forming an opening 18 for the insertion of objects.
[0066] The edge 9 of the lower part 5 can be seen in detail in FIG. 4 . Said edge has a tear-open tab 10 which is arranged between two encircling grooves 11 , 12 . The at least one tear-open tab 10 projects away perpendicularly from the lower part 5 and in particular is of angled design in cross section, such as, for example, is of L-shaped or V-shaped design.
[0067] The encircling grooves 11 , 12 extend virtually through the entire thickness of the edge 9 and weaken the edge 9 in such a manner that, by bending and subsequently pulling the tear-open tab 10 in the longitudinal direction of the edge 9 , the user can tear open said edge into two separate sections. The encircling grooves therefore form a predetermined breaking region.
[0068] Furthermore, the edge 9 of the lower part 5 has two upwardly extending, encircling projections 13 , 14 . The projections 13 , 14 are arranged on that side of the tear-open tab 10 which faces away from the side walls 7 . The projections 13 , 14 serve as power direction indictors in the ultrasonic welding operation described in more detail below. The tight and germ-free connection between the edge 3 of the upper part and the edge 9 of the lower part 5 can be realized in the region of the projections 13 , 14 . By way of example, a section of the edges 3 , 9 that serves as the connecting region is denoted by the reference number 17 (see FIG. 5 ).
[0069] The lower side of the edge 3 of the upper part 1 is of planar design in the connecting region 17 .
[0070] In particular, the tear-open tab 10 and the encircling grooves 11 , 12 serving for weakening purposes are arranged further inward than the connecting region 17 , and therefore the connection of the upper part 1 and lower part 5 can be released by actuating the tear-open tab 10 .
[0071] In the second embodiments according to FIGS. 6 to 19 and FIG. 21 and FIG. 22 , identical or functionally identical parts are provided with the same reference numbers as in FIGS. 1 to 5 . The second embodiments do not differ substantially from the first embodiments.
[0072] The second embodiment of the lower part 5 according to FIGS. 6 to 12 and FIG. 21 and FIG. 22 has a stacking rib 23 in each of the corners, the stacking rib projecting outward from an upper region of the side walls 7 (see FIG. 22 ). Furthermore, each of the side walls 7 has a step 24 which is at a distance from the upper edge and from which the lower part of the side wall 7 is set back somewhat. The step 24 ′ of an upper lower part 5 ′ can rest on the edge 3 of a lower part 5 (see FIG. 9 ). The stacking ribs 23 are longer than the tear-open tab 10 (see in this respect FIG. 21 ). As a result, the tear-open tabs 10 cannot be damaged when stacked one inside another.
[0073] By means of the steps 24 and the stacking ribs 23 , the lower parts 5 , 5 ′ can be stacked one inside the other in such a manner that they can simply be pulled apart again. The provision of the steps 24 permits a somewhat greater inclination of the side walls 7 of, for example, 5° without the volume of the lower part 5 being too greatly reduced by the inclination. The inclination simplifies unstacking.
[0074] FIG. 6 clarifies, by means of the arrow 25 , the tearing-open direction in which the tab 10 has to be moved in order to release the connection between the upper part 1 and the lower part 5 .
[0075] FIG. 10 shows that the projection 13 arranged further outward is higher than the projection 14 arranged further inward. In this case, the outer projection 13 and the corresponding region of the edge 3 and the upper part 1 are melted, for example by means of the ultrasonic sonotrode 26 depicted in FIG. 20 , such that said molten material contributes particularly to a tight welding connection. The reduction in size of the inner projection 14 in comparison to the outer projection 13 prevents molten material from passing into the predetermined breaking region arranged in the region of the grooves 11 , 12 and from reinforcing said region and therefore making it unusable under some circumstances.
[0076] The lower part 5 can have an opening 22 in one of its side walls 7 , which opening, like the opening 4 in the upper part 1 , can be provided with a filter (said opening 22 is indicated by dashed lines in FIG. 12 ). In this case, the opening 22 can be arranged in particular in the lower half of the side wall 7 . In particular, the opening 22 is arranged as low as possible, but above the typical filling height of the nutrient medium. This makes it possible to ensure that CO 2 can escape out of the container through the opening 22 .
[0077] In the second embodiment of the upper part 1 according to FIGS. 13 to 19 , the lower side of the edge 3 should not be provided with grooves in the connecting region 17 , but rather is of planar design (see, for example, FIG. 15 ).
[0078] The second embodiment of the upper part 1 according to FIGS. 13 to 19 furthermore has a stacking foot 27 , for example a T-shaped stacking foot, in each corner. The stacking foot 27 ′ of an upper upper part 1 ′ can stand on the upper side of a lower upper part 1 such that, as a result, the unstacking of the upper parts 1 , 1 ′ is more easily possible, in particular if the edge region has a slight slope.
[0079] The edges 3 , 9 of the upper part 1 and of the lower part 5 and of the connecting region 17 arranged thereon can have, for example, a length of between 50 cm and 55 cm in the circumferential direction. In order to produce such a large connecting region by ultrasonic welding in a single working step, use is made of an ultrasonic sonotrode 26 according to FIG. 20 .
[0080] In order to carry out the method according to the invention, the ultrasonic sonotrode 26 is pressed onto the upper side of the edge 3 of an upper part 1 while the edge 3 rests on the edge 9 of a lower part 5 . In the process, the circumference of the ultrasound-dispensing end 28 (at the top of FIG. 20 ) of the sonotrode 26 precisely matches the circumference of the edges 3 , 9 . While the ultrasonic sonotrode 26 is pressed onto the upper side of the edge 3 , the ultrasonic sonotrode 26 is operated in such a manner that the upper side of the edge 3 is acted upon by ultrasound.
[0081] The ultrasonic sonotrode 26 has individual segments 29 which are spaced apart from one another in the circumferential direction. In the welding region, which corresponds in FIG. 20 to the upper end 28 of the ultrasonic sonotrode 26 , the distance between the individual segments 29 is approximately 1 mm. Somewhat further below, the distance between the individual segments 29 is somewhat greater, and therefore the width of the individual segments 29 increases in the direction of the welding region. This enables a good welding result to be obtained even in the transition region from one segment 29 to the adjacent segment 29 . | A container for receiving objects has a lower part with an opening and a receiving space, which is accessible via the opening, for objects, an upper part which can be connected to the lower part via at least one connecting region, wherein the at least one connecting region is designed in such a manner that the receiving space is tightly closed, and a device for releasing the connection between the upper part and lower part. The device for releasing the connection is formed between the opening and the at least one connecting region. | 1 |
BACKGROUND OF THE INVENTION
The present invention relates to a rear bed spoiler which is installed onto the upper rim of a vehicle tailgate and onto adjacent upper rear corners of the rear bed.
Spoilers comprise one of many types of vehicle aftermarket accessories which most commonly serve to enhance the aesthetic appearance of a vehicle such as, for example, a pick-up truck. Such spoilers, however, such as the rear bed vehicle spoiler of the present invention, often serve one or more various other useful functions. In particular, a truck bed spoiler serves to provide protection to portions of the tailgate area of a truck which are particularly prone and susceptible to scratching, denting, etc. Since, with regard to pick-up trucks, the loading and unloading of heavy and cumbersome objects (e.g. furniture, lumber, boxes, etc.) into and out of the truck bed is a relatively frequent occurrence, the tailgate rim and adjacent truck corners are commonly subject to the banging and scraping resulting from with such activities. A truck bed spoiler serves to protect the body of the truck from such damage.
Additionally, a truck bed spoiler may be given a shape so as to impart aerodynamically beneficial properties to the truck when the truck is in motion.
The present invention is directed to an improved design for a rear bed spoiler incorporating the foregoing characteristics.
SUMMARY OF THE INVENTION
The present invention relates to a spoiler which attaches to the tailgate area of a vehicle such as a pick-up truck. An elongated center piece is provided which is secured to an upper lip of a tailgate of the truck. The center piece has opposing, flexible, flange-like portions which act to advantageously grip the lip of the tailgate. Further, the center piece has an aerodynamic shape which enhances the aerodynamic characteristics of the pick-up truck.
The present invention is provided with two corner pieces which independently attach to the upper rear corners of the pick-up truck on both sides of and adjacent to the center piece. The independent attachment of the corner pieces advantageously provides protection to the truck rear corners when the tailgate is in the down position, avoids protruding ends of an otherwise single piece spoiler when the tailgate is in the down position, and permits a single part of the spoiler to be dislodged without affecting the other parts of the spoiler.
These, together with other objects and advantages which will subsequently become apparent, reside in the details of construction and operation as more fully hereinafter described and claimed.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of the rear truck bed spoiler of the present invention installed onto the tailgate portion of a pick-up truck as seen from a frontal view.
FIG. 2 is a perspective view of the rear truck bed spoiler illustrating the rear and side portions of the spoiler as seen from a rear view.
FIG. 3 is a perspective view of the rear truck bed spoiler looking inside the spoiler.
FIG. 4 is a cross sectional view of the rear truck bed spoiler of FIG. 2 taken along lines 4--4.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1, a rear truck bed spoiler 10 is shown installed onto a tailgate portion 12 of a pick-up truck. Although the device disclosed in the present invention is most commonly used on pick-up trucks, the device will function equally effectively on other types of vehicles having a tailgate 16.
The aerodynamic spoiler 10 of the present invention comprises three independent pieces, namely, a main body or center piece 51 and two end or corner pieces 53. The center piece 51 is an elongated, flared, single-piece unit which attaches to the rim at the top of the tailgate 16. The center piece 51 preferably extends in length from a left edge 20a of the tailgate 16 to a right edge 20b of the tailgate 16, thereby covering the entire rim thereof.
The spoiler 10 sits atop the tailgate 16 and is supported thereon by one or more attachment means which are described below. The spoiler 10 comprises an upper portion which is the top section of the center piece 51. In the preferred embodiment, the upper portion comprises a wind surface 55. Preferably, the wind surface 55 slopes gradually rearward and upward and abuttingly rests atop the rim of the tailgate 16. The wind surface 55 may be, in one embodiment, provided with bevels or ribs 56 protruding upward therefrom. These ribs 56 cause the air passing the wind surface 55 to be spoiled. Also, the upward sloping of the wind surface 55 causes passing air to press the rear of the truck downward, thereby increasing traction on the rear tires. A front edge 57 of the wind surface 55 is integral with a forward tongue 59 of the center piece 51 and is equivalent to an upper edge 57 of the tongue 59. The forward tongue 59 is an abbreviated lip-like portion which extends substantially downward from the front edge 57 of the wind surface 55. Further, the tongue 59 has an outer side 61 and an inner side 63 (FIG. 4).
Referring to FIG. 2, a rear edge 65 of the center piece 51 is integral with a rear flange 67 and is equivalent to an upper edge 65 of the flange 67. In the preferred embodiment, the rear flange 67 comprises an outer side 69, an inner side 71 (FIG. 3), a curved section 73 and a vertical section 75. The curved section 73 curves forward and downward from the upper edge 65 of the rear flange 67 and is integral with the vertical section 75. The vertical section 75 extends substantially straight down from the curved section 73. As seen in FIG. 4, the inner side 71 of the vertical section 75 is preferably formed with a projecting surface 79 which protrudes forward therefrom. The projecting surface 79 is flat and is substantially defined in a vertical plane. Although the center piece 51 is shown in FIG. 3 and FIG. 4 to be hollow, the space between the wind surface 55 and the curved section 73 may also be filled to conform to the rim of the tailgate 16.
Referring to FIG. 2 and FIG. 3, each of the two corner pieces 53 attaches to and protects one of the rear outside upper corners 80 of a pick-up truck bed 82. Similar to the center piece 51, the corner piece 53 has a wind surface 55 having a rear edge 65, the wind surface 55 being extended further forward than the wind surface 55 of the center piece 51. The corner piece 53 also has a rear flange 67 having an outer side 69, an inner side 71, a curved section 73, and a vertical section 75. An outer side edge 84 of the corner piece 53 is integral with a side panel 86 of the corner piece 53. The side panel 86 is also integral with a corner edge 88 of the rear flange 67.
In use, the spoiler 10 is installed onto the tailgate portion 12 of the truck bed 82. In installing the center piece 51, the center piece 51 is placed on top of the rim of the tailgate 16 and pushed downward such that the rim passes up in between the forward tongue 59 and the rear flange 67 until the rim abuts against the bottom side of the wind surface 55.
In accordance with one feature of the present invention, the forward tongue 59 and the rear flange 67 cooperate to grip the rim of the tailgate 16. To accomplish this, the center piece 51 is advantageously manufactured from a rigid, high-impact, yet slightly flexible material, for example, urethane or glass-reinforced nylon. The weight of the spoiler 10 ranges approximately from 4.5 lbs. to 5.5 lbs. Depending upon the material used, the spoiler 10 may be formed using injection molding. The flexibility and resiliency of the material allows the tongue 59 and flange 67 to flex outward during placement of the center piece 51 over the rim while maintaining, due to the rigidity of the flange 67, an inwardly acting force against the rim. Accordingly, the projecting surface 79 of the inner side 71 of the flange 67 is pressed against the outer or rear surface of the tailgate 16 while the inner side 63 of the tongue 59 presses against the inner or front surface of the tailgate 16. The projecting surface 79 provides a flat contact surface which abuts and presses against the planar rear surface of the tailgate 16. These opposing forces act to grip the rim of the tailgate 16. Thus, the spoiler 10 may be independently and securely attached to the tailgate 16 without the need for additional structure extending into and attaching to the bed 82 of the truck.
Although, the gripping force described above may provide a force substantial enough to maintain the center piece 51 on the rim of the tailgate 16, the center piece 51 may also, nevertheless, be further secured by an additional attachment means. For example, screws, bolts, or other similar attachment means may be employed to secure the center piece 51 to the tailgate 16. Preferably, however, two-sided tape 77 (FIG. 3), preferably 3/4 in. in width, may be applied along those inside edges of the center piece 51 which abut against the tailgate 16. This method is deemed to be particularly advantageous because it obviates the need for puncturing the truck body (i.e. the tailgate 16), such as occurs with screws and bolts, which puncturing breaches any protective coating on the truck body and thus exposes same to rust. In addition, this method provides a means for easy and quick installation of the spoiler 10 onto the tailgate 16. For example, the spoiler 10 may be installed in this manner in as little as ten (10) minutes.
In accordance with a primary feature of the present invention, the two corner pieces 53 are installed onto the rear corners 80 of the truck bed 82 completely independently of the center piece 51. As will be seen, this provides several distinct and significant advantages. The installation of the corner pieces 53 onto the corners 80 of the truck bed 82 may be accomplished using any of the attachment means discussed above, namely, double-sided tape, screws, bolts, etc. Again, however, double-sided tape is deemed to be preferable.
Providing independently attached corner pieces 53 is advantageous for several reasons. First, such an arrangement provides protection to the corners 80 of the truck bed 82 even when the tailgate 16 is in the down position. This is of particular importance because loading and unloading of heavy and/or large objects is most likely to occur while the tailgate 16 is down. Second, if the corner pieces 53 were attached to the center piece 51, the corner pieces 53 would protrude awkwardly and dangerously from the sides of the tailgate 16 when the tailgate 16 is in the down position. Finally, should a corner piece 53 or the center piece 51 somehow become dislodged or torn off of the tailgate 16 as a result of forceful impact with a heavy object, the remaining parts of the spoiler 10 would be unaffected and would remain independently secured to the tailgate portion 12 of the truck. As a result, only the damaged parts would need to be replaced or reinstalled.
Having described the invention in connection with certain specific embodiments thereof, it is to be understood that further modifications may now suggest themselves to those skilled in the art, and it is intended to include such modifications as fall within the scope of the appended claims. | An aerodynamic spoiler mounts on and attaches to the tailgate area of a pick-up truck. A center piece has opposing flanges for mounting over and gripping the rim of the truck tailgate. Two end pieces advantageously attach independently to the rear corners of the truck adjacent the center piece. The spoiler of the present invention provides protection and enhanced aesthetic appeal to the pick-up truck and additionally imparts aerodynamic benefit thereto. | 1 |
FIELD OF THE INVENTION
This invention relates to maintenance of a microgravity environment within a portion of the volume on-board an orbiting space vehicle and, more particularly, to a vibration isolation system and stabilized platform for isolating a microgravity sensitive payload from external acceleration forces that customarily occurs in operation of the space vehicle during orbit.
BACKGROUND
One unique quality of travel aboard a space vehicle, such as the Space Shuttle, is the feeling that occurs due to weightlessness, which few persons are privileged to experience. Within the artificial atmosphere existent in the confines of the space vehicle, persons, objects and materials can simply float in space. In more scientific terms, the environment in an ideal spacecraft is referred to as a microgravity environment, one in which the acceleration experienced by a mass, such as the human body, tools and like, is reduced to the order of one millionth or less of the level found at sea level at the earth's equator, 9.8×10 -6 meters per second per second, relative to the spacecraft.
A microgravity environment has long been recognized as an ideal environment to carry on certain types of experiments and manufacture, which, due to gravity, cannot be carried out on earth. As example, furnaces, crystal growth modules, biological experimental apparatus, combustion and mixing facilities, and materials science investigations, including but not limited to semiconductors, glass amorphous solids, high temperature alloys, ceramics, fluid and combustion physics; biotechnology, including protein crystal growth, separation of biological products, and controlled microgravity experiments, should all benefit in a microgravity environment. To further explore the reasons for the desirability of a gravity-free environment for such experiments and manufactures, the reader may refer to the technical literature for additional details.
Theoretically thus, crystal-growing apparatus and other equipment may be placed in a corner of the space vehicle and allowed to function in a microgravity environment unimpeded. However, transient force effects produced in practice during space vehicle operation interferes with the microgravity; a practical difficulty inherent in space vehicle operation. Astronauts moving about the space vehicle and bumping into or pushing themselves off the space craft's walls create a reaction in the space vehicle; bumping into or shoving off of the equipment itself creates a reaction in the equipment. Performing required exercise on the treadmill, carried in the space vehicle as a physical health measure, produces vibration. Electric motors from time to time are actuated to adjust the position of the spacecraft's solar arrays. That motor operation creates a torque and that torque produces a counter torque on the spacecraft. Each such action produces an equal and opposite reaction, an elementary law of Newtonian physics.
Such shock and vibration are acceleration forces. If the sensitive equipment is thereby momentarily accelerated, that acceleration simulates a gravitational effect, often one that is greater than 9.8×10 -6 meters (per second) 2 . Thus during the period when all the astronauts are at work, the "work day", the environment in practice is one of only milligees of gravitation, one one-thousandths of earth's gravitational acceleration, several orders of magnitude higher than the ideal. Only when the astronauts are all at rest does the environment consistently achieve a lower level of gravitational effect, such as those produced from time to time by the solar array adjustment motors, interrupted by periods of microgravity.
In a practical spacecraft, the term microgravity is given a more expanded definition which allows for accelerations of microgee levels or below at frequencies of 0.1 Hz or less and increases from that level linearly to milligee levels at between 0.1 Hz and 100 Hz, the latter being the levels produced by the solar array motors and the like. In practice thus, in spacecraft useage, and as used herein, the term microgravity is intended to encompass such an expanded meaning.
While all such microgee and milligee forces are minute by standards on earth, they are significant enough as compared to microgravity levels to jeopardize the results obtained from the on-board experiment or manufacture. A need exists to isolate those manufacturing apparatus requiring a microgravity environment on board the spacecraft from such externally created acceleration forces; to stabilize the manufacturing equipment.
Accordingly an object of the present invention is to enable manufacturing processes and experiments to be carried out in a microgravity environment.
Another object is to isolate selected equipment carried within the environment inside an orbiting space vehicle from large accelerating forces, in excess of the levels of microgravity, over extended periods.
An additional object is to provide a non-contacting active vibration isolation system and a stabilized platform for use within an orbiting space vehicle.
The subject of vibration isolation is not new. Others, including the assignee of the present invention, have heretofore provided active isolation devices for stabilizing aiming and tracking devices used in helicopters, recognized as a high angular vibration environment. Active isolation devices for stabilizing aiming and tracking devices has also found use in space vehicles, a low vibration environment, but in which distance to a potential object being monitored are great, in which the effect of such low vibrations on the target is magnified. Such systems must permit the aiming device to be moved and be pointed at a target and then allow that target to be tracked over a limited period of time. With vibrations isolated to a great degree, a steady aim is possible.
As one example, the McDonnell Douglas Company, Huntington Beach, Calif., assignee of the present invention, markets and sells a stabilized aiming device, referred to as the "McDonnell Douglas Mast Mounted Sight" that is mounted atop the rotor mast on helicopters. That aiming device allows the helicopter pilot to obtain a stable television picture of a distant target, despite the inherent vibrations encountered in helicopter operation.
As another example U.S. Pat. No. 4,848,525 granted Jul. 18, 1989 to Jacot et al for a Dual Mode Vibration Isolator ("Jacot") describes a laser targeting and aiming device intended for use in space vehicles, wherein like the helicopters, transmission of vibrations to the aiming device must be minimized while allowing the laser to be moved. For this Jacot employs a combination of narrow gap magnetic actuators and linear actuators. Jacot notes a prior proposal to use magnetic actuators to support one body relative to another by magnetic fields, citing NASA Contractor Report 3343, entitled "Design of the Annular Suspension and Pointing System", October 1980 in which the actuator's stator is suspended between the pole faces of the stator cores by the magnetic field. Further, Jacot notes that the magnetic actuators in such proposal must contain very large gaps between the pole portions and requires large stators as requires large currents and weight. Jacot concludes that employing wide gap magnetic actuators in on-board orbiting systems is a significant disadvantage.
Applicants recognized that design concerns for a target and aiming systems, which accomplish an assigned function in a short period of time, are not identical with those for a microgravity manufacturing environment, wherein manufacturing is carried out over long periods, such as a day, a week or longer. Even so, the present applicants believe some aspects of vibration isolation in the former kind of apparatus, particularly, the wide gap magnetic actuators, can be employed to advantage in the latter microgravity environment, envisioning an advantage in minimizing the time and expense in design and manufacture. Wide gap magnetic actuators and the associated control electronics are of proven capability and are available essentially off-the-shelf.
A still further object of the invention, therefore, is to provide an easily manufactured non-contacting active vibration isolation system and associated stabilized platform for orbiting space vehicle microgravity manufacturing operations that incorporates wide gap magnetic actuators.
SUMMARY OF THE INVENTION
In accordance with the foregoing objectives a microgravity sensitive payload is isolated from external acceleration forces over extended periods of time in the weightless environment inside an orbiting space vehicle by a platform system that comprises a platform for seating microgravity sensitive apparatus in floating relationship with a frame; a plurality of wide gap magnetic actuators and dual axis accelerometer combinations spaced about the platform and frame; position sensors for sensing position of the platform relative to the frame; and a control system for maintaining the platform in a predetermined position in spaced floating relationship with the frame. The control system includes an analog computer, responsive to the accelerometers, for neutralizing any acceleration forces applied to said platform means; and a digital computer means, responsive to the position sensors, for maintaining said platform means in a predetermined position relative to said frame via the analog computer.
The foregoing and additional objects and advantages of the invention together with the structure characteristic thereof, which was only briefly summarized in the foregoing passages, becomes more apparent to those skilled in the art upon reading the detailed description of a preferred embodiment, which follows in this specification, taken together with the illustration thereof presented in the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
In the Drawings:
FIG. 1 is a partial perspective view of an embodiment of the mechanical aspects of a platform and base used in the invention;
FIGS. 2A, 2B and 2C schematically illustrate portions of the magnetic actuators appearing in FIGS. 1 and 3;
FIGS. 2D and 2E are pictorial front and side views of the collocated actuator and accelerometer assembly used in the embodiment of FIG. 1, and FIG. 2F is a pictorial view of the actuator depicting the orthogonal direction of actuator movement;
FIGS. 3A, 3B and 3C are partial perspective views of the mechanical aspects of another platform and base used in the invention and their assembly;
FIG. 4 illustrates the invention in schematic and block diagram form; and
FIG. 5 is a functional block diagram of the control system used in the preceding embodiments.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Considering first the mechanical aspects of the system as shown in the partial perspective illustration of FIG. 1, to which reference is made, a platform 1 is positioned over a base or frame 3. The illustration is of those elements in orbital operation and, being weightless, platform 1 essentially floats, while frame 3 is tied down or otherwise affixed to and held in a fixed position on the space craft, not illustrated, by brackets or other devices, also not illustrated. Three wide gap magnetic actuators 5, 7 and 9 are included to hold platform 1 in position spaced from frame 3 using magnetic fields without direct physical contact between the frame and platform.
Each magnetic actuator, considering actuator 9 as representative, contains two physically separated parts, that magnetically interact in operation, but are not in physical contact; a pole piece and an armature, the former being connected to the platform and the latter connected to the base. The pole piece includes a horseshoe or U-shaped pole piece 11 formed of ferromagnetic material that contains a permanent magnet at each of the pole piece tips, illustrated at 12 and 14 in FIG. 2A. One of those two magnets connected to pole piece 11 is oriented with its north pole facing horizontally toward and spaced from the other magnet of the pair and the other magnet has its south pole facing horizontally toward the first magnet to thereby establish lines of magnetic flux that extend essentially straight across a relatively wide spacing gap between the pole piece ends and magnets. Pole piece 11 is attached to a bracket 13 and, in turn, the bracket is attached to platform 1 at one of the corners of the rectangular shaped platform.
The magnetic actuator's armature or paddle 15, as variously termed, is suitably formed of electrical coils of wire that is potted within an electrically non-conductive epoxy material. The armature fits within the wide gap formed between the stems of associated pole piece 11 with a portion of the coil located in the lines of flux and another portion of the coil located outside the flux. Armature 15 is supported by and affixed to frame 3 by any conventional means, such as by metal bracket 16. It may be noted that platform 1 appears free to float or move relative to base 3, within limits, until the armature bumps up against the pole piece of one or more actuator. However, as hereafter explained in greater detail, with the controls exerted by the system, the platform should not move to that great an extent, and should remain approximately centered relative to the frame in which it is set by the system operator.
A pictorial of the magnetic actuator and armature coils is illustrated in FIGS. 2A, 2B and 2C to which brief reference is made. FIG. 2A shows an actuator in side view with the pole piece 11 and the armature 15. Note that the armature is of a pancake like geometry and is relatively thin compared to the width of the magnetic gap between the pole piece magnets. An individual coil 18 is wound as shown in FIG. 2B into two D-shaped halves in which the stem of the D is straight and is intended to be immersed in the magnetic field, while the curved section of the D is outside the magnetic field. Two such coils 18 and 20 are oriented as illustrated in FIG. 2C with the straight section of one oriented perpendicular to the straight section of the other.
In the operation of magnetic actuators, electrical current in the armature's electrical coil creates a force on the coil assembly in accordance with the vector relationship F=nI×B, where B is the flux density, n is the number of turns in the coil immersed in the field and I is the current through the coil. That force moves the armature into or away from the lines of flux, depending on the direction of current in the coil, or, relatively speaking, since the armatures are held fixed to frame 3, the force generated thereby causes the pole piece to move in response to such force. Since the pole piece is affixed to the platform, the platform moves accordingly. Thus current through one of the armature coils creates a force in one direction, such as the horizontal direction, and relative movement in that direction; while current through the other coil creates a force in a direction, such as the vertical direction, orthogonal to the first force created by the first coil, and, accordingly, movement in an orthogonal direction.
Returning to FIG. 1, pole piece 11 of magnetic actuator 9 is attached by associated bracket 13 at the lower left corner of the platform and extends radially outward, and its associated armature is oriented perpendicular thereto; the corresponding pole piece of actuator 7 is attached by the associated bracket at the lower right corner and extends radially outward and is oriented at a ninety degree angle to pole piece 11. The associated armature is oriented perpendicular to that pole piece.
The pole piece of actuator 5 is located on the opposite upper side of the platform midway between the other two actuators or between the left and right ends and is oriented in a "wye" or triangular configuration with respect to the remaining two pole pieces, which, in the illustrated embodiment places it at an angle of 135 degrees to each of the two other pole pieces. That relationship maximizes the activation efficiency in the six degrees of freedom in which the platform may be moved, minimizing electrical power consumption and avoiding large current demands. Alternative placement of those actuators is permissible and within the scope of the invention, but such alternative would have lesser electrical efficiency. The pole piece is also attached to the platform by a metal bracket. The associated armature of the actuator is oriented perpendicular thereto. As those skilled in the art appreciate, the foregoing arrangement permits the actuators to move the platform in six degrees of freedom, that is translate the platform in any of three directions and rotate the platform in any of three directions through appropriate current applied to one or more of the three actuators.
Two accelerometers are connected to each pole piece mounting bracket 13, forming a collocated or integral assembly, as variously termed, and, hence, is thus connected with each magnetic actuator, for a total of six accelerometers on the platform assembly. The accelerometers are conventional high sensitivity accelerometers, inertial grade that are capable of sensing microgravity accelerations or lesser. Such accelerometers are available off-the-shelf. As example those produced by the Allied Signal Company of Redmond, Wash.
The accelerometers are oriented orthogonal to one another on a bracket that supports the u-shaped magnet support member of the actuator to monitor any acceleration to which such magnet components are subjected in each of two mutually perpendicular directions or axes. Those two mutually perpendicular directions or axes are the same directions along which the associated magnetic actuator is capable of moving the platform.
Accelerometer 17, illustrated in FIG. 1 with magnetic actuator 5, and accelerometer 19, the latter not being visible in this figure are attached to the magnetic actuator's supporting bracket 13 with the actuator's pole piece to form an integral assembly, essentially being collocated. This is better illustrated in the pictorial front and side views of FIGS. 2D and 2E to which brief reference is made. Both accelerometers are attached to bracket 13 together with the pole piece. Bracket 13 is very rigid and may be formed of a strong metal, such as aluminum. Accelerometer 19 measures acceleration in the relative vertical direction and accelerometer 17 measures acceleration along a perpendicular axis, laterally.
As illustrated in the pictorial of the actuator in FIG. 2F, each actuator moves the armature relative to the frame in each of two mutually orthogonal directions, labeled x and y, up or down, to or fro along such axes. The accelerometers are arranged to measure acceleration along those same axes. Ideally, for the best theoretical accuracy, the two accelerometers should be positioned at same focal point as the armature to pole piece center, but that is not physically possible. By mounting those accelerometers as close to that location as possible and ensuring a rigid connection with the pole piece through the rigid mounting bracket 13, the best possible measuring arrangement is achieved.
Returning to FIG. 1, one observes that the the six accelerometers on the platform provide acceleration information on six degrees of movement, displacements and rotations along each of a set of three orthogonal axes. The accelerometer also conventionally includes a temperature sensing device and associated output circuit, discussed later herein, for temperature calibration purposes. The outputs of the accelerometers are later further described in connection with the control system.
The foregoing magnetic actuators are recognized as being the two axis wide gap torquer manufactured by the McDonnell Douglas Company, Huntington Beach, Calif., assignee of the present invention, which is marketed and sold as part of that company's Mast Mounted Sight, a stabilized aiming device intended to be mounted atop the rotor mast on helicopters on which that system is employed. That aiming device allows the helicopter pilot to obtain a stable television picture of a distant target, despite the large vibrations encountered in helicopter operation. Aspects of that wide gap torque are described in the patent literature in U.S. Pat. No. 4,443,743 and U.S. Pat. No. 4,833,351 and some related aspects in U.S. Pat. No. 4,033,541, and U.S. Pat. No. 3,703,999 to which the interested reader may refer.
The platform in the embodiment of FIG. 1 is a machined metal part that contains cut out portions leaving essentially a frame like member with bracing ribs for increased stiffness. However, any structure that is rigid enough to place its natural frequencies of resonance well above the bandwidth of the control system, later herein described, and accommodate the particular mountings needed by the sensors and actuators and the scientific or commercial gravity sensitive payload to be mounted to the platform may be substituted.
Three position sensors, not illustrated in FIG. 1 for clarity, are included in the assembly on frame 3. Those position sensors monitor the position or spacing between the platform 1 and base 3 and thereby detect any relative movement, tilt or rotation of the platform and supply that information to the electronic controllers, discussed hereafter. Position sensors are illustrated in the different mechanical embodiment of the platform and frame considered in the succeeding figures.
Reference is next made to FIGS. 3A, 3B and 3C which show an alternative mechanical configuration for the platform and frame and its easy assembly. For convenience, the component elements which appear in these figures are given the same designation used for those elements in FIG. 1. As shown in the perspective view of FIG. 3a, a payload, represented by box 21 is attached to platform 1'. Position sensors 23, 25 and 27, which contain two spaced parts, labeled a and b, respectively, have the sensor source portion mounted to platform 1', as at 23a, 25a, and 27a, and the target section mounted to frame 3', as at 23b, 25b and 27b. The actuator pole pieces, such as 11, accelerometers, not visible in this view, and the target portion of the position sensor are each illustrated in preferred locations on the platform. Frame 3' appears in FIG. 3b as being in the form of a ribbed rectangular cage. The frame contains the actuator armatures, such as 15, which are of a somewhat paddle shape and the remaining portion of the position sensors, illustrated at 23b, 25b and 27b. Although the position sensors are illustrated as being separate from the actuator dual axis accelerometer assembly in the preceding figures, a more preferred arrangement is to use the assembly created by one of the present inventors in which the position sensors are mechanically packaged in a single assembly, which is now the subject of a copending patent application Ser. No. 08/576,232 filed Dec. 21, 1995, entitled Collocated Sensor Actuator. That improvement simplifies fabrication and assembly of the platform and avoids any slight inaccuracy in measurement as might be caused by flexure in the platform or variation in mounting of parts.
As is evident the mechanical arrangement allows the platform to be inserted within the frame, the open end of each pole piece easily fitting over the associated armature, with the latter fitting in spaced relation to the pole pieces without physical contact, an advantage to the invention, and the assembled relationship appears as in FIG. 3C. For convenience the various connections to payload 21, such as electrical cables, vacuum lines and the like, and those containing the electrical leads to the accelerometers on the platform, necessarily used in the practical embodiment, are omitted for clarity in illustration.
From the foregoing, it is apparent that the platform may be separate from the payload or may be formed integral therewith. As used herein, thus, the term "platform" refers not only to a base or panel on which microgravity laboratory apparatus or manufacturing apparatus and the like, the "payload" is fastened or otherwise attached in the weightlessness of outer space and, in a more generic sense, also refers to a portion of the payload itself, such as a frame portion or panel portion of such laboratory and manufacturing apparatus to which the magnetic actuator and dual accelerometer combination is attached as described, which, in the system, serves the same function as a separate frame or panel, although being integral with the manufacturing apparatus.
Reference is made to the stabilization system presented in the block diagram and pictorial form in FIG. 4. The foregoing mechanical assemblies are pictorially illustrated as part of the system and those elements earlier described are identified by the same number used for same earlier in FIGS. 1, 3a, 3b, and 3c. A microgravity sensitive payload 21 situated upon platform 1 is represented by dash lines, as is the associated umbilical 22 which carries electricity, vacuum, and/or fluids required by the payload for operation.
As illustrated, the umbilical 22 extends from frame 3 to platform 1. Those umbilical together with those electrical leads to the accelerometers, represent the sole physical connection between the frame or external areas and the platform. Although the structure of those umbilical is purposely made as soft or limp as is possible so as to dampen or prevent transmittal of any force due to shock or vibration occurring on the frame side of the umbilical from reaching the platform, such isolation is not entirely possible and some small level of force or vibration may reach the platform due to the stiffness of the umbilical coupling the platform to the base. In addition a surge in the fluid lines, or in the vacuum lines, when such types of lines are used for a given payload, as example, creates a mechanical force that travels along the line that is sufficient in level to disturb the experiment or manufacturing process of the payload. As becomes apparent, the present system compensates for any such disturbing force.
The system includes a controller 31 that includes a digital computer-controller 33 and an analog computer-controller 35. Each of position sensors 23b, 25b and 27b is connected, via cables, to the digital computer 33 and provides position information to that computer, together providing complete information on the platform's position, including tilt and rotation. Each of the coils in the respective armatures of the magnetic actuators is coupled to the output of the analog computer, whereby the analog computer supplies appropriate electrical current to actuators 5, 7 and 9 that serves to create the magnetic forces to cancel the platform's acceleration or hold the platform steady against load forces as might be caused by the umbilical extending to the payload or by disturbances caused by the payload.
An output of digital computer 33 is connected to an input of the analog controller. When the digital computer senses that the platform is shifting in position, the computer issues a centering command to the analog controller. Responding to that command, the analog controller issues the appropriate output to the armatures of the respective magnetic actuators 5, 7 and 9. Each of the accelerometers is connected to corresponding inputs of analog computer 35. The accelerometers provide information of the inertial acceleration along a given axis and each pair of accelerometers provide that information along two mutually perpendicular axes at each location at which the accelerometers are located, such as was illustrated in FIGS. 1 and 2. As graphically represented in connection with actuator 5 the arrow and encircled dot indicate the orthogonal directions measured by the associated pair of accelerometers, up and down relative to the plane of the paper as represented by the encircled dot and straight across the figure as represented by the adjacent arrows. Like representations are included for each of the other two actuators 7 and 9. Of those, both measure along an axis orthogonal to the plane of the paper, while the associated orthogonol axis, along the plane of the paper, are angled relative to that axis which extends from actuator 5.
The control system uses the information from the accelerometer pairs and position sensors to inertially stabilize and position the platform within the "sway space". It includes a high bandwidth decentralized analog inertial acceleration control loop; a low bandwidth digital position control loop, and a low bandwidth digital force management control loop. As those skilled in the art appreciate, the foregoing functional operation is best described in terms of a functional block diagram of one of the six channels, such as is presented in FIG. 5, to which reference is made.
Digital controller or computer, as variously termed, 33 is suitably one that has a low sampling rate, analog controller or computer, as variously termed, 35 and a control loop for only one of the two axes of movement of one of the magnetic positioning actuators, such as 5 in FIG. 4, are shown. While only one channel is illustrated in this diagram it is understood that a different analog computer is provided for each channel; six in the arrangement described. However, a single digital computer 33 is employed. Whereas, the digital computer illustrated in this diagram contains an output connected to one of the analog computers it is understood that the digital computer contains multiple outputs, one output for each of the analog computers, comparable to the one set of outputs illustrated.
In this block diagram, the elements to the right of the Analog control block, as is conventional practice, represent physical actions, such as forces 45, accelerations, Xdd1, and displacements dX1. A force disturbance, Fd, 45 applied to the platform mass 47 produces an acceleration, Xdd1. That acceleration, Xdd1 is then fedback through the circuit 48, by accelerometer, G accel , to the input of the loop, represented by the "summing block" circle 40. That acceleration signal is in turn acted upon at block 43 to produce a contra force signal at the output of 43 to null or cancel the disturbance force. The acceleration Xdd1, continued for any time results in displacement, indicated at dX1, following the double time integration indicated by 49 which ideally is minimal, if, as desired the disturbance force is effectively cancelled out in the fedback arrangement, reducing any acceleration to zero. As those skilled in the art recognize, the foregoing is a standard force or acceleration nulling system.
Initially digital computer 33 receives inputs at T1 to detect temperature information from the associated accelerometer. As is known accelerometers are ambient temperature sensitive and, therefore its output may differ, depending on the particular temperature existing. The accelerometers thus are calibrated from time to time to adjust the bias currents for a given ambient temperature. That calibration ensures that the accelerometers outputs are accurate. This calibration is conveniently handled by digital computer 33, which contains the appropriate calibration information for the various temperatures and the corresponding bias levels needed for compensation stored in its memory. With the temperature information as input, the digital computer outputs the appropriate bias currents thus to the control loop via an output 42, through high gain digital to analog controller 41 or through the low gain channel, as appropriate, and from there to the input or summing junction 40 of the control loop. The digital computer determines the size of the signal to be outputted and selects the appropriate high or low gain channel as appropriate for the output.
The displacement in the channel illustrated is represented as dX1, and the displacements in the remaining five channels are represented as dX2 through dX6 are connected to a position sensor subsystem 37 which converts displacements of the platform into a non-singular set of measurements representing position that provides a minimum of six outputs, which are applied as inputs P1 through P6 to digital computer 33. It should be recognized that in other embodiments, incorporating additional actuators and position sensors, additional displacement channels would be included and that additional inputs may likewise be provided to the digital computer for input of additional position representing numbers.
Following the start up and correction of accelerator bias, digital computer 33 monitors the position of platform 1 by monitoring the position sensors 23, 25, and 27 at input P1 through P6. In customary manner, computer 33 is programmed to scan each such input in serial order and check the information thereby received against the position information stored in its memory. When the digital computer senses a condition at any of those inputs that represents a change of position of the platform from its center position, the computer determines the necessary outputs and outputs appropriate acceleration commands to one or more of the six analog computers, and assuming one is necessary for the illustrated channel, outputs a command via 44 over the low gain 39 to the analog controller. The analog computer issues the electrical current to the respective magnetic actuators to restore the platform to its correct predetemined position.
The digital computer serves another function that is indicated in FIG. 5, serving to resolve and balance multiple magnetic actuators in the system. If the particular system contains extra, that is, redundant, sets of magnetic actuators, it is possible for some combination of actuators to be acting contrary to one another, applying force in opposite directions, as example, in which instance large and unnecessary amounts of electrical power, a precious commodity on board a spacecraft, to be consumed. To avoid that occurance, the digital computer monitors the force applied to the platform by each magnetic actuator. Thus, F1, which is a measure of force that the actuator in this channel is applying in one direction is input to the computer, as is the corresponding force for the other perpendicularly directed force of the same actuator and for each of the other four additional channels associated with the two remaining magnetic actuators.
The computer then uses that information to determine if a force imbalance exists and, if so, internally recognizes a balance error. Once a balance error is determined, the computer creates an acceleration command that is proportional to the imbalance in forces and outputs that command via output 44, the low gain digital to analog converter, to add to the acceleration command existant at 40. If the level of imbalance is large enough the computer may also output an acceleration command from the high gain channel via output 42.
The acceleration control loops isolate the platform from base motion and attenuate on-platform disturbances. In this mode, the magnetic actuators hold the platform movement to approximately zero acceleration, while the platform may drift slightly from the center position. With the appropriate acceleration control loop compensation, the overall system isolation performance is relatively insensitive to the base motion disturbances as might be coupled to the platform through umbilical cables.
The low bandwidth position loop generates inertial acceleration commands from the set of position measurements, maintaining the platform's position within the sway space. Thus should the platform be found to have moved relative to the platform, the position sensors provide the position information to the position loop and the position loop generates sufficient acceleration commands to start movement. As the platform is moved toward the center position within the frame, the sensors continue to provide new position information, new commands are determined and issued, the magnetic actuators are appropriately energized with the appropriate level of current and create the appropriate magnetic force to move the platform. This centering process continues until the platform is returned to the center of the sway space. In this mode the magnetic actuators recenter the platform at the predetermined position.
The high bandwidth control system functions are implemented by an analog processor or computer, which renders the system more responsive and reliable in orbital operation. As those skilled in the art recognize, analog electronics is inherently more quick acting than digital and is less susceptible to single event upset, SEU, caused by incidence of cosmic rays and high energy particles. Such incident energy often induces faults in high speed digital computers, either causing an upset, which is temporary in nature, or a latch up, in which the high speed digital computer cannot reset itself and is thereby rendered incapable of carrying out its stored programming. Those faults are not found in the low speed digital computer, which is preferably used with the invention. Such low speed digital computer, contains a digital processor whose transistor chip structure is fabricated with spacings on the order of three microns, while the high speed digital computer contains processors fabricated using spacings on the order of 1/2 to 1 micron, which makes the latter more vulnerable to any incident high energy particles.
The control system should be recognized as the same elements found in the foregoing helicopter "Mast Mounted Sight" control system, except that in the helicopter control system what the computer commands is angular velocity, and the feedback is angular position, whereas in the present system what the computer instead commands is acceleration and the feedback is force and translational position and a minimum of three magnetic actuators are used, giving six degrees of freedom of movement instead of only two actuators and two degrees of freedom in the helicopter system.
A weightless platform intended to essentially float in the defined region within the frame is, however, subject to steady state forces associated with the pre-loads created by the umbilical cables that extend between the frame and the platform, including those to the payload and gravity gradient forces. The platform is also affected by the consequences of aerodynamic drag that the space vehicle encounters, a force that gradually slows the space vehicle. Such also slows the frame, but not the platform and as a consequence, the frame moves toward the platform. The centering system corrects for all of the foregoing effects.
The low bandwidth force management loop selects the appropriate force control system compensation to generate inertial acceleration commands that manage redundant actuator and accelerometer control loops in overdetermined actuator accelerometer pair configurations. "Overdetermined" means that the required forces could be provided by a non-unique arrangement of actuators. That is not unusual. As example, a minimum of three actuators is necessary to position the platform in any of six degrees of motion, positive or negative in the x, y and z axial directions. If instead four actuators are employed by choice in the system, it is apparent that more than one solution is available to move the platform to a given position, using three actuators or four and so on. The integral arrangement of actuator and dual accelerometers simplifies system design. For one reason, such unit is readily available off-the-shelf, and for another the mechanical design reduces volume, cost assembly time and part count. Three such dual axis sensing units accomplishes the same work as six separate single axis units.
The only contact between the platform and frame is through small, soft or limp, as variously termed, umbilical. Platform controlling and centering forces are applied between the armatures and the field of the magnet assembly. Because there is no contact between the magnets and the associated armatures, there is no transfer of force across the gap, except that due to current flowing in the armature. No force is coupled through the gap even when the armature moves relative to the magnetic filed. No cogging forces occur because the paddle is non-ferrous; no eddy current forces are produced, because the armature is electrically non-conductive, except for the embedded coils; no ripple forces appear because the actuator is not commutated and no back EMF forces are generated because the actuator is driven by high bandwidth current source, one greater than 2 kHz.
Because the actuators do not require physical contact between the frame and platform or payload, mechanical disturbances created on-board the spacecraft, including those disturbances affecting the frame, are not communicated to the platform. The non-contacting actuators avoid a potential disturbance load path to the platform inherent in mechanical type actuators, through the actuation mechanism. Non-contacting actuators eliminate the need for pushrods, flexures, hinges, pivots and other mechanical mechanisms that decrease performance due to friction, slop, free-play, or other mechanical effects and avoid the possibility that the actuator itself might decrease performance due to the effects of any flexibility inherent in the components that form a mechanical actuator. Of additional advantage, installation, operation and servicing of the payload is simplified; one need only disconnect the electrical umbilical cord to the payload and withdraw the payload from the frame without the necessity for mechanically disassembling any of the actuators.
The computation required by the centering loop is low level, such as at 10 Hz., ten samples per second, which is very slow. Being thus slow and essentially little used, the digital processor does not generate significant heat and, hence, liquid or forced air cooling, characteristically required of high speed computers, is not required. Since only low sample rate computations are required, the digital processor employed in the system is preferably a proven one that is known to have substantial immunity to SEU's, such as the Intel 80196 processor, as example. For the foregoing reasons a fast digital computer is neither required nor desired in the present system.
It is also seen that the isolation arrangement is particularly suited to a "kit" approach, which is readily adapted to any geometry ranging from a "glovebox" size volume up to a full orbiting rack or larger.
The position control loops also set the base to platform stiffness. That stiffness determines both the low frequency isolation performance and the speed of response of the centering system. In a practical embodiment of the invention, as example, the digital computer is programmed to reposition the platform in one-hundred seconds, doing so by issuing commands at only ten commands per second. And that rate is used for each of the dual axis actuators. This is recognized as a very soft spring like stiffness. Conveniently, the digital position controller architecture permits independent tailoring of the low frequency stiffness and damping characteristics of the positioning system in each of the six degrees of freedom in which the platform may be translated or rotated. In alternative embodiments other rates may be selected to achieve different stiffness, with well understood modifications to the digital computer's program, and the rates in each of the six degrees of freedom may be different from one another to satisfy the designer's particular goals.
In addition to isolating the tray or platform from mechanical disturbances on the orbiting satellite, the system may be easily adapted instead to provide pre-programmed sinusoidal or general periodic shaking of the platform in experiments and or manufacturing techniques, not presently known, as requires controlled measures of movement or acceleration in the direction of any or all of the three independent axes of movement. The foregoing may be accomplished by substituting a software program into the computer that gives the appropriate movement commands.
The foregoing describes the operation of the stabilized platform assembly during orbit. It is recognized that on earth and during lift off into orbit, the platform is properly stowed, either in place in the rack, by fastening it down, or separately stowed and assembled only after the space vehicle is in orbit, prior to activating the manufacturing operation in the payload.
The foregoing description of the preferred embodiments of the invention is sufficient in detail to enable one skilled in the art to make and use the invention. However, it is expressly understood that the detail of the elements presented for the foregoing purposes is not intended to limit the scope of the invention, in as much as equivalents to those elements and other modifications thereof, all of which come within the scope of the invention, will become apparent to those skilled in the art upon reading this specification. Thus the invention is to be broadly construed within the full scope of the appended claims. | Microgravity sensitive payloads placed on a platform are isolated from external acceleration forces over extended periods of time in the weightless environment inside an orbiting space vehicle by canceling acceleration on the platform. Wide gap dual axis magnetic actuators and accelerometer pairs are spaced about the platform with the magnetic actuators providing a non-contacting magnetic position control, wherein physical contact with the platform is avoided. Position sensors sense platform positioning and the control system, containing both digital and analog computers, controls the magnetic actuators to ensure proper positioning and neutralize any transient acceleration forces applied to the platform. | 1 |
BACKGROUND OF THE INVENTION
The present invention relates to a system for automatically effecting speed change in power transmission from an internal combustion engine or the like. By utilizing the gear ratio change action of a planetary gear mechanism.
More specifically, the invention relates to an automatic transmission in which a planetary gear mechanism is mounted on a drive shaft to permit reduction of the length dimension of the drive shaft, mainly for the purpose of making the entire system more compact.
In general, a motorcycle has a body which is considerably small compared to a common passenger car or other such vehicle, and the space required for assembling necessary parts and devices is limited. Particularly, in small motorcycles such as "mopeds" which are designed to have a reduced weight and size and a simplified driving operation, the smaller the size of the motorcycle, the smaller the space available for assembling necessary parts and devices. In order to cope with the limitation upon available space, it is necessary to make the apparatus to be accommodated in such a space more compact. Further, this requirement may be applied not only to motorcycles, but also to common vehicles and other machines and apparatuses wherein a compact arrangement of a number of parts and devices is necessary to avoid excessive space consumption.
In the aforementioned small motorcycles or similar vehicles, it is necessary to provide a construction which permits ready driving operation even by one who is not skilled in driving techniques, in addition to minimizing the number of parts so as to simplify construction. Because a construction in which a gear ratio change is effected by a pedalling operation requires much skill for expert handling, it is desirable to employ an automatic transmission in which the gear ratio of an output shaft for rotating the drive wheel is automatically changed with the increase of the engine rpm. The automatic transmission usually has an assembly including a number of parts such as clutch means, and with an increase of the number of component parts, the space for assembling the parts is correspondingly increased, leading to a size increase for the entire system. For example, in an automatic transmission which comprises a centrifugal clutch mounted on a drive shaft, a plurality of first gears coupled to inner and outer members of the clutch, and a plurality of second gears provided on a counter shaft which are different in diameter from the first gears, the first gears are naturally spaced apart from each other in the axial direction because they must be coupled to the inner and outer members of the clutch, and the second gears in mesh with the first gears are also axially spaced apart from each other. Therefore, the length dimension of the shafts is increased. In addition, the counter shaft for taking out the transmitted power has to be provided in parallel with the drive shaft, which inevitably causes a further increase in the size of the system. Increased size of the system, however, must be avoided, which results in one of the problems associated with the design of the automatic transmission. A compact automatic transmission is useful not only for motorcycles but also for other machines and apparatuses, i.e., it can also be employed for systems other than motorcycles.
In view of the foregoing problems, the present invention provides a transmission system extending from a drive shaft to an output shaft as an automatic transmission, such automatic transmission being compact so as to be readily mounted even on a very small motorcycle.
SUMMARY OF THE INVENTION
An object of the invention is to provide an automatic transmission which comprises a drive shaft driven from a drive source, a centrifugal clutch, a planetary gear mechanism and an output shaft from which power from the drive shaft is taken out through the planetary gear mechanism. The drive shaft is of the cantilever-support type with a proximal end of the drive shaft being supported by a bearing near the drive source. The planetary gear mechanism includes an outermost ring gear, a central sun gear, and planet gears provided between and meshing with the ring and sun gears. The drive shaft is coupled to one of the three different types of gears of the planetary gear mechanism through the centrifugal clutch. The output shaft is coupled to another one of the three different types of gears. The planetary gear mechanism is mounted on the drive shaft with the sun gear at the center of the planetary gear mechanism being fitted on the drive shaft, and the centrifugal clutch and planetary gear mechanism are disposed so as to face each other.
With such construction according to the invention, the three different types of gears of the planetary gear mechanism are not spaced apart from each other in the axial direction but are arranged in the radial direction, so that it is thus possible to reduce the length dimension of the drive shaft and make the system compact. In addition, the output shaft from which the transmitted power is taken out may be arranged coaxially with the drive shaft, thus permitting further size reduction of the system.
Another object of the invention is to provide an automatic transmission in which a one-way clutch is coupled to either one of the ring gear, planet gears and sun gear of the planetary gear mechanism which is coupled to neither the drive shaft nor the output shaft. The one-way clutch is secured to a stationary member such as a crank case and disposed at a position on the opposite side to the drive source for the drive shaft with respect to a power take-out member, such as a sprocket wheel secured to the output shaft.
If the drive source comprises an internal combustion engine and the drive shaft comprises a crankshaft, the crankshaft is supported at a position near the internal combustion engine by a bearing. Because in this case the driving wheel of a motorcycle, for example, is rotated by the output from the power take-out member secured to the output shaft, bending forces are applied to the crankshaft through the power take-out member and to the output shaft. With the provision of the one-way clutch at a position spaced apart further from the internal combustion engine than from the power take-out member, a role similar to that of a bearing provided on the side opposite to the above-mentioned bearing with respect to the power take-out member is played by the one-way clutch because it is coupled to both the stationary member and also to the planetary gear mechanism mounted on the drive shaft. In this manner, the power take-out member is supported on both sides by members acting as bearings, so that flexing of the crankshaft due to bending forces acting thereupon can be prevented. In other words, because the one-way clutch also serves as a bearing, there is no need to provide a separate bearing at the free end of the crankshaft, and a cantilever support with only a single bearing suffices.
Yet another object of the invention is to provide an automatic transmission in which the drive shaft and ring gear of the planetary gear mechanism are coupled together via a first clutch of the centrifugal type, the output shaft is coupled to the planet gears, and the one-way clutch is coupled to the sun gear. With such construction, when the engine rpm reaches a predetermined value, the first clutch is coupled to cause rotation of the ring gear in unison with the drive shaft. As a result, the planet gears meshing with the ring gear and also with the sun gear, the rotation of which is prevented by the one-way clutch, are caused to revolve over the sun gear at a lower speed of revolution than the ring gear while also rotating themselves, and this revolution is taken out by the output shaft, which is thus rotated at a reduced speed with respect to the drive shaft. Further, the planet gears are supported by a carrier, through which the planet gears and output shaft are coupled together. A second clutch of the centrifugal type is provided between the drive shaft and carrier. In this manner, the second clutch is coupled with an increase of speed of revolution of the planet gears with increasing engine rpm. With the coupling of the second clutch, the drive shaft and output shaft are directly coupled to each other with the one-way clutch de-coupled. Thus, the drive shaft and output shaft are rotated at the same speed in the accelerating state.
A further object of the invention is to provide an automatic transmission in which the planetary gear mechanism and second clutch are arranged to oppose each other in the axial direction such that a projection of an inner member of the second clutch, projecting in the axial direction, is disposed at least partially in the space defined by the afore-mentioned three different types of gears comprising the planetary gear mechanism. With such arrangement of the projection of the inner member of the second clutch which is provided for obtaining necessary centrifugal forces, the clutch and planetary gear mechanism partially overlap each other in the axial direction, which further promotes a compact design of the entire transmission system.
Another object of the invention is to provide an automatic transmission in which the second clutch is assembled in the inner space in the first clutch. With such construction, two clutches can be accommodated in a space for a single clutch. In other words, two clutches can be used without requiring an extra shaft length dimension, which further promotes the compact design of the entire system.
Yet another object of the invention is to provide an automatic transmission in which the sun gear of the planetary gear mechanism is fitted on an output shaft sleeve rotatably fitted on the drive shaft. With such construction, in the state of the reduced speed of rotation of the output shaft sleeve before its direct coupling to the drive shaft, the drive shaft rotating at a high rotational speed, the output shaft sleeve rotating at a reduced speed and the sun gear in the stationary state are disposed in order in the radial direction, so that it is possible to reduce wear of and frictional resistance offered to the frictional surfaces of these parts.
The above and other objects, features and advantages of the present invention will become apparent from the following detailed description of preferred embodiments of the invention, with reference being had to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an axial sectional view showing the entire automatic transmission embodying the invention.
FIG. 2 is a view partly broken away in the axial direction, showing a centrifugal clutch and a planetary gear mechanism.
FIG. 3 is a front elevational view taken in the direction of arrow 3 in FIG. 1, showing the planetary gear mechanism.
FIG. 4 is a back elevational view taken in the direction of arrow 4 in FIG. 1, showing a one-way clutch.
FIG. 5 is a schematic representation of the power transmission system in the automatic transmission according to the invention.
DETAILED DESCRIPTION
The present embodiment of the automatic transmission according to the invention is applied to a small-sized light motorcycle. A crankshaft 13 of an internal combustion engine 10 including a piston 11 and a connecting rod 12, is journalled in a bearing 14 at its proximal end on the side of the internal combustion engine 10. Crankshaft 13, which serves as a drive shaft, extends into the interior of a crank case 20 accommodating the automatic transmission, and has a cantilever structure with only the proximal end thereof supported by bearing 14. Because no other bearing is provided at the free end thereof, the length of drive shaft 13 can be correspondingly reduced. A starter shaft 30 is provided within case 20 and is supported by a shaft support 20a. Starter shaft 30 is coaxial with drive shaft 13, and the free end thereof faces the free end of drive shaft 13. A spiral spring 31 is disposed on the outer periphery of the proximal end of starter shaft 30, with one end thereof attached to starter shaft 30 and the other end thereof attached to the inner surface of case 20. The starter shaft 30 has an integral sprocket wheel 33, to which is coupled a chain 32 which extends to a foot pedal of the motorcycle. By operating the foot pedal, the sprocket wheel 33 and starter shaft 30 are rotated to wind spiral spring 31 and store a spring force for starting the internal combustion engine.
The end of starter shaft 30 facing drive shaft 13 is increased in diameter, and the outer periphery thereof is provided with ratchet teeth 34. The free end of drive shaft 13, on the other hand, is provided with an integral drive plate 35 extending radially outwardly at right angles to drive shaft 13 and retained thereon by a nut 36. A pawl 37 is pivoted by a pin 38 to a peripheral edge portion of drive plate 35. When pawl 37 meshes with one of the teeth 34 and the spring force stored in spiral spring 31 is released, starter shaft 30 is rotated. This torque is transmitted through ratchet teeth 34 and pawl 37 to drive plate 35 so as to cause rotation of drive shaft 13 integral with drive plate 35 for starting the internal combustion engine 10. After the engine has been started, drive shaft 13 is thereby rotated at a high speed, so that pawl 37 is caused to move pivotally about pin 38 by centrifugal forces and is thus released from meshing engagement with ratchet teeth 34 to ensure the driving of drive shaft 13.
While in the present embodiment the starting system for the internal combustion engine is of the type using a foot pedal, starter shaft 30 and spiral spring 31 for manually storing and releasing the spring force, the automatic transmission according to the invention (which is described hereinbelow) is also applicable to kick starters or starters using starter motors as generally employed for motorcycles.
A first clutch 40 of the centrifugal type serves as a starter clutch, and the inner members 41 thereof are pivoted by respective pins 43 to peripheral edge portions of drive plate 35. Normally, the inner members 41 are spring-biased radially inwardly by associated springs 44, respectively. The starter clutch 40 has a drum-like outer member 42 closed on the side thereof closest to engine 10, and coaxially fitted for rotation on the outer periphery of drive shaft 13. The mouth of drum-like outer member 42 on the opposite side is closed by drive plate 35 to define an enclosed inner space, which is available for accommodating various other parts and mechanisms. More specifically, a planetary gear mechanism 45 is assembled in the inner space defined by drum-like outer member 42 such that it is in close contact with the inner side of outer member 42. The planetary gear mechanism 45 comprises three different types of gears arranged in the radial direction, i.e., an outermost ring gear 46 having an internal gear, a central sun gear 48, and three planet gears 47 provided between ring gear 46 and sun gear 48. As clearly shown in FIG. 3, the three planet gears 47 are uniformly spaced in the circumferential direction in the space between sun gear 48 and ring gear 46, and in mesh with both gears 46 and 48. The planetary gear mechanism 45 is coaxially mounted on drive shaft 13 with a central through hole 48a of sun gear 48 fitted on drive shaft 13. The outermost ring gear 46 of planetary gear mechanism 45 is secured to the inner peripheral surface of the drum-like outer member 42 of starter clutch 40, so that ring gear 46 is coupled, through clutch 40 and drive plate 35, to drive shaft 13. The three planet gears 47 are each rotatably mounted on a pin 51 provided on a plate-like carrier 50, the center of which is secured to an end of an output shaft 52, so that planet gears 47 are coupled to output shaft 52 through carrier 50. The output shaft 52 is in the form of a sleeve coaxially fitted for rotation on the outer periphery of drive shaft 13. Output shaft 52 extends from the end thereof coupled to carrier 50 toward the engine 10, and has a power take-out member 53 integrally mounted thereon adjacent to the end thereof closest to engine 10. In the present embodiment, power take-out member 53 comprises a sprocket wheel coupled by a chain 54 to the driving wheel of the motorcycle, so that the driving wheel is rotated by power from output shaft 53.
The radially central sun gear 48 of the planetary gear mechanism is coupled to an end of a sleeve member 60 rotatably fitted on the outer periphery of output shaft 52, thus providing a triple shaft structure consisting of drive shaft 13, output shaft sleeve 52, and sleeve member 60 radially arranged in the mentioned order. Sleeve 60 extends from the end thereof coupled to sun gear 48 toward the engine 10, and has a length shorter than the length of output shaft sleeve 52. Sleeve 60 is provided at the end thereof closest to engine 10 with a one-way clutch 70. The one-way clutch 70 is thus located at a position spaced apart further from engine 10 than sprocket wheel 53 coupled to output shaft 52, i.e., it is provided on the side opposite to bearing 14 with respect to sprocket wheel 53 constituting the power take-out member.
As shown in FIG. 4, one-way clutch 70 includes a central clutch plate 71 which is coupled to the end of sleeve 60 as described above. Clutch plate 71 is assembled within a ring-like ratchet plate 72, which is provided on its inner periphery with teeth 72a slanted in one direction and covered with an elastic material such as rubber. As shown in FIG. 1, ratchet plate 72 is secured by bolts 73 to case 20, which is a stationary member. Clutch plate 71 has two pawls 74 each pivoted by a pin 74a thereto and biased by a spring 75 such that when a force tending to rotate it is applied in the direction of arrow A, the pawls 74 are engaged with teeth 72a of ratchet plate 72. If the force is applied in the direction of arrow B, the engagement between pawls 74 and teeth 72a is released to permit rotation.
As shown in FIG. 1, a second clutch 80 of the centrifugal type serves as a change-gear clutch. Second clutch 80 is provided on the side of carrier 50 opposite to the planetary gear mechanism 45. The inner members 81 of second clutch 80 are pivoted by respective pins 83 to carrier 50, as shown in FIGS. 1 and 2. The inner members 81 are normally spring-biased radially inwardly by a spring 84. An outer member 82 of change-gear clutch 80 has a ring-like configuration and is integrally coupled to drive plate 35 on the inner side of inner member 41 of starter clutch 40. It will be appreciated that change-gear clutch 80 is assembled within the space inside starter clutch 40, with the first and second clutches 40 and 80 being thus arranged in the radial direction. Change-gear clutch 80 thus faces the planetary gear mechanism 45 together with starter clutch 40 in the axial direction of drive shaft 13, i.e., the planetary gear mechanism 45 and change gear clutch 80 are coaxially arranged and face each other. The inner members 81 of change-gear clutch 80 are each provided with an integral projection 81a projecting in the axial direction of drive shaft 13 for obtaining necessary centrifugal forces. The projections 81a cross the carrier 50 through notches formed thereon at peripheral portions not supporting the planet gears 47 and extend near planetary gear mechanism 45. Further, projections 81a occupy at least part of the space S defined by the three different types of gears of planetary gear mechanism 45, i.e., ring gear 46, planet gears 47 and sun gear 48. Such arrangement effectively further reduces the dimension of the system in the axial direction, in addition to the reduction afforded by the assembly of change-gear clutch 80 in the inner space of starter clutch 40.
The operation of the automatic transmission is described hereinbelow.
The internal combustion engine 10 is started by releasing the spring force stored in spiral spring 31 as described above. Drive plate 35 is thus rotated in unison with the crankshaft, i.e., drive shaft 13, of engine 10. When the engine rpm is increased to a predetermined value from idling, inner members 41 of starter clutch 40, pivoted by pins 43 to drive plate 35, are driven by centrifugal forces to be urged against the outer member 42. With the coupling of starter clutch 40 being effected in such manner, outer member 42 is rotated in unison with drive shaft 13, thus causing rotation of ring gear 46 of planetary gear mechanism 45 mounted on outer member 42, in unison with drive shaft 13.
The direction of rotation of ring gear 46 is indicated by arrow C in FIG. 3. With the rotation of ring gear 46 in the direction of arrow C, planet gears 47 tend to revolve over sun gear 48 in the direction of arrow E while rotating themselves in the direction of arrow D. As a result, sun gear 48 receives a torque in the direction of arrow F opposite to the direction E of revolution of planet gears 47, and thus tends to rotate in the direction F. However, sun gear 48 is coupled through sleeve 60 to one-way clutch 70, and the direction F of the torque exerted to sun gear 48 is the same direction as that of arrow A in FIG. 4 for clutch plate 71 of one-way clutch 70 (FIGS. 3 and 4 are in front and back relation). Thus pawls 74 are brought into meshing engagement with teeth 72a of ratchet plate 72 to prevent the rotation of clutch plate 71, so that sun gear 48 is not rotated in the direction F but is locked in position. Consequently, with the rotation of ring gear 46, planet gears 47 effect revolution over sun gear 48 in the direction E while rotating themselves in the direction D.
With concurrent rotation and revolution of planet gears 47, the power derived from drive shaft 13 is reduced in speed in the power transmission system by means of planetary mechanism 45 because the speed of revolution of planet gears 47 is lower than the speed of rotation of ring gear 46, i.e., the planetary gear mechanism 45 has an effect of changing speed. The revolution of planet gears 47 is transmitted to carrier 50, which rotatably supports planet gears 47 by pins 51, so that revolution of reduced speed is taken out by output shaft 52 through carrier 50. Thus, sprocket wheel 53 mounted on output shaft 52 rotates the driving wheel of the motorcycle via the chain 54, in a low-speed state.
In the above-described operation, a load for rotating the driving wheel acts upon sprocket wheel 53, and acts as a bending force tending to cause flexing of drive shaft 13 because output shaft sleeve 52 is fitted on drive shaft 13. Drive shaft 13 has a cantilever construction with its proximal end on the side of the internal combustion engine 10 supported by bearing 14 as described above. However, in the low speed state, one-way clutch 70 is kept in the coupled state with pawls 74 being meshed with ratchet plate 72, is coupled to case 20 as a stationary member, and is integrally coupled to sun gear 48 and sleeve 60 both fitted on drive shaft 13. Thus, in its state coupled to case 20, one-way clutch 70 serves as a bearing supporting drive shaft 13. Because one-way clutch 70 is disposed at a position on drive shaft 13 on the side of sprocket wheel 53 opposite to bearing 14, drive shaft 13 is supported on both sides of sprocket wheel 53 by one-way clutch 70 and bearing 14, respectively. Thus, shaft 13 can be reliably supported in the low speed state, during which a high bending force acts upon the shaft. Further, the disposition of sprocket wheel 53 at a position near engine 10 is effective for reducing the magnitude of the bending force.
Further, in such low speed state, output sleeve 52 is rotated at a reduced speed compared to drive shaft 13 as described above. Output shaft sleeve 52 is fitted on the outer periphery of drive shaft 13, and sleeve 60 coupling sun gear 48 to one-way clutch 70 is fitted on the outer periphery of output shaft sleeve 52, wherein the sun gear 48 and sleeve 60 are not rotated. Thus, with the provision of sun gear 48 on output shaft sleeve 52, drive shaft 13, output shaft sleeve 52 and sun gear 48 are radially arranged in the order of degree of rotational speed in the mentioned order. Consequently, the difference in the rotational speed between drive shaft 13 and output shaft 52, and between output shaft 52 and sun gear 48, is not substantial, so that it is possible to reduce wear of and frictional resistance offered by the frictional surfaces of members 13, 52 and 48 compared to the case where sun gear 48 is directly fitted on drive shaft 13.
With the increase of the rpm of engine 10, the rotational speed of drive shaft 13 is increased to increase the speed of revolution of planet gears 47. The planet gears 47 are coupled through carrier 50 and pins 83 to the inner members 81 of change-gear clutch 80. Thus, with the increase of the speed of revolution of planet gears 47, the inner members 81 are urged against the outer member 82 by centrifugal forces to effect the coupled state of change-gear clutch 80, with outer member 82 being coupled to drive plate 35 rotating in unison with drive shaft 13. As a result, planet gears 47 are coupled, through drive plate 35, change-gear clutch 80 and carrier 50, to drive shaft 13, i.e., output shaft 52 coupled to carrier 50 is directly coupled to drive shaft 13.
In this case, ring gear 46 of planetary gear mechanism 45 is continuously rotated at the same speed as drive shaft 13 because starter clutch 40 is still in the coupled state. Thus, planet gears 47, having started to rotate in unison with drive shaft 13, are now caused to revolve in the direction of arrow E (FIG. 3) at the same speed as the rotational speed of ring gear 46, which is rotating in the direction of arrow C, and the gears 47 stop their rotation. With the sole revolution of planet gears 47 in the direction E in unison with ring gear 46, sun gear 48 receives torque in the direction of arrow G, opposite to the direction of the low speed state. This direction corresponds to the direction of arrow B in FIG. 4 for clutch plate 71 of one-way clutch 70 coupled to sun gear 48 through the sleeve 60. Thus, engagement between pawls 74 and teeth 72a of ratchet plate 72 is released to permit rotation of sun gear 48 in the direction of arrow G. In this manner, the three different gears 46, 47 and 48 of planetary gear mechanism 45 are rotated in the same direction and at the same speed.
It will be understood from the foregoing that as soon as change-gear clutch 80 is coupled, drive shaft 13 and output shaft sleeve 52 are directly coupled to each other through change-gear clutch 80 to increase the speed from the low speed to a second speed, so that the rpm of the driving wheel of the motorcycle is correspondingly increased.
Although there have been described what are at present considered to be the preferred embodiments of the invention, it will be understood that the invention may be embodied in other specific forms without departing from the spirit or essential characteristics thereof. The present embodiments are therefore to be considered in all respects as illustrative, and not restrictive. The scope of the invention is indicated by the appended claims rather than by the foregoing description. | An automatic transmission including a drive shaft directly connected to a drive source, an output shaft, and a planetary gear mechanism provided between the drive shaft and output shaft and serving to effect automatic speed change in power transmission. The planetary gear mechanism is mounted on the drive shaft with its sun gear fitted thereon. Thus, the length dimension of the drive shaft can be reduced to provide a very compact system. Further, a plurality of clutches are arranged in a radial plane between the drive shaft and the output shaft, thus permitting a further reduction in the size of the system. | 5 |
BACKGROUND OF THE INVENTION
This invention relates generally to magnetic flowmeter systems, and in particular to a magnetic flowmeter whose electromagnet is excited by DC power applied thereto periodically.
In a magnetic flowmeter, the liquid whose flow rate is to be measured, is conducted through a flow tube provided with a pair of diametrically-opposed electrodes and an electromagnet establishing a magnetic field perpendicular to the longitudinal axis of the tube. When the flowing liquid intersects the magnetic field, a voltage is induced therein which is transferred to the electrodes. This voltage, which is proportional to the average velocity of the liquid and hence to its average volumetric rate, is then amplified and processed to actuate a recorder or indicator.
Historically, in volumetric flow measurement utilizing a magnetic flowmeter, it was originally the practice to use a DC magnetic field. However, when employing a DC magnetic field, a polarization effect occurs. It is therefore now the practice to use an AC magnetic field in the magnetic flowmeter in order to overcome this drawback, for with an alternating magnetic flux operation, the polarization effect is rendered negligible.
Though an AC-excitation type of magnetic flowmeter is clearly advantageous in that polarization is obviated and the AC flow-induced signal may be more easily amplified, it has the following distinct drawbacks.
1. Eddy currents which flow through the fluid to be metered are induced by the use of AC magnetic field, and these eddy currents introduce error signals.
2. Because of stray capacitance between the loop from the AC excitation source to the electrodes and the fluid, the resultant electrostatic induction gives rise to zero drift.
3. Since the output signal of the magnetic flowmeter is alternating, the amplitude of the signal is reduced by reason of the electrostatic capacitance of the cable connection between the detector and a transmitter. This drawback is more pronounced in the case of flow measurement of low conductivity fluids.
4. A spurious voltage, which is 90 degrees out of phase with the AC flow induced voltage, is generated from the signal leads, thereby producing a changing zero voltage.
SUMARY OF THE INVENTION
In view of the foregoing, the main object of this invention is to provide a magnetic flowmeter system which overcomes the disadvantages of an AC excitation system and yet is free from the polarization effect inherent in DC excitation.
More specifically, an object of this invention is to provide a magnetic flowmeter system, in which the electromagnet in the flowmeter is excited by periodically applied DC power, so that unwanted common mode noise is minimized without giving rise to polarization effects.
Briefly stated, in a magnetic flowmeter system in accordance with the invention, both the flow signal and the zero voltage generated during the excitation period are held by a first hold circuit and the zero signal generated during the nonexcitation period is held by a second hold circuit. Each held signal is fed to an amplifier system in which zero voltage is subtracted from the combined voltage of the flow signal and the zero voltage, in order to obtain an output signal directly proportional to the flow velocity.
OUTLINE OF THE INVENTION
For a better understanding of the invention, as well as other objects and further features thereof, reference is made to the following detailed description to be read in conjunction with the accompanying drawings, wherein like reference numerals in the several figures are used to designate like components.
In the drawings:
FIG. 1 is a schematic diagram of a first preferred embodiment of a magnetic flowmeter in accordance with the invention;
FIGS. 2(a) to (e) are wave forms illustrating the operation of the first embodiment of the invention;
FIG. 3 is a schematic diagram of a second preferred embodiment of a magnetic flowmeter in accordance with the invention;
FIG. 4(a) and (b) are wave forms illustrating the operation of the second embodiment of the invention;
FIG. 5 is a schematic diagram of a third preferred embodiment of a magnetic flowmeter in accordance with the invention; and
FIG. 6(a) and (b) are wave forms illustrating the operation of the third embodiment of the invention.
DESCRIPTION OF THE INVENTION
Before describing the structure and operation of the embodiments of the invention, we shall first consider the zero point problem which arises in a magnetic flowmeter with a DC magnet field as well as in a magnetic flowmeter with an AC magnetic field.
When a metal electrode is immersed in an electrolyte, a polarization potential is generated. It is well known that the magnitude of this voltage varies in accordance with the nature of the electrode and that of the fluid, and that it is also a function of temperature, pH and other factors. If the electrodes in a magnetic flowmeter are identical in character, nearly equal polarization potentials are generated at the respective electrodes.
Since these polarization potentials are developed in opposition to each other in the loop constituted by the electrodes and the liquid therebetween, the effect of the polarization potentials is for the most part eliminated. However, a slight error signal of 100 mV or so inevitably appears between the electrodes. The voltage existing between the electrodes in the non-excitation period represents the zero point in a DC magnetic flowmeter.
On the other hand, with AC magnetic flux operation, electromagnetic induction occurs in the magnetic flowmeter and eddy currents are induced. As previously mentioned, the eddy currents introduce error signals and hence give rise to zero drift.
First Embodiment: Referring now to FIG. 1, there is shown a first preferred embodiment of the invention. In this figure, the liquid to be metered is conducted through a flow tube 1. An excitation coil 2 connected through a switching circuit 3 to a DC source 4, serves to establish a magnetic field in the flow tube perpendicular to the direction of flow. A timing control circuit 5 serves to govern the operation of switching circuit 3. Electrodes 6a and 6b are disposed at diametrically-opposed positions on the flow tube along an axis which is perpendicular both to the longitudinal direction of flow and the transverse magnetic field.
The flowmeter is primarily constituted by flow tube 1, excitation coil 2 and electrodes 6a and 6b. A pre-amplifier 7 receives the signal voltage yielded at the output terminals 8 connected to the electrodes of the flowmeter. The output of pre-amplifier 7 is applied to switching circuits 9 and 10 which are respectively connected to hold circuits 11 and 12. These switching circuits are alternately driven by timing control circuit 5. The respective outputs of hold circuit 11 and 12 are fed through a filter circuit 14 to the non-inverting input terminal and the inverting terminal of a subtracting circuit 13 having an output terminal 15.
We shall now explain the operation of the first embodiment with reference to the wave forms shown in FIGS. 2(a) to (e). Switching circuit 3, controlled by timing control circuit 5, operates so that it is alternately on and off as shown by FIG. 2(a). Power from the DC source 4 is periodically turned off by switching circuit 3 at a rate determined by control circuit 5 and the resultant periodic DC is fed to excitation coil 2, thereby producing a periodic DC magnetic field in the flowmeter. It will be seen in FIG. 2(a) that the "on" or excitation period is about twice as long as the "off" or non-excitation period.
The output of the flowmeter during the excitation period and that during the non-excitation period appear alternately at output terminals 8. The output during the excitation period corresponds to the combined voltage of the live flow voltage signal and the zero voltage, whereas the output during the non-excitation period corresponds to zero voltage only. Each output is amplified by pre-amplifier 7 and then fed to switching circuits 9 and 10.
Switching circuits 9 and 10 are controlled by timing control circuit 5 in synchronism with switching circuit 3. Though each switching circuit is switched alternately as shown in FIGS. 2(b) and (d), when switching circuit 9, for instance, is controlled to operate in coincidene with the operation of switching circuit 3, then switching circuit 9 operates as shown in FIG. 2(b) and hold circuit 11 holds the output during the excitation period, while hold circuit 12 holds the output during the non-excitation period.
Thus hold circuit 11, as shown in FIG. 2(c), holds the output voltage V 1 developed at output terminals 8 immediately before the switching circuit 9 is turned off, this voltage being held until switching circuit 9 is again turned on. On the other hand, hold circuit 12, as shown in FIG. 2(e), holds the output voltage V 2 developed at the output terminals 8 immediately before switching circuit 10 is turned off, this voltage being held until the switching circuit 10 is again turned on.
The outputs of hold circuits 11 and 12 are smoothed by filter circuit 14. The filter circuit output is fed to subtracting circuit 13, thereby subtracting the held zero voltage from the combined voltage of the live flow voltage and the zero voltage to eliminate zero error due to polarization. Hence there is developed at terminal 15, an output signal V 4 which is free from the polarization effect.
Second Embodiment: FIG. 3 shows a second preferred embodiment of the invention, in which a signal conditioning stage 16 constituted by a differential amplifier 16a of limited gain (generally gain 1), a switching circuit 16b and a capacitor 16c, replaces hold circuits 11 and 12 as well as subtracting circuit 13 in FIG. 1. To the non-inverting input terminal of amplifier 16a, there is applied the output of pre-amplifier 7. The inverting input terminal of amplifier 16a is connected to a first fixed contact in switching circuit 16b whose movable contact is controlled by the timing control circuit 5. The second fixed contact of switching circuit 16b is connected to a point A, the output terminal of amplifier 16a. The movable contact of switching circuit 16b is connected to one end of the capacitor 16c whose other end is grounded.
This circuit is advantageous in that hold circuits 9 and 10, and subtracting circuit 13 in FIG. 1 are supplanted by a single stage 16. However, since the output of the stage is influenced by the on-off ratio of timing control circuit 5, the stage should generally be used only when the non-excitation period is short compared to the excitation period, or when, in the case of a fixed on-off ratio, the magnitude of the zero voltage is small.
The operation of the second embodiment shall now be explained with reference to the wave forms in FIG. 4(a) and (b).
Periodic DC power, as shown in FIG. 4(a), is applied to excitation coil 2. It will be seen that the excitation period is long compared to the non-excitation period. When the movable contact of switch 16b is shifted as shown by FIG. 3, during the non-excitation period to engage terminal A, capacitor 16c is charged with the output produced by amplifier 16a when the magnetic field is off. When the movable contact of switch 16b is disconnected from terminal A and switch 3 is closed so that DC power is applied to excitation coil 2, the zero voltage charge in the capacitor is now applied to the inverting input terminal of amplifier 16a. Amplifier 16a subtracts the zero point voltage from the combined voltage of the flow signal and the zero voltage during the excitation period. Therefore, the composite signal as shown by FIG. 4(b), which includes a zero error-compensated signal component and zero error voltage component, appears at the output terminal A of the amplifier 16a. The output indicated by the dotted line in FIG. 4(b) is obtained at output terminal 15 by smoothing the output of the amplifier 16a by means of filter circuit 14.
Third Embodiment: FIG. 5 shows a third preferred embodiment of this invention, in which the disadvantages of the second embodiment are obviated. In addition to the components shown in FIG. 3, a switching circuit 17 and a hold circuit 18 are provided between stage 16 and filter circuit 14. Switching circuit 17 is controlled by timing control circuit 5 so that the movable contact of switching circuit 17 is closed when capacitor 16c is connected to the inverting input terminal of amplifier 16a.
Hold circuit 18 is constituted by an amplifier 18a of limited gain, a capacitor 18b, and a switching circuit 18c. The non-inverting input terminal of amplifier 18a is connected to the movable contact of switching circuit 17, and the inverting input terminal of the same amplifier is connected to a first fixed contact of switching circuit 18c whose second fixed contact is grounded.
Output terminal B of amplifier 18a is connected both to one end of capacitor 18b and to the input of filter circuit 14. The other end of capacitor 18b is connected to the movable contact of switching circuit 18c. This switching circuit is controlled by timing control circuit 5 so that the movable contact is shifted to the non-inverting input terminal of amplifier 18a when switching circuit 17 is opened, as shown in FIG. 5. The movable contact of switching circuit 18c is shifted to the grounded fixed contact when the switching circuit 17 is closed.
The difference between the second and third embodiments of the invention will now be explained with reference to the wave forms in FIGS. 6(a) and 6(b).
The composite signal, as shown in FIG. 6(a), which includes a live signal component and a zero error component, appears at point A, as previously explained. At the outset, when the movable contact of switching circuit 16b is connected to output terminal A of amplifier 16a, as shown in FIG. 5, during the non-excitation period, this output is not applied to hold circuit 18. When, however, switching circuit 17 is closed during the excitation period, capacitor 18b of hold circuit 18 is charged by the zero error compensated output voltage of amplifier 16a.
Amplifier 18a holds the output of amplifier 16a, which is established immediately before switching circuit 17 is turned off during updating of the non-excitation period. Therefore, a signal output as shown in FIG. 6(b), in which the polarization effect is substantially eliminated, is obtained at output terminal B of amplifier 18a.
It is apparent from the foregoing explanation that a magnetic flowmeter in accordance with the present invention has the following features:
A. Because zero error compensation is effected by every updated zero voltage, a highly efficient zero error compensation can be accomplished.
B. Because external noise effects are eliminated, as well as polarization effects, a flowmeter which is stable against external noise can be obtained.
C. Because the magnetic field is in periodic DC form, eddy currents are not induced; hence zero shift effects do not occur at the electrodes even though the electrodes are contaminated.
D. Because the magnetic field is in periodic DC form, stray capacitance has no effect on the output signal; and hence flow measurement of low-conductivity fluids can be effected without difficulty.
E. Because spurious noise, i.e., 90° noise, does not appear, the construction of the transmitter can be made simple, and therefore the transmitter can be produced at low cost.
F. Since it is unnecessary to take into account electrostatic induction effects, the construction of the detector may be simplified.
G. Because zero point stability is improved markedly, the flowmeter is capable of highly efficient flow measurement of low-velocity fluids.
H. Even though spike noise is generated by every on-off operation of the switching circuit and/or external AC noise introduced in the detecting circuit, these noise components can be filtered out by means of a filter capacitor.
Although in the embodiments shown in FIGS. 1, 3 and 5, the compensation is carried out periodically, the compensation need not necessarily be periodic. For instance, when zero point a changes very slowly, the compensation can be carried out with a manual switching operation. On the other hand, semiconductor elements may be used as switching elements to effect fast switching operations.
Furthermore, although in the embodiment in accordance with the present invention, a non-magnetic field is created by interrupting the flow of DC power, the non-magnetic field may be produced by applying voltage of opposite polarity to another set of excitation coils mounted at diametrically-opposed points on the tube.
While there has been shown and described preferred embodiments in accordance with the invention, it will be appreciated that many changes and modifications may be made therein without, however, departing from the essential spirit thereof. | A magnetic flowmeter wherein liquid to be metered is conducted through a flow tube to intersect a transverse magnetic field produced by an electromagnet, the voltage induced in the fluid being transferred to a pair of electrodes mounted at diametrically opposed positions on the tube. The electromagnet is excited by DC power which is applied thereto periodically, this being effected by means of a switch interposed between the electromagnet and the DC power source. When DC excitation is cut off by the switch, the output voltage of the flowmeter is fed to a first hold circuit, whereas during the excitation period, both the flow signal and zero voltage are fed to a second hold circuit. The outputs from both hold circuits are fed to an amplifier whereby the held zero signal is subtracted from the total voltage of flow signal and zero voltage in order to eliminate zero error due to polarization. | 6 |
CROSS-REFERENCE TO RELATED APPLICATIONS
The present application is a Continuation In Part of U.S. patent application Ser. No. 12/567,679 filed Sep. 25, 2009, which application is incorporated in its entirety herein by reference.
BACKGROUND OF THE INVENTION
The present invention relates to supercharger cooling and in particular to cooling a hotter end of a supercharger including two or more rotating rotors.
Modern roots supercharger have improved efficiency by having an axial inlet at an inlet end and timing gears at an opposite end. Unfortunately, the opposite end is hotter than the inlet end exposing the timing gears to such heat reduced gear and lubricant life.
Twin screw type superchargers draw air into the rear of the supercharger and compress the air as it travels from the rear to the front of the supercharger between supercharger rotors. According to the ideal gas law, the air traveling through the supercharger is heated proportional to the compression of the air inside the supercharger and is thus hotter at the front of the supercharger then at the rear of the supercharger. Further, no supercharger is 100 percent efficient, and although screw type superchargers are more efficient than roots-type superchargers, they remain approximately 70 to 80 percent efficient, which means that if the ideal temperature increase is 100 degrees, the actual temperature increase in 20 to 30 percent greater (in terms of absolute temperature). This temperature variation from the front and the rear of the supercharger results in a corresponding unequal heating of supercharger components, and as a result, unequal expansion of the supercharger components and an accompanying variation in clearances (for example, rotors, cases, front plate, gears, bearings, and the like) between supercharger components. The rotor bearing are interference fit, and when the end cover becomes hot enough, the bearing may rotate in the bearing seats, damaging the seats, and causing the rotors to contact and destroy the supercharger.
When the front plate expands from heat, gears positioned by the front plate experiences an increased gear clearance. Correct gear positions are critical in a twin screw supercharger because the gear positions determine the location of the male and female rotors and their separation. Excessive gear clearance may also result in rotor contact, and proper operation of the supercharger requires that the rotors remain in phase with each other throughout the operating temperature range of the supercharger, which is between 100° F. and 450° F.
A possible solution to the variation of clearances with temperature is to increase rotor to rotor clearance to compensate for the temperature variation over the entire temperature range of supercharger operation. Unfortunately increasing the clearances in a twin screw type supercharger reduces supercharger efficiency. Further, increasing gear clearance results in noisy supercharger operation which is often objectionable to a driver, and accelerates wear of the gears.
Further, the rotors of twins screw type superchargers are generally made from aluminum. The aluminum rotors generally have 0.003 inches to 0.004 inches of clearance and thus controlling the expansion of the rotors, regardless of the clearances between gears, has been an issue with the twin screw type superchargers for decades. Greater than ideal clearances have been incorporated into the supercharger designed to deal with rotor expansion. Unfortunately these large clearances reduce supercharger efficiency resulting in hotter air charges, lower output, and higher power requirement for operating the supercharger. Further, should the rotors contact each other due to excessive expansion, the supercharger is generally destroyed.
The front (output) or discharge side of the supercharger is the hottest and rotor contact always occurs towards the front of the supercharger. The rear (inlet) or intake is ingesting cooler ambient air so there is generally no rotor contact at the rear end of the supercharger. And, the higher the temperatures inside the supercharger, the more severe the rotor contact and the farther the contact reaches from the rear to the front of the supercharger.
The rotors fore and aft shafts and bearings support and stabilize the positions of the rotors. Unfortunately, the front plate having a higher temperature expands more than the rear plate which is closer to ambient air temperature. This temperature imbalance accompanied by the expansion imbalance causes the front of the rotors to separate more than the rear of the rotors. The rotor gears are attached to the front of the rotors and as a result experienced increased gear lash as the fronts of the rotors separate. Both the gear lash and the rotor expansion move the rotors outward closer to the supercharger case and the timing change from the excess gear lash results in circumferentially excess movement of one rotor or in relation to the other.
In addition to loss of efficiency and damage to the supercharger, the increased temperatures shorten the life of supercharger seals.
The front case of the supercharger contains the oil used to lubricate the gears and bearings. Friction from the rotating gears, bearings, and seals heat the oil, and higher supercharger rpm, greater boost, and higher air temperature at the front of the supercharger, further contribute to higher oil temperature. These effects combine to make controlling the temperature of the twin screw supercharger extremely difficult.
A possible solution to cooling the supercharger is to provide a pressurized flow of engine oil to the supercharger gears. Unfortunately, this approach requires external lines to provide a source of pressurized oil to the supercharger, and external drain lines from the supercharger to the engine oil pan to drain the oil from the supercharger, which create potential oil leaks. Further, additional heating of engine oil raises oil temperature and affects oil flow reducing the cooling affect of the oil.
Thus, a need remains for cooling the front (output) end of a screw type supercharger.
BRIEF SUMMARY OF THE INVENTION
The present invention addresses the above and other needs by providing a supercharger cooling system which provides a path for coolant from an air/coolant heat exchanger to a supercharger intercooler and then loops around the supercharger housing proximal to a hot outlet end of the supercharger and back to the heat exchanger. The heat exchanger may be a dedicated air/coolant heat exchanger or be a vehicle radiator. The intercooler is sandwiched between the supercharger and intake manifold and cools the flow of hot compressed air from the supercharger into the intake manifold. The supercharger cooling loop cools the bearings and seals, the forward ends of the male and female rotors, and the male and female rotor gears. The cooling loop is preferably located between the supercharger rotors and the rotor drive gears to form a barrier to heat. A dedicated pump cycles the coolant flow and restrictions control the flow of coolant to the supercharger.
In accordance with one aspect of the invention, there is provided a system for circulating engine coolant generally at 160 degrees Fahrenheit to 200 degrees Fahrenheit to the hot front (outlet end) of the supercharger. The cooling provided reduces the temperatures of the rotor bearings, seals, and gears. Providing the coolant flow to the outlet end wall of the supercharger provides a barrier to heat thereby improving performance and reduces wear and failures.
In accordance with another aspect of the invention, there is provided a system for circulating engine coolant through the outlet end wall of the supercharger. The outlet end wall includes seats for the outlet end rotor bearings and separates the rotor drive gears from the hot compressed air in the outlet end of the supercharger. Preventing overheating of the outlet end wall maintains proper rotor centerdistance thereby improving performance and reduces wear and failures.
In accordance with yet another aspect of the invention, there is provided the a system for circulating engine coolant through the outlet end wall of the supercharger. The outlet end wall separates the outlet end wall from the hot compressed air in the outlet end of the supercharger. Cooling the outlet end wall provides a barrier to heat reaching the rotor drive gears and lubricating oil inside the discharge side cover which lubricates the rotor drive gears. Such cooling improves lubrication and extends the life of the lubricating oil.
In accordance with still another aspect of the invention, there is provided the a system for circulating engine coolant through a supercharger housing proximal to the outlet end wall of the supercharger. Cooling the housing proximal to the outlet end wall provides a barrier to heat reaching the rotor drive gears and lubricating oil inside the discharge side cover which lubricates the rotor drive gears. Such cooling improves lubrication and extends the life of the lubricating oil.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING
The above and other aspects, features and advantages of the present invention will be more apparent from the following more particular description thereof, presented in conjunction with the following drawings wherein:
FIG. 1A is a side view of a supercharged engine according to the present invention.
FIG. 1B is a top view of the supercharged engine according to the present invention.
FIG. 1C is a front view of the supercharged engine according to the present invention.
FIG. 2A is a side view of a supercharger, intercooler, and intake manifold according to the present invention.
FIG. 2B is a top view of the supercharger, intercooler, and intake manifold according to the present invention.
FIG. 3 is a cross-sectional view of the supercharger, intercooler, and intake manifold according to the present invention taken along line 3 - 3 of FIG. 2B .
FIG. 4 shows the supercharged engine, a heat exchanger, and coolant lines according to the present invention.
FIG. 5 is a front view of a supercharger outlet end wall and intercooler coolant flow according to the present invention.
FIG. 6 is a cross-sectional view of the supercharger outlet end wall taken along line 6 - 6 of FIG. 5 .
FIG. 7A is a front view of a coolant channel cover according to the present invention.
FIG. 7B is an edge view of the coolant channel cover according to the present invention.
FIG. 8 shows the supercharged engine, a heat exchanger, and coolant lines according to the present invention.
FIG. 9 shows a cutaway view of the supercharger housing proximal to the outlet end wall showing a coolant path according to the present invention.
FIG. 10 shows a cross-sectional view of the supercharger housing proximal to the outlet end wall taken along line 10 - 10 of FIG. 9 showing a coolant path according to the present invention.
FIG. 11 shows a cross-sectional view of a single piece supercharger housing and outlet end wall proximal to the outlet end wall taken along line 6 - 6 of FIG. 5 showing a coolant path according to the present invention.
Corresponding reference characters indicate corresponding components throughout the several views of the drawings.
DETAILED DESCRIPTION OF THE INVENTION
The following description is of the best mode presently contemplated for carrying out the invention. This description is not to be taken in a limiting sense, but is made merely for the purpose of describing one or more preferred embodiments of the invention. The scope of the invention should be determined with reference to the claims.
A side view of a supercharged engine 10 according to the present invention is shown in FIG. 1A and a top view of the supercharged engine 10 is shown in FIG. 1B . The supercharged engine 10 includes a screw compressor type supercharger 12 attached to an intake manifold 20 through an intercooler 22 . The screw compressor type supercharger 12 compresses air received through a throttle body 16 and provides the compressed air to the supercharged engine 10 through the intercooler 22 and intake manifold 20 . The screw compressor type supercharger 12 is driven by a belt 14 connecting a crankshaft pulley to a supercharger pulley.
A side view of the screw compressor type supercharger 12 according to the present invention is shown in FIG. 2A and a top view of the screw compressor type supercharger 12 is shown in FIG. 2B . A supercharger pulley 18 is attached to the screw compressor type supercharger 12 at a front (outlet) end 12 a of the supercharger and the throttle body 16 is attached at a rearward end 12 b . While the supercharger is shown as having the outlet end to the front, belt drives may also be provided to position the inlet end of the supercharger to the front and the supercharger driven from the rear, and such variations are intended to come within the scope of the present invention. The supercharger includes a housing 13 having a length L, an inlet end wall 51 behind the housing 13 , and the outlet end wall 47 ahead of the housing 13 .
A cross-sectional view of the screw compressor type supercharger 12 taken along line 3 - 3 of FIG. 2B is shown in FIG. 3 . A first rotor 24 and a second rotor 26 are rotatably housed in a housing 13 of the screw compressor type supercharger 12 . The rotors 24 and 26 are turned by the pulley 18 and draw ambient air 28 through the throttle body 16 and through the rear (inlet) end 12 b and into the screw compressor type supercharger 12 . The ambient air is compressed as it passes through the screw compressor type supercharger 12 by the rotors 24 and 26 . The compressed air 29 is pumped through compressed air passage 30 and through the intercooler 22 and the intake manifold 20 into the engine 10 .
The power produced by a supercharging internal combustion engine 10 is generally increased by increasing the supercharger 12 boost pressure. Increasing the boost pressure necessarily results in increased temperature of the compressed air 29 being pumped into the engine 10 . Such temperature increase is proportional to the absolute pressure increase (the Ideal Gas Law) and further increased by less than 100 percent supercharger efficiency. The hot air flowing through the supercharger further heats mechanical components and lubrication oil of the supercharger. The air flow is heated as it passes from the inlet end 12 b to the outlet end 12 a , and as a result, the components near the front 12 a of the supercharger 12 experience significantly greater temperature rise than near the rear 12 b . Such heating of elements near the front 12 a of the supercharger 12 has resulted in reduced performance, wear to components, and mechanical failures.
The supercharged engine 12 , a heat exchanger 45 , and coolant lines 40 a , 40 b , and 40 c according to the present invention are shown in FIG. 4 . Increased pressure (i.e., boost) often requires intercooling to prevent detonation. The air to liquid coolant intercooler 22 is popular for many installations because of the compact size and the elimination of a cooling air flow through the intercooler required by air to air intercoolers. The intercooler 22 is conveniently mounted between the supercharger 12 and the intake manifold 20 . The circulating liquid coolant is cooled by air 43 in a radiator 45 which is generally mounted in the front of the car. The line 40 a carries the coolant 41 from a heat exchanger coolant outlet 45 b on the heat exchanger 45 to an intercooler coolant inlet 22 a on the intercooler 22 through a pump 44 . The line 40 b carries the coolant 41 from an intercooler coolant outlet 22 b on the intercooler 22 to a supercharger coolant inlet 12 a on the supercharger 12 . The line 40 c carries the coolant 41 from a supercharger coolant outlet 12 b on the supercharger 12 back to a heat exchanger coolant inlet 45 a on the heat exchanger 45 to complete the cycle.
The pump 44 may be a mechanical pump or an electric pump. When an electric pump is used the pump may be controlled, for example using a pulse width modulated power signal, to provide the required coolant flow 41 to the supercharger 12 .
Two restricted flows 41 a and 41 b connect the line 40 b to the line 40 c . The restricted flow 41 a passed through a fixed restriction 48 and the flow 41 b passes through a variable restriction 49 to control the amount of coolant 41 flowing through the supercharger 12 . The variable restriction 49 may be thermostatically controlled and is preferably controlled based on supercharger 12 temperature.
A front view of a supercharger outlet end wall 47 and coolant flow 41 according to the present invention is shown in FIG. 5 and a cross-sectional view of the supercharger outlet end wall 47 and discharge end cover 59 taken along line 6 - 6 of FIG. 5 is shown in FIG. 6 . As the boost is increased, the temperature of the compressed air 30 pumped into the engine 10 also increases, particularly at the outlet end 12 a of the supercharger (see FIG. 2A ). The outlet end wall 47 is in contact with the hot compressed air 30 causing the temperature of the outlet end wall 47 , the bearings 52 and 53 , the shaft seals 54 and 55 , the rotor drive gears 50 a and 50 b , and lubricating oil inside the discharge end cover 59 to increase under high boost, reducing performance and increases wear and failures.
The outlet end wall 47 is generally made of aluminium and includes seats 52 a and 53 a for the bearings 52 and 53 . Because of the high thermal expansion of aluminum, outlet end wall 47 does not maintain the centerdistance of the gears 50 a and 50 b and the rotors 24 and 26 when the hot compressed air 30 heats the outlet end wall 47 to high operating temperatures. The gears 50 a and 50 b are made of steel having a coefficient of thermal expansion different from the outlet end wall 47 and as a result the gear mesh of the gears 50 a and 50 b is affected by the expansion of the outlet end wall 47 . The supercharger inlet end wall is also made of aluminium but is continuously cooled by the inlet air 28 at ambient temperature, and as a result, the outlet ends 24 a and 26 a of the rotors 24 and 26 do not maintain the same rotor centerdistance as the inlet ends. Heat is also generated by the rotor drive gears 50 a and 50 b , the pulley 18 , the bearings 52 and 53 and the seals 54 and 55 .
Some of the heat is further transferred to oil in the space 57 between the discharge end cover 59 and the outlet end wall 47 . The oil is continuously thrown against neighbouring walls, and additionally, a number of mounting bosses spaced around the interior of the discharge end cover 59 tend to collect the oil in the top half of the discharge end cover 59 delaying the oil from running down into the oil sump, resulting in the hot oil heating the discharge end cover 59 . The lubricating quality of the oil may be reduced when the oil is heated excessively resulting in wear to the gears 50 a and 50 b.
The supercharger cooling system according to the present invention cools the outlet end wall 47 thereby effectively cooling the bearing seats 52 a and 53 a , the bearings 52 and 53 , and the seals 54 and 55 , and creating a barrier to heat from the hot compressed air 30 reaching the gears 50 a and 50 b . As a result, the rotor centerdistance in the outlet end 12 a remains very close to the rotor centerdistance in the inlet end 12 b , and proper gear mesh is maintained, thereby improving performance and reducing wear and failures. Additionally, reducing expansion allows the rotor to rotor centerdistance to be kept small for optimum performance and safe operation.
More preferably, the flow 41 through the liquid coolant channel 46 circles around the outside radii of the seats 52 a and 53 a of the two bearings 52 and 53 to cool the seats 52 a and 53 a , the bearings 52 and 53 , and the outlet end wall 47 . Cooling the outlet end wall 47 contributes to maintaining the centerdistance between the rotors and the gears, even under high boost conditions. Cooling the bearing seats 52 a and 53 a also helps to maintain an interference fit of the bearings 52 and 53 to the bearing seats 52 a and 53 a . Cooling the outlet end wall 47 also provides a barrier to heat flowing from the hot compressed air flow 30 through the outlet end wall 47 and into the space 57 inside the discharge end cover 59 , thereby preventing or reducing heating of the gears 50 a and 50 b and the oil residing in the space 57 .
A front view of a coolant channel cover 56 is shown in FIG. 7A and an edge view of the coolant channel cover 56 is shown in FIG. 7B . The coolant channel cover 56 includes an O-ring 56 a circling it's outside edge for sealing outside the coolant flow 41 against a recess edge of the outlet end wall 47 . O-rings 46 a (see FIG. 6 ) provide a second seal between the outlet end wall 47 and the coolant channel cover 56 for sealing inside the coolant flow 41 .
The present invention reduces heating of the discharge end cover 59 because a rear face of the cooling channel cover 56 is directly cooled by the liquid coolant 41 in channel 46 . The oil in the space 57 is exposed to a front face of the cooling channel cover 56 and is cooled as the oil runs down the front face of the cooling channel cover 56 .
A supercharged engine 10 ′, the heat exchanger 24 , and coolant lines are shown in FIG. 8 . The supercharged engine 10 ′ is similar to the supercharged engine 10 but does not include an intercooler. The heat exchanger coolant outlet 45 b is connected to the supercharger coolant inlet 12 a.
In another embodiment, a liquid coolant channel between forward edges 24 ′ and 26 ′ of the rotors 24 and 26 respectively and the bearings 52 and 53 creates a barrier to heat from the hot compressed air 30 reaching the gears 50 a and 50 b improving performance and reducing wear and failures. A cutaway view of a second supercharger housing 13 a proximal to the outlet end wall 47 showing a coolant path 60 through the housing 13 a is shown in FIG. 9 and a cross-sectional view of the supercharger housing 13 a proximal to the outlet end wall 47 taken along line 10 - 10 of FIG. 9 showing the coolant path 60 is shown in FIG. 10 . The rotors include rotor shaft 24 ′ and 26 ′ connecting the rotors to the gears 50 a and 50 b and the coolant path 60 circles the rotor shafts. The coolant path 60 is centered a distance [[D]] D 1 or alternatively no portion of the supercharger coolant path is greater than a distance D 2 , from an outlet end wall portion of the supercharger, from the outlet end wall 47 . The distances D 1 and D 2 are preferably less than three inches and more preferably less than two inches.
A cross-sectional view of a single piece supercharger housing and outlet end wall 13 ′ taken along line 6 - 6 of FIG. 5 showing the coolant channel 46 is shown in FIG. 11 . The single piece supercharger housing and outlet end wall 13 ′ is a single piece, and is otherwise similar to the supercharger housing and the outlet end wall 47 .
Space in the engine compartment is often limited and an embodiment of the supercharger cooling system according to the present invention described below uses an existing engine cooling system to provide the desired cooling without adding significant additional parts. The existing engine cooling system includes a radiator mounted in the front of the car and a water pump. The water pump circulates the existing liquid coolant through the radiator and the engine. The water pump may also be used to circulate a part of the total coolant flow to the cooling channel 46 in the outlet end wall 47 to cool the supercharger. A parallel circuit comprising the lines 40 a , and 40 c is connected to the existing vehicle cooling system with the line 40 a connected to a higher pressure point and the line 40 c to a lower pressure point. The amount of liquid coolant cycled through the cooling channel 46 is controlled by the two restrictions 48 and 49 . By altering the size of the two restrictions 8 and 9 each flow can be determined for optimum cooling performance.
While the above description focuses on a screw type supercharger, those skilled in the art will recognize that the present invention is equally applicable to a roots type supercharger and such cooling for a roots type supercharger is intended to come within the scope of the present invention.
The liquid coolant is often a water based coolant but may also be a Propylene glycol coolant or any other liquid coolant.
While the invention herein disclosed has been described by means of specific embodiments and applications thereof, numerous modifications and variations could be made thereto by those skilled in the art without departing from the scope of the invention set forth in the claims. | A supercharger cooling system provides a path for coolant from an air/coolant heat exchanger to a supercharger intercooler and then loops around the supercharger housing proximal to a hot outlet end of the supercharger and back to the heat exchanger. The heat exchanger may be a dedicated air/coolant heat exchanger or be a vehicle radiator. The intercooler is sandwiched between the supercharger and intake manifold and cools the flow of hot compressed air from the supercharger into the intake manifold. The supercharger cooling loop cools the bearings and seals, the forward ends of the male and female rotors, and the male and female rotor gears. The cooling loop is preferably located between the supercharger rotors and the rotor drive gears to form a barrier to heat. A dedicated pump cycles the coolant flow and restrictions control the flow of coolant to the supercharger. | 5 |
CROSS-REFERENCES TO RELATED APPLICATIONS
[0001] This application is the National Stage of International Application No. PCT/DE2008/001971, filed Nov. 28, 2008, which claims priority to German Patent Application No. DE 10 2007 057 642.2, filed Nov. 28, 2007, the entire contents of each of which are expressly incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The present invention relates to how an executable machine code may be generated for a given higher-language program considering that, possibly because of a processor change, for example the utilization of newer processor generations, a change in the machine code may become necessary.
BACKGROUND OF THE INVENTION
[0003] In the context of the execution of programs on data processing installations, such as laptops, servers and such, a plurality of files, which are executable, may typically be kept available with the system, meaning for example on the hard drive of a laptop or on the hard drive array of a server. In order for a user to be able to start a single program, typically a plurality of module-like interacting, executable parts may be required. In conventional operating systems such as MICROSOFT WINDOWS, these program parts may feature endings such as “.exe” and “.dll”.
[0004] During the processing of a program, a plurality of different modules, which are executable, may be frequently called. These executable modules together may form a library.
[0005] The individual elements of a library may be in that context adapted for the execution to the respective data processing architecture. This adaptation may typically be implemented through the compilation of a program part or program written in a higher programming language. During the compilation, a plurality of conversions of the higher-language program or program part may be performed in order to arrive at a code section that is executable on the target architecture. The compilation may be a very well established process in the technology. One refers in particular to standard textbooks such as WIRTH, Compilerbau, AHO, SETHI and ULLMANN “Red Dragon.”
[0006] With conventional compilers the high-language source text may be initially parsed into sections, so-called “symbols” or instructions, that may be suitable for compilation, searched in regard to syntax errors, etc. This may occur in the so-called front end of the compiler. The processed code that is received from the front end may then be abstracted in order to obtain a so-called RTL code (Register Transfer Level-Code). At this stage the data flow and control flow graphs may typically already be available that, for example, find mention also in the publications of the applicant (PCT/DE02/03278, PCT/EP02/10065, PCT/EP04/009640, PCT/EP03/00624), including all family members. The named publications are, for the purpose of disclosure, incorporated herein by reference in their entirety.
BRIEF SUMMARY OF THE INVENTION
[0007] Target architectures of the compiler may be reconfigurable architectures.
[0008] What is understood to be a reconfigurable architecture, and such, may be components (VPU) that feature a plurality of elements (PAE) that may be modified in function and/or networking during operation and which may preferably be disposed in a two- or higher-dimensional matrix. Part of the elements may be arithmetic logic units, FPGA areas, input/output cells, memory cells, analog components, etc. These may usually be coarse-granular, consequently for example at least 4 bits, preferably 8 bits, wide and configurable in their function and networking. In between fine-granular areas may however also be disposed. Components of this kind may for example be those known under the label VPU. This encompasses what may typically be called PAEs, such as one- or more-dimensionally disposed arithmetic, logic, analog, storing, networked, and/or communicating peripheral components (IO) that may be connected to one another either directly or through one or several bus systems. The PAEs may be arranged in any implementation, mixture and hierarchy, whereby the arrangement may be called PAE-Array (PA). Associated with the PAE Array may be a configuration unit. In principle, besides VPU components, systolic arrays, neuronal networks, multi-processor systems, processors with several computational cores and/or logic cells, networking and network components such as crossbar-circuits, etc. may be those known, as is the case with FPGAs, DPGAs, transputer, etc.
[0009] In particular FPGAs may belong to the target architectures, whereby the FPGAs features preferably at least some of the previously listed (usually coarse-granular configurable) elements (PAEs). Particularly preferred may be at least a row or column within the FPGA architecture that features elements with at least an adder and a multiplier, or an arithmetic-logic unit (ALU).
[0010] Apart from that, one refers, regarding the target architectures and advantageous data processing procedures on these target architectures, to the following documents of the applicant: P 44 16 881.0-53, German Patent Application No. DE 197 81 412.3, German Patent Application No. DE 197 81 483.2, German Patent Application No. DE 196 54 846.2-53, German Patent Application No. DE 196 54 593.5-53, German Patent Application No. DE 197 04 044.6-53, German Patent Application No. DE 198 80 129.7, German Patent Application No. DE 198 61 088.2-53, German Patent Application No. DE 199 80 312.9, International Patent Application No. PCT/DE00/01869, German Patent Application No. DE 100 36 627.9-33, German Patent Application No. DE 100 28 397.7, German Patent Application No. DE 101 10 530.4, German Patent Application No. DE 101 11 014.6, International Patent Application No. PCT/EP00/10516, European Patent Application No. EP 01 102 674.7, International Patent Application No. PCT/DE97/02949, International Patent Application No. PCT/DE97/02998, International Patent Application No. PCT/DE97/02999, International Patent Application No. PCT/DE98/00334, International Patent Application No. PCT/DE99/00504, International Patent Application No. PCT/DE99/00505, German Patent Application No. DE 101 39 170.6, German Patent Application No. DE 101 42 903.7, German Patent Application No. DE 101 44 732.9, German Patent Application No. DE 101 45 792.8, German Patent Application No. DE 101 54 260.7, German Patent Application No. DE 102 07 225.6, International Patent Application No. PCT/DE00/01869, German Patent Application No. DE 101 42 904.5, German Patent Application No. DE 101 44 733.7, German Patent Application No. DE 101 54 259.3, German Patent Application No. DE 102 07 226.4, German Patent Application No. DE 101 10 530.4, German Patent Application No. DE 101 11 014.6, German Patent Application No. DE 101 46 132.1, German Patent Application No. DE 102 02 044.2, German Patent Application No. DE 102 02 175.9, German Patent Application No. DE 101 35 210.7, International Patent Application No. PCT/EP02/02402, European Patent Application No. EP 01 129 923.7, International Patent Application No. PCT/EP03/00624, International Patent Application No. PCT/EP02/10084, International Patent Application No. PCT/DE03/00942, International Patent Application No. PCT/EP03/08080, International Patent Application No. PCT/EP02/10464, International Patent Application No. PCT/EP02/10536, International Patent Application No. PCT/EP02/10572, International Patent Application No. PCT/EP02/10479, International Patent Application No. PCT/EP03/08081, International Patent Application No. PCT/EP03/09956, International Patent Application No. PCT/EP03/09957, German Patent Application No. DE 102 36 269.6, German Patent Application No. DE 102 43 322, European Patent Application No. EP 02 022 692.4, German Patent Application No. DE 103 00 380.0-53, German Patent Application No. DE 103 10 195.0-53, European Patent Application No. EP 03 009 906.3, International Patent Application No. PCT/EP04/006547, European Patent Application No. EP 03 015 015.5, International Patent Application No. PCT/EP04/009640, German Patent Application No. DE 103 41 051.1, International Patent Application No. PCT/EP04/003603, European Patent Application No. EP 03 025 911.3, German Patent Application No. DE 103 57 284.8-55, International Patent Application No. PCT/EP05/001211, German Patent Application No. DE 10 2004 004 955.6, German Patent Application No. DE 04 002 719.5, German Patent Application No. DE 04 075 382.4, European Patent Application No. EP 04 003 258.3, European Patent Application No. EP 04 004 885.2, European Patent Application No. EP 04 075 654.6, European Patent Application No. EP 04 005 403.3, European Patent Application No. EP 04 075 707.2, European Patent Application No. EP 04 013 557.6, European Patent Application No. EP 04 018 267.7, European Patent Application No. EP 04 077 206.3, International Patent Application No. PCT/EP06/001014, European Patent Application No. EP 05 003 174.9, European Patent Application No. EP 05 017 798.9, European Patent Application No. EP 05 017 844.1, European Patent Application No. EP 05 027 332.5, European Patent Application No. EP 05 027 333.3, International Patent Application No. PCT/EP07/000,380, German Patent Application No. DE 10 2007 054 903.4, and German Patent Application No. DE 10 2007 055 131.4, respectively, including all family members.
[0011] These references are, for the purposes of disclosure, incorporated herein by reference in their entirety without being restricted here to the particular cases presented or mentioned in the publications.
[0012] It should be pointed out that, besides the known XPP components of the application, also other parallel data processing architectures may be considered as the target architectures of the present invention, such as the already known FPGAs. For example, the VIRTEX components of the company XILINX (SPARTAN, VIRTEX-2, VIRTEX-II Pro, VIRTEX-4, VIRTEX-5), etc., or components by Altera, for example STRATIX, etc., should be mentioned. The components feature PAE elements in the form of DSP cells. For a better understanding, one may refer to the data sheets of the corresponding components, which are publicly available, for example, may be obtained via the internet pages of the manufacturers XILINX and ALTERA, and are, for purposes of disclosure, incorporated herein by reference in their entirety.
[0013] In addition, multi-thread systems and processors, such as for example INTEL Pentium and XEON or AMD Athlon, may be part of the target architectures.
[0014] For a better understanding, one may refer here also to the data sheets of the corresponding components, which are publicly available, for example, may be obtained via the internet pages of the manufacturers INTEL and AMD, and are, for purposes of disclosure, incorporated herein by reference in their entirety.
[0015] In conventional compiler construction, the RTL-code, which may already be optimized, may then be further translated in a so-called Backend into the code that can be understood by the respective “machine,” meaning the actual target structure. In the case of re-configurable architectures, the function of the Backend may encompass typically the generation of actually executable configurations from the data flow and control flow graphs that were optimized for this purpose, which may require for example the performance of placing and routing. The relevant prior art, for example, PCT/DE02/03278 of the applicant, was already referred to herein. Other methods may likewise be useable with the present invention.
[0016] It may now be problematic that the Backend, which distributes the program or library parts that are adapted to the machine, may have to be very tightly adapted to the respective computer architecture or machine. This typically prevents that the library parts that were generated for a particular target architecture may be executed on a different target architecture or, as far as this could even be the case, execute performance-oriented.
[0017] In view of the significant progress in the hardware area that occurs regularly, it may, however, be necessary to provide the end user the opportunity to run his previously executable programs also on improved hardware. This should occur with the least effort, which may typically mean that a compilation of the high-level language code cannot be implemented because such a compilation may be managed, by average or DAU users, only subject to significant difficulties, if at all.
[0018] It may be desirable to provide libraries that are machine-adapted.
[0019] According to a first exemplary embodiment of the present invention, it is therefore proposed to provide the user a precompilation in which certain optimizations have already been implemented in order to generate, as such a precompilation, an intermediate format that prior to (first) implementation may be ready to be compiled without problems.
[0020] The compilation may encompass certain architecture—but not component-specific optimizations of a high-level language code, for example, for the precompilation generation, those optimizations that are mentioned in PCT/EP02/10065, PCT/EP2004/003603, PCT/EP2004/009640, and PCT/EP02/06865. Therefore, for example, optimizations may be implemented that concern the distribution into parallel and vector/sequential program sections or flow parts, or concern a (hyper-) threading, etc. These optimizations may, as the case may be, be supported manually by a programmer; this is however not cogently required. It should be mentioned that, as the case may be, if not in the optimal case, also programs, program parts and modules, meaning existing binaries that are executable on sequentially known processors, may be used as starting code for a precompilation, said programs may be subjected to an architecture-specific analysis, such as to determine parallel components and to facilitate an adaption to parallel architectures even without knowledge of the source code, which may be of an advantage for so-called legacy-code and its application. That it may apply primarily to binaries that can be executed on sequential architectures should be mentioned. It should be mentioned that it may be possible to make certain optimizations for the precompilation generation in such a manner that an adaptation follows also in regard to component characteristics that may generally be expected, for example, by means of adaptation to the number of sequential units that might possibly be expected, such as functions- and/or graphing fold elements in an array. In this case the—typically iteratively—determined object code may admittedly already be optimized in reference to the target components; often however such optimizations remain useful in the context of generation changes.
[0021] The precompilation may then be subjected to a component-specific optimization as an object code prior to execution. This component-specific optimization may, for example, be adapted to the breadth and number of available busses, depths of registers and/or locally available storage, the command set of elements such as ALUs in an array, or the different command sets of different elements in an array; during the course of the (second) optimization, temporal partitionings may be implemented corresponding to PCT/EP03/00624. The correspondingly further optimized parts of the RTL may be submitted to a backend and a binary code may be determined therefrom. This may be advantageous for the reason that during change-overs of the actually executing components, for example during the switch from one processor generation to another processor generation, slight adaptations may be implemented through simple postcompilation of the precompilation.
[0022] This may be of interest particularly in the case of those target architectures whose hardware architecture cannot be completely abstracted from the executable binary code (executable)—or for reasons of complexity and/or costs should not be. This group may therefore encompass primarily the previously mentioned Field-Programmable-Gate-Arrays (FPGAs) and re-configurable processors, such as for example the VPUs of the applicant, components of the manufacturer SiliconHive (Netherlands), the ADRES architecture of IMEC (Belgium) and IPFlex (Japan). The architecture details may be publicly accessible, and one is referred to the websites and patent applications of the respective providers which, for purposes of disclosure, are fully incorporated herein by reference in their entirety.
[0023] It may also be possible to have the binaries that may typically be part of a library for different processors or processor combinations in store, which may make it possible to continue working without the entire operation being affected in the event of a failure of parts of processors. This contributes to a system with a high failure safety. The component-specific data, such as bus widths, field sizes, command sets, etc. may be provided to the post-compiler of the present invention by different means. In the particularly preferred exemplary embodiment, they may be read out of each relevant chip that may be available in the system. In this way, corresponding data may be stored in a ROM or in a flash memory with or on the processor or module. Analogously a storage in a BIOS or similar object may be possible even if it is not preferred.
[0024] It may be also possible, particularly if the system has connection to the internet or other data sources, to receive the relevant chip or module data, which may be necessary for compilation, externally.
[0025] The present invention therefore may provide a system and/or method for the provision of more flexible and processor-independent code for the end user, as follows:
[0000] 1. A precompilation may be generated at the software manufacturer by means of a compiler. The precompilation is not a processor-specific binary code in the conventional sense but an intermediate format of the code, for example in the form of graphs or a register transfer language (RTL). The code may preferably feature no machine-specific parts but may instead be a pure processor-independent intermediate format.
2. This precompilation may be provided to the user instead of the usual executable in binary format.
3. The precompilation may be translated on the processor system or computer of the user by means of a post-compiler into the implementable executable in binary format. Different times may be suitable for code translation and may be selected based on system-, market-, and user-specific considerations.
[0026] The precompilation may for example be translated at the following times:
[0000] a. during the installation of the software,
b. during the loading of the software,
c. during the booting of the computer, and
d. during the execution, whereby even here the interpretation of the precompilation may suggest itself.
[0027] At this point the programming language JAVA should be referred to. JAVA is also not distributed as executable binary code (executable) but in the form of an intermediate representation. This is, however, as a significant difference to the present invention, already processor-specific translated for the JAVA Virtual Machine and therefore no longer completely target system-independent. While the code can admittedly be implemented on different target processors, they implement or emulate, however, either within an interpreter at runtime, or by means of a compiler, the JAVA Virtual Machine. All specific limitations of the JAVA Virtual Machine are therefore already implicitly contained in the precompilation and are either barely or no longer optimizable on the target system. This is furthermore one of the primary disadvantages of JAVA because the possible performance is hereby significantly reduced.
[0028] In contrast to JAVA, the precompilation according to the present invention may be a pure intermediate format that features no processor- or architecture-specific characteristics and may thereby be efficiently compiled on any possible target system.
[0029] The precompilation may thereby however already be preferably optimized and implemented in regard to certain processor types and base architectures. A precompilation for FPGAs may for example already have undergone other optimization steps and transformations in the pre-compiler than the precompilation for conventional sequential processors. The precompilation may also already feature manufacturer-specific optimizations, and the precompilation may distinguish itself in architecture details between, for example, Altera and XILINX FPGAs. The compiler may however be completely independent of certain components within a certain component- or architecture family (for example, Virtex-4) and may be non-preferential in the broadest sense between similar component- or architecture families (such as, for example, Virtex-4 and Virtex-5) and thereby may make possible a flexible and efficient end-compilation in regard to the corresponding target components or target processors.
BRIEF DESCRIPTION OF THE DRAWINGS
[0030] FIG. 1 shows an exemplary embodiment according to the present invention.
[0031] FIG. 2 a shows a conventional compiler layout.
[0032] FIG. 2 b shows an exemplary embodiment of a compiler layout according to the present invention.
DETAILED DESCRIPTION
[0033] A conventional compiler layout may be represented as shown in FIG. 2 a . As shown, 0201 refers to the high-level language source code, for example C-code. 0202 represents the frontend, 0204 the intermediate format, 0205 the backend, and 0206 the binary data provided by the backend. 0203 a to 0203 n may be the optimizers or transformer, which may be required for the optimization of the intermediate format, and which may be implemented in hardware and/or typically software, and insofar may represent certain process steps.
[0034] In FIG. 2 b essentially the same units or steps are described as in FIG. 2 a , now however subject to an exemplary embodiment of the present invention. The finally released binary code, which may be recorded in a library or related, is designated in FIG. 2 b as 0214 . The backend is designated as 0213 . The generation of the precompilation may be accomplished in 0204 after a run-through of the upper-level language code or of a binary code 0201 prepared for a sequential processor or co-processor by means of a front end 0202 in the stage 0204 , whereby the different optimizations 0203 a to 0203 i that were already mentioned may be executed. The generated and provided precompilation 0210 may be fed as object code into an intermediate stage 0211 which in turn may have access to specific data regarding those chips on which the program parts, modules, etc. are to be actually run later on. Chip-specific optimizations 0212 a to 0212 g may be implemented. The fact that the precompilation is available, manageable, and transmittable may therefore be advantageous.
[0035] It should be mentioned that the execution of the chip-specific or component-specific optimization may typically take place significantly later and/or on a different computer system than the precompilation generation. In particular, the postcompilation may take place through the target architecture itself. This in itself may respectively be considered advantageous. It should however be pointed out that, as the case may be, the same computer system may also be used, for example, because an existing high-level language program after precompilation is to be translated by a software manufacturer for a plurality of different computer components.
[0036] The post-compiler 0211 may feed the postcompilation to the back end 0213 that may generate a chip-specific binary. It should be pointed out that, as the case may be, a single binary may encompass a plurality of partial binaries for specific chips, whereby during loading of such a binary that is deposited in a library, the corresponding partial binary may be selected from the binary that was assembled in such a manner. Alternatively, it may be possible to store binaries in a library that, while they execute the same program parts or functions, may nevertheless be compiled for different machines or chips and typically may also run only and exclusively on these or at least run only performance-oriented on them.
[0037] FIG. 1 shows then how a given object code 0105 may be post-compiled in the (local) translator/post-compiler 0104 subject to consideration of chip-specific information from a data bank 0106 or a chip, in a particular a chip-ID, compare 0102 , extraction 0103 , in order to generate binaries in a backend 0107 which may then be deposited in a library 0101 in order to be instantiated after linking with a program 0108 .
[0038] In the context of the desired instantiation of a program or program part, one may then test whether an element or module that is present in the library features a chip-ID or similar object that matches the chip-ID of the chip that is presently to be loaded with the program or program part. If this is the case, the program part may be loaded. If this is not the case the object code may be post-compiled for the target architecture that is actually present. This may, given sufficiently high performance of the target architecture and/or other data processing processors present in the system, also happen in a manner that may be transparent to the user, such as during a loading process in real-time; in that case, the object code, meaning the precompilation, may be stored along in a manner that makes access possible. | The invention relates to a method for compiling high-level language code for various architectures and/or components. The invention proposes that an architecture-specific precompilation be generated and subsequently the architecture-specific precompilation be compiled taking into account component-specific information. | 6 |
BACKGROUND
[0001] The subject matter disclosed herein relates to fluid injection systems, and more particularly to a manifold.
[0002] Various combustion systems include combustion chambers in which fuel and an oxidant, such as air, oxygen, and oxygen-containing mixtures, combust to generate hot gases. For example, a gas turbine engine may include one or more combustion chambers that are configured to receive compressed air from a compressor, inject fuel and, at times, other fluids into the compressed air, and generate hot combustion gases to drive one or more turbine stages. Each combustion chamber may include one or more nozzles, a combustion zone within a combustion liner, a flow sleeve surrounding the combustion liner, and a gas transition duct. Compressed air from the compressor flows to the combustion zone through a gap between the combustion liner and the flow sleeve. Unfortunately, inefficiencies may be created as the compressed air passes through the gap, thereby negatively effecting performance of the gas turbine engine.
BRIEF DESCRIPTION
[0003] In one embodiment, a system including a gas turbine engine, including a combustor configured to generate products of combustion, a turbine driven by the products of combustion from the combustor, a compressor having a compressor discharge leading into a chamber between the combustor and a compressor discharge casing, an extraction manifold coupled to the combustor, wherein the extraction manifold is fluidly coupled to the chamber.
[0004] In another embodiment, a system including a turbine combustor casing having a wall and a flange, wherein the wall and the flange extend circumferentially about an interior space, and the flange comprises an extraction aperture configured to be in fluid communication with a compressor discharge, and an extraction manifold coupled to the flange over the extraction aperture, wherein the extraction manifold including a first portion having a first passage with a first axis, and a second portion having a second passage with a second axis, wherein the first and second axes are offset from one another by an offset distance, and the first and second axes are oriented crosswise to one another.
[0005] In another embodiment, a system including an extraction manifold, including a first portion having a first passage with a first axis, wherein the first portion has a mounting flange configured to mount to a turbine combustor in fluid communication with a compressor discharge, and a second portion having a second passage with a second axis, wherein the first and second axes are offset from one another by an offset distance, the first and second axes are oriented crosswise to one another, and the second passage comprises at least one flow guide configured to inhibit swirl of an extraction flow, straighten the extraction flow, or a combination thereof.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] These and other features, aspects, and advantages of the present invention will become better understood when the following detailed description is read with reference to the accompanying drawings in which like characters represent like parts throughout the drawings, wherein:
[0007] FIG. 1 is a block diagram of an embodiment of a gas-turbine system;
[0008] FIG. 2 is a cross-sectional side view of an embodiment of a combustor with a high-pressure-air-extraction manifold;
[0009] FIG. 3 is a perspective view of an embodiment of a combustor casing with a high-pressure-air-extraction manifold;
[0010] FIG. 4 is a perspective view of an embodiment of a combustor-aft casing;
[0011] FIG. 5 is a cross-sectional view of an embodiment of a high-pressure-air-extraction manifold along line 5 - 5 of FIG. 3 ;
[0012] FIG. 6 is a cross-sectional view of an embodiment of a high-pressure-air-extraction manifold along line 5 - 5 of FIG. 3 ; and
[0013] FIG. 7 is a cross-sectional view of an embodiment of a high-pressure-air-extraction manifold along line 5 - 5 of FIG. 3 .
DETAILED DESCRIPTION
[0014] One or more specific embodiments of the present invention will be described below. In an effort to provide a concise description of these embodiments, all features of an actual implementation may not be described in the specification. It should be appreciated that in the development of any such actual implementation, as in any engineering or design project, numerous implementation-specific decisions must be made to achieve the developers' specific goals, such as compliance with system-related and business-related constraints, which may vary from one implementation to another. Moreover, it should be appreciated that such a development effort might be complex and time consuming, but would nevertheless be a routine undertaking of design, fabrication, and manufacture for those of ordinary skill having the benefit of this disclosure.
[0015] When introducing elements of various embodiments of the present invention, the articles “a,” “an,” “the,” and “said” are intended to mean that there are one or more of the elements. The terms “comprising,” “including,” and “having” are intended to be inclusive and mean that there may be additional elements other than the listed elements.
[0016] The disclosed embodiments are generally directed towards a system for providing steady pressurized airflow to pilot and/or blank cartridges (i.e., nozzles) in the combustor, to improve combustion dynamics. More specifically, the disclosed embodiments are directed to a combustor-aft casing with a high-pressure-air-extraction manifold. The combustor-aft casing includes an aperture in fluid communication with a source of steady pressurized air in the gas-turbine system. Steady pressurized airflow is therefore able to travel through the combustor-aft casing and the air-extraction manifold to the pilot and/or blank cartridges. Moreover, the air-extraction manifold includes features that reduce airflow swirl, thereby reducing pressure losses. A reduction in pressure losses through the air-extraction manifold increases the pressure available for the pilot and/or blank cartridges, improving combustion dynamics. For example, the air-extraction manifold may include an interior surface capable of reducing airflow swirl. The interior surface may be rough, jagged, pentagonally shaped, among others, reducing the ability of the airflow to swirl through the air-extraction manifold. By further example, the interior surface may include one or more flow guides (e.g., grooves, protrusions, or flats), which inhibit swirl of the airflow and help guide the airflow along the longitudinal axis of the manifold.
[0017] FIG. 1 is a block diagram of an embodiment of a turbine system 10 . The turbine system 10 may use liquid or gas fuel, such as natural gas and/or a synthetic gas, to drive the turbine system 10 . As depicted, one or more fuel nozzles 12 may intake a fuel supply 14 , partially mix the fuel with air (e.g., an oxidant, such as O 2 and O 2 mixtures), and distribute the fuel and air mixture into the combustor 16 where further mixing occurs between the fuel and air. As described in the disclosed embodiments, a high-pressure-air-extraction manifold 64 couples to the combustor 16 , guiding stable high-pressure air from the compressor to the fuel nozzle(s) 12 . The stable high-pressure air enables purging of blank fuel nozzles/cartridges and/or to feed a pilot fuel nozzle/cartridge. The air-fuel mixture combusts in the combustor 16 , thereby creating hot pressurized exhaust gases. The combustor 16 directs the exhaust gases through a turbine 18 toward an exhaust outlet 20 . As the exhaust gases pass through the turbine 18 , the gases force turbine blades to rotate a shaft 22 along an axis of the turbine system 10 . As illustrated, the shaft 22 is connected to various components of the turbine system 10 , including a compressor 24 . The compressor 24 also includes blades coupled to the shaft 22 . As the shaft 22 rotates, the blades within the compressor 24 also rotate, thereby compressing air from an air intake 26 through the compressor 24 and into the fuel nozzles 12 and/or combustor 16 . The shaft 22 may also be connected to a load 28 , which may be a vehicle or a stationary load, such as an electrical generator in a power plant or a propeller on an aircraft, for example. The load 28 may include any suitable device capable of being powered by the rotational output of turbine system 10 .
[0018] FIG. 2 is a cross-sectional side view of an embodiment of a combustor 16 . As shown in FIG. 2 , an axial axis 30 runs horizontally and is considered generally parallel to the shaft 22 . A radial axis 32 runs vertically and is generally perpendicular to the shaft 22 . Lastly, a circumferential direction 34 is considered to encircle the axial axis 30 . The combustor 16 includes an aft end 36 and a fore end 38 . The fore end 38 is located near the front (or upstream) of the turbine 18 and the aft end 36 is located near the back (or downstream) nearest the turbine 18 . The radial outermost layer of the combustor 16 is the combustor-aft casing 40 , which may enclose the components of the combustor 16 . Portions of the combustor-aft casing 40 may be directly in contact with a flow sleeve 41 , which aids in cooling the components of the combustor 16 . Continuing inward in the radial direction 32 , the next component is a combustion liner 42 , which may contain the combustion reaction. An empty space is disposed between the flow sleeve 41 and the combustion liner 42 , and may be referred to as an annulus 44 . The annulus 44 may direct airflow to a head end 46 of the combustor 16 . More specifically, airflow reaches the annulus 44 from compressed airflow discharged by the compressor 24 into the air plenum 50 . The air plenum 50 surrounds the flow sleeve 41 enabling compressed air 48 to pass through apertures 52 and into the annulus 44 . After passing through the apertures 52 , the annulus 44 channels the compressed air 48 to the head end 46 . In the head end 46 , the compressed air 48 may be turned or redirected toward one or more fuel nozzles 12 (e.g., a set of fuel nozzles 54 ). The fuel nozzles 12 are configured to partially premix air and fuel to create a fuel air mixture 56 . The fuel nozzles 54 discharge the fuel air mixture 56 into a combustion zone 58 , where a combustion reaction takes place. The combustion reaction generates in hot pressurized combustion products 60 . These combustion products 60 then travel through a transition piece 62 to the turbine 18 , thereby generating mechanical power.
[0019] As explained above, the gas-turbine system 10 may include multiple fuel nozzles 12 . The fuel nozzles 12 may include fuel cartridges, a pilot cartridge, and blank cartridges (e.g., cartridges that inject air but not fuel). The fuel cartridges combine fuel and air to create a fuel air mixture for combustion in the combustion zone 58 . The pilot cartridge, like the fuel cartridges, combines fuel and air to create a fuel air mixture for combustion. However, the pilot cartridge anchors the combustion flame (i.e., affects combustion dynamics) for the remaining fuel cartridges. The blank cartridges, unlike the fuel and pilot cartridges, inject air into the combustion zone 58 . Moreover, the blank cartridges, like the pilot cartridge, affect the combustion dynamics within the combustor 16 . During operation, the air flowing through annulus 44 may not provide sufficiently stable airflow and pressure to the pilot cartridge and/or the blank cartridges. Accordingly, the gas-turbine system 10 includes a high-pressure-air-extraction manifold 64 , which enables a steady flow of pressurized air to travel from the air plenum 50 directly to the fore end 38 of the combustor 16 for use in the pilot and/or blank cartridges. The pressure of the air inside the air plenum 50 is more stable and consistent than the airflow traveling through the annulus 44 . Accordingly, the high-pressure extraction air manifold 64 facilitates combustion dynamics by channeling the steady supply of pressurized air in the air plenum 50 to the pilot and/or blank cartridges. As illustrated, the high-pressure-air-extraction manifold 64 couples to the combustor-aft casing 40 and is in fluid communication with the opening 66 . The opening 66 enables airflow from the plenum 50 to travel through the manifold 64 , through conduit or line 68 , and into the head end 46 for use by the pilot and/or blank cartridges.
[0020] FIG. 3 is a perspective view of an embodiment of a combustor-aft casing 40 with the high-pressure-air-extraction manifold 64 . As explained above, the combustor-aft casing 40 enables the high-pressure-air-extraction manifold 64 to channel a source of steady pressurized airflow from the air plenum 50 (seen in FIG. 2 ) to the pilot and/or blank cartridges. As illustrated, the combustor-aft casing 40 includes a casing wall 88 , flange 90 , and flange 92 . The flanges 90 and 92 include respective apertures 94 and 96 . The flanges 90 and 92 enable combustor-aft casing 40 to connect to the combustion flow sleeve 41 and to the head end 46 (seen in FIG. 2 ). Moreover, the apertures 94 enable the air-extraction manifold 64 to couple to the combustor-aft casing 40 with bolts, fasteners, etc. Specifically, the air-extraction manifold 64 couples to the flange 90 and over an air-extraction aperture (illustrated in FIG. 4 ). Accordingly, airflow is able to pass through the flange 90 and into the high-pressure-air-extraction manifold 64 . The air-extraction manifold 64 includes a combustor-connection portion 98 , and an air-line-connector portion 100 . The combustor-connection portion 98 includes a flange 102 and a body portion 104 . The combustor-connection portion 98 couples to the flange 90 with flange 102 using bolts that pass through apertures 106 . The body portion 104 couples to the air-line-connector portion 100 . Accordingly, as airflow passes through the flange 90 it enters the body portion 104 , which then channels the airflow into the air-line-connector portion 100 for movement through line 68 (seen in FIG. 2 ). The air-line-connector portion 100 may be annular in shape and include an annular aperture 108 (e.g., bore or passage) and annular grooves 110 and 112 . The annular grooves 110 and 112 enable connection of a line or hose 68 (e.g., an air conduit), for directing the steady pressurized air from the air plenum 50 to the head end 46 (seen in FIG. 2 ). In addition, the air-line-connector portion 100 may be offset from a conduit that runs through the combustor connector portion 98 . Indeed, offsetting the air-line-connector portion 100 enables connection of the line or hose 68 without interference between the air-extraction manifold 64 and the combustor casing wall 88 . As high-pressure airflow enters the air-extraction manifold 64 in direction 114 , the airflow passes through the body portion 104 and into the aperture 108 of the air-line-connector portion 100 . The pressurized airflow then exits the air-extraction manifold 64 in direction 116 into the line or hose 68 (seen in FIG. 2 ). Thus, airflow travels through the air-extraction manifold 64 in two directions that are generally crosswise (e.g., perpendicular) to one another. The change in direction of the airflow may induce swirling that may cause the airflow to lose pressure. As will be explained in more detail in FIGS. 5-7 , the aperture 108 may include various anti-swirl surfaces that reduce swirling, and the associated pressure drops.
[0021] FIG. 4 is a perspective view of an embodiment of a combustor-aft casing 40 with an air-extraction aperture 120 at a mounting region 121 for the air-extraction manifold 64 . The air-extraction aperture 120 enables the steady high-pressure air to travel from the air plenum 50 and into the air-extraction manifold 64 (seen in FIG. 2 ). Moreover, by including the aperture 120 in the flange 90 , existing gas-turbine systems may be retrofitted with the air-extraction manifold 64 . As illustrated, the flange 90 defines the air-extraction aperture 120 . In the present embodiment, the aperture 120 forms a kidney bean shape (i.e., narrow opening between two large openings), enabling the aperture 120 to be adequately sized, but conform to the flange 90 (e.g., avoid interference with the apertures 94 ). In other embodiments, the aperture 120 may form different shapes to include rectangular, half-moon, elliptical, etc.
[0022] FIG. 5 is a cross-sectional view of an embodiment of a high-pressure-air-extraction manifold 64 taken along line 5 - 5 of FIG. 3 . As explained above, the air-extraction manifold 64 enables pilot and blank cartridges to receive steady high pressure air from the air plenum 50 (seen in FIG. 2 ). In addition, the air-extraction manifold 64 reduces air pressure drops by blocking or inhibiting airflow swirl, thereby improving combustion dynamics with the pilot and/or blank cartridges. The air-extraction manifold 64 includes a combustor-connection portion 132 and an air-line-connector portion 134 . The combustor-connection portion 132 includes a flange 136 and a body portion 138 . As explained above, the flange 136 enables the air-extraction manifold 64 to couple to the combustor-aft casing 40 (seen in FIGS. 3 and 4 ). The body portion 138 includes a conduit 140 (i.e., a first passage). The conduit 140 conducts airflow 141 from the aperture 120 in the combustor-aft casing 40 (seen in FIG. 4 ), to the air-line-connector portion 134 . As illustrated, the air-line-connector portion 134 includes an axis 135 (i.e., a first axis) and the body portion 138 includes an axis 139 (i.e., a second axis). The two axes 135 and 139 are offset from one another by a distance 143 . The offset 143 between the two axes 135 and 139 may cause the airflow to swirl as the airflow 141 exits the conduit 140 and enters a conduit 142 (i.e., a second passage) of the air-line-connector portion 138 . The swirling airflow causes pressure drops, thus reducing the air pressure available for the pilot and/or blank cartridges. As illustrated, the conduit 142 includes a rough interior surface 144 . The rough interior surface 144 breaks up the airflow 141 (i.e., inhibiting swirl of the airflow 141 ) reducing the pressure drop of the airflow 141 through the air-extraction manifold 64 . Thus, the disclosed embodiments include anti-swirl features on the interior surface of the conduit 142 to inhibit swirling flow of the airflow circumferentially about the first axis 135 , while helping guide the airflow axially along the first axis 135 (i.e., the anti-swirl features may be described as flow guides, which extend in an axial direction along the first axis 135 ). Accordingly, the pilot and/or blank cartridges receive increased steady pressurized airflow from the air plenum 50 (seen in FIG. 2 ), improving combustion dynamics.
[0023] FIG. 6 is a cross-sectional view of an embodiment of a high-pressure-air-extraction manifold 64 taken along line 5 - 5 of FIG. 3 . As explained above, the air-extraction manifold 64 enables pilot and blank cartridges to receive steady high pressure air from the air plenum 50 (seen in FIG. 2 ). Moreover, the air-extraction manifold 64 reduces airflow swirling and the associated pressure drops, thereby improving combustion dynamics with the pilot and/or blank cartridges. The air-extraction manifold 64 includes a combustor-connection portion 162 and an air-line-connector portion 164 . The combustor-connection portion 162 includes a flange 166 and a body portion 168 . As explained above, the flange 166 enables the air-extraction manifold 64 to couple to the combustor-aft casing 40 (seen in FIGS. 3 and 4 ). The body portion 168 includes a conduit 170 (i.e., a first passage). The conduit 170 enables airflow 171 to travel from the aperture 120 (seen in FIG. 4 ) in the combustor-aft casing 40 to the air-line-connector portion 164 . As illustrated, the air-line-connector portion 164 includes an axis 165 (i.e., a first axis) and the body portion 168 includes an axis 169 (i.e., a second axis). The two axes 165 and 169 are offset from one another by a distance 173 . The offset 173 between the two axes 165 and 169 may cause airflow entering a conduit 172 (i.e., a second passage) to swirl and lose pressure. As illustrated, the conduit 172 includes a jagged interior surface 174 (i.e., a surface that alternates between protrusions and grooves). The jagged interior surface 174 breaks up the airflow 171 , enabling the airflow 171 to transition from the conduit 170 to the conduit 172 without swirling. More specifically, the jagged interior surface 174 reduces pressure losses by breaking up the swirling airflow 171 . Thus, the disclosed embodiments include anti-swirl features on the interior surface of the conduit 172 to inhibit swirling flow of the airflow circumferentially about the first axis 165 , while helping guide the airflow axially along the first axis 165 (i.e., the anti-swirl features may be described as flow guides, which extend in an axial direction along the first axis 165 ). Accordingly, the pilot and/or blank cartridges receive increased steady pressurized airflow from the air plenum 50 (seen in FIG. 2 ), improving combustion dynamics.
[0024] FIG. 7 is a cross-sectional view of an embodiment of a high-pressure-air-extraction manifold 64 along line 5 - 5 . As explained above, the air-extraction manifold 64 enables pilot and blank cartridges to receive steady high pressure air from the air plenum 50 (seen in FIG. 2 ). Moreover, the air-extraction manifold 64 reduces swirling of the airflow and the associated pressure drops, enabling improved combustion dynamics with the pilot and/or blank cartridges. The air-extraction manifold 64 includes a combustor-connection portion 192 and an air-line-connector portion 194 . The combustor-connection portion 192 includes a flange 196 and a body portion 198 . As explained above, the flange 196 enables the air-extraction manifold 64 to couple to the combustor-aft casing 40 (seen in FIGS. 3 and 4 ). The body portion 198 includes a conduit 200 (i.e., a first passage). The conduit 200 enables airflow 201 to travel from the aperture 120 (seen in FIG. 4 ) in the combustor-aft casing 40 to the air-line-connector portion 194 . As illustrated, the air-line-connector portion 194 includes an axis 195 (i.e., a first axis) and the body portion 198 includes an axis 199 (i.e., a second axis). The two axes 195 and 199 are offset from one another by a distance 203 . The offset 203 between the two axes 195 and 199 may cause airflow entering a conduit 202 (i.e., a second passage) to swirl and lose pressure, reducing the air pressure available for the pilot and/or blank cartridges. As illustrated, the conduit 202 includes a pentagonal shaped interior surface 204 . However, in other embodiments the interior surface may be any polygonal shape having 3, 4, 5, 6, 7, 8, 9, 10, or more sides (e.g., a triangle, square, rectangle, pentagon, hexagon, etc.). The pentagonal interior surface 204 breaks up the airflow 201 , enabling the airflow 201 to transition from the conduit 200 to the conduit 202 without swirling. More specifically, the pentagonal interior surface 202 reduces pressure losses by breaking up the swirling airflow 201 . Thus, the disclosed embodiments include anti-swirl features on the interior surface of the conduit 202 to inhibit swirling flow of the airflow circumferentially about the first axis 195 , while helping guide the airflow axially along the first axis 195 (i.e., the anti-swirl features may be described as flow guides, which extend in an axial direction along the first axis 195 ). Accordingly, the pilot and/or blank cartridges receive increased steady pressurized airflow from the air plenum 50 (seen in FIG. 2 ), improving combustion dynamics.
[0025] Technical effects of the invention include a combustor-aft casing with an aperture, capable of receiving an air-extraction manifold. The aperture and air-extraction manifold enable steady compressed airflow to travel to the pilot and/or blank cartridges, enabling the pilot and/or blank cartridges to improve combustion dynamics in the gas-turbine system. Moreover, the air-extraction manifold includes swirl inhibiting features that reduce pressure losses. Accordingly, the air-extraction manifold increases the pressure available for the pilot and/or blank cartridges, improving combustion dynamics in the gas-turbine system.
[0026] This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims. | A system including a gas turbine engine, including a combustor configured to generate products of combustion, a turbine driven by the products of combustion from the combustor, a compressor having a compressor discharge leading into a chamber between the combustor and a compressor discharge casing, an extraction manifold coupled to the combustor, wherein the extraction manifold is fluidly coupled to the chamber. | 8 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the priority benefit of Taiwan application serial no. 92108199, filed Apr. 10, 2004.
BACKGROUND OF INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to an electrolyte, and more particularly to a composition of nano-tube composite polymer electrolyte and a fabrication method thereof.
[0004] 2. Description of the Related Art
[0005] In 1973, Wright et al. mixed polyethylene oxide (PEO) and KSCN for forming a crystal complex. In 1975, they further proved that the complex had a conductivity higher than 10 −4 S/cm at high temperature (>100° C.). PEO salt could have conductivity about 10 −3 S/cm similar to that of organic electrolyte solution at 100° C. Then, more research and study were undertaken for improving the conductivity of the polymer electrolyte at room temperature and achieving practical application.
[0006] Generally, the polymer electrolyte is made of a polymer substrate and a metal salt. In the amorphous region of the polymer substrate, the metal salt interacts with functional groups of the polymer so that the metal salt moves along the chains of the polymer for transmitting the metal ions.
[0007] For the time being, the systems of polymer electrolyte includes Polyethylene Oxide (PEO), Polyvinylidene Fluoride (PVDF), Poly(methyl Methacrylate) (PMMA), Polyvinylidene chloride (PVC), Polyacrylonitrile (PAN), etc. The cations of the metal salt can be, for example, Li, Na, K, Mg, etc; the anions can be BF 4 , SCN, SO 3 CF 3 , AsF 6 , PF 6 , N(CF 3 SO 3 ), etc. The bigger anion group has higher delocalized charges and easily ionizes.
[0008] Generally, the conductivity and the mechanical properties of the electrolyte can be improved by adding organic material for inhibiting the crystallization of the polymer, reducing Tg, enhancing the mobility of ions. It also can be achieved by selecting a proper salt with effectively dissociation property for enhancing the mobility of ions in the electrolyte. U.S. Pat. No. 5,643,490 disclosed a method of manufacturing a polymer containing tetraalkylammonium. U.S. Pat. No. 5,688,613 disclosed a method of doping-polybenzoimidazole with H 3 PO 3 . U.S. Pat. Nos. 5,581,394, 5,705,084, 5,645,960, 5,731,104, 5,609,974 and 5,586,001 disclosed a method of adding organic plasticizer such as Ethylene Carbonate (EC), Propylene Carbonate (PC) or Dimethylcarbonate (DMC) into polymer electrolytes. Although these methods can improve the conductivity of the solid-state electrolyte at room temperature, they will crate other problems. Under high temperature and pressure, the electrolyte has bad thermal stability, softens and causes circuit shortage within cells.
[0009] The modifier can be inorganic material, such as nano-particle TiO 2 in addition to organic material. Although the inorganic modifier can improve the mechanical properties of the polymer electrolyte, form a good interface between electrodes and the electrolyte, reduce the sediment of Li ions and extend the service life of battery, the conductivity and distribution of the electrolyte are not desirable at room temperature.
SUMMARY OF INVENTION
[0010] Accordingly, an objective of the present invention is to provide a composition of a nano-tube composite polymer electrolyte and a fabrication method thereof, wherein a nano-tube modifier is added into the polymer electrolyte for enhancing the conductivity thereof.
[0011] The other objective of the present invention is to provide a composition of a nano-tube compositepolymer electrolyte and a fabrication method thereof, which have excellent ionic conductivity, and good mechanical and process properties. Therefore, they can be applied to high-energy Li secondary cell or other electrochemical devices, such as super capacitors or sensors.
[0012] The present invention discloses a composition of a nano-tube compositepolymer electrolyte, which comprises a polymer substrate having main-chains and side-chains, which have at least a Lewis base functional group; a metal salt, which can form a polymer salt complex with the polymer substrate; and a nano-tube modifier, which can form Lewis acid-base force with the polymer substrate and the polymer salt complex.
[0013] With regards to the polymer substrate, it has main-chains and side-chains, which at least have an ether group, an acyl group, an amino group, a fluoro group or a Lewis base functional group. The polymer substrate can be polyalkylene oxide, polyvinyl fluoride, polyacrylonitrile, polyester, polyether, polysulfone, polyethylene oxide, polyvinylidene fluoride, poly(methyl methacrylate) (PMMA), polysiloxane, polyphosphazene or derivates thereof. The Lewis base functional group includes oligo(oxyalkylene), flouralkyl group, fluoralkylene group, carbonate group, cyano group and sulfonyl group.
[0014] The metal salt comprises a metal cation and an anion, which includes salt formed of alkaline-earth metal, alkali metal and transitional metal, such as LiPF 6 , LiAsF 6 , LiBF 4 , LiClO 4 , LiN(SO 2 CF 3 ) 2 , LiSbF 6 and LiSO 3 (CF 2 ) n CF 3 , wherein n is 1˜12. The metal salt forms a polymer salt complex with the polymer substrate.
[0015] The nano-tube modifier can enhance the conductivity and property of the polymer electrolyte. The surface of the nano-tube modifier has functional groups OR and O. The functional groups form Lewis acid-base interactions with the polymer substrate and the polymer salt complex. The nano-tube modifier includes TiO 2 , SiO 2 or Al 2 O 3 with different crystal structures. The diameter (length) of the nano-tube modifier is, for example, about from 20 nm to about 160 nm. The aspect ratio (length/width) of the nano-tube modifier is more than 8. Because the total surface area of the nano-tube modifier is larger than that of nano-particle (therefore, even larger compared to a microsized partice) and the nano-tube modifier is hollow, the interfacial interaction between the tube modifier and the polymer substrates establishes strong surface charge field. This unique structure characteristic has lead to tremendous improvements in physical properties, including ion conductivity displayed in the present invention. Furthermore, the metal cations can go through or be temporarily stored therein.
[0016] The present invention also discloses a method for fabricating a nano-tube compositepolymer electrolyte, comprising: mixing a nano-tube modifier and an anhydrous solvent, adding metal salt into the solution and then adding a polymer substrate therein; heating and completely stirring the mixed solution for generating a uniform polymer electrolyte; and coating the uniform polymer electrolyte on a plate electrode, a container or a surface of an object and removing the solvent for forming a polymer electrolyte film.
[0017] In the method for fabricating a nano-tube composite polymer electrolyte of the present invention, the anhydrous solvent comprises tetrahydrofuran (THF) having a dielectric constant higher than 20. During the step of stirring, it is performed with the assist of microwave or ultrasonic for completely mixing. After forming the polymer electrolyte film, an electrical field treatment is performed at a temperature higher than a Tg of the polymer and cooling down to room temperature for enhancing the conductivity thereof.
[0018] The nano-tubes of the compositepolymer electrolyte of the present invention are formed by a base treatment to nano particles for forming the tube shape. During the process of forming the compositepolymer electrolyte, the nano-tubes are stirred with the polymer substrate by ultrasonic for achieving high uniformity. Moreover, the nano-tubes of the compositepolymer electrolyte, the metal salt and the Lewis base functional group of the polymer substrate can form a complex, which can enhance the ratio of amorphous region and dissociation of the metal salt for improving the conductivity of the polymer electrolyte.
[0019] Furthermore, the dielectric constant of the nano-tubes of the compositepolymer electrolyte of the present invention is higher than 183. By heating or electrical field treatment, the nano-tubes will be arranged in order and the dielectric constant of the compositepolymer electrolyte will be increased as to enhance the conductivity thereof by one to three orders. It will have better performance than that of the traditional polymer electrolyte. Accordingly, the resistance of device using the electrolyte will has low resistance, better electrical properties at low temperature and longer service time.
[0020] In order to make the aforementioned and other objects, features and advantages of the present invention understandable, a preferred embodiment accompanied with figures is described in detail below.
BRIEF DESCRIPTION OF DRAWINGS
[0021] [0021]FIG. 1 TEM picture of nano-particle TiO 2 .
[0022] [0022]FIG. 2 TEM picture of nano-tube TiO 2 .
[0023] [0023]FIG. 3 is a relationship between temperature and conductivity of experiments 9 and 10.
[0024] [0024]FIG. 4 is a relationship between temperature and conductivity of experiments 12, 15, 17 and 19.
DETAILED DESCRIPTION
[0025] The nano-tube composite polymer electrolyte of the present invention comprises a polymer substrate, a metal salt and a nano-tube modifier.
[0026] The polymer substrate has, for example, main-chains and side-chains, which at least have an ether group, an acyl group, an amino group, a fluoro group or a Lewis base functional group. The polymer substrate has amorphous region between the melting point thereof and a temperature. As to the polymer substrate of the present invention, it can be polyalkylene oxide, polyvinyl fluoride, polyacrylonitrile, polyester, polyether, polysulfone, polyethylene oxide, polyvinylidene fluoride, poly(methyl methacrylate) (PMMA), polysiloxane, polyphosphazene or derivates thereof. The Lewis base functional group includes oligo(oxyalkylene), flouralkyl group, fluoralkylene, carbonate group, cyano group or sulfonyl group.
[0027] The metal salt comprises a metal cation and an anion, which includes, for example, salt formed of alkaline-earth metal, alkali metal and transitional metal. The anion is, for example, ClO 4 − , S 2 O 8 2− , BF 4 − , AsF 6 − , PF 6 − and TeF 6 − . The metal salt can be, for example, LiPF 6 , LiAsF 6 , LiBF 4 , LiClO 4 , LiN(SO 2 CF 3 ) 2 , LiSbF 6 and LiSO 3 (CF 2 )nCF 3 , wherein n is 1˜12. The metal salt forms a polymer salt complex with the polymer substrate.
[0028] The nano-tube modifier can enhance the conductivity and property of the polymer electrolyte. The surface of the nano-tube modifier has functional groups OR and O. The functional group will form Lewis acid-base force with the polymer substrate and the polymer salt complex. The nano-tube modifier includes TiO 2 , SiO 2 or Al 2 O 3 with different crystal structures. The diameter of the nano-tube modifier is, for example, about from 50 nm to about 160 nm. The aspect ratio (length/width) of the nano-tube modifier is higher than 8. Because the total surface area of the nano-tube modifier is larger than that of a nano-particle and the nano-tube modifier is hollow, the metal cations can go through or be temporarily stored therein.
[0029] The nano-tube composite polymer electrolyte of the present invention comprises the polymer substrate about from 30% to about 90% by weight; the metal salt about from 2% to about 30% by weight; and the nano-tube modifier about from 3% to about 30% by weight. It also can comprise the polymer substrate about from 60% to about 90% by weight; the metal salt about from 2% to about 50% by weight; and the nano-tube modifier about from 1% to about 20% by weight. Moreover, the weight-average molecular weight of the polymer substrate should be high enough to establish free standing film. This character can vary from polymer to polymer but typically it varies from about 1000 to about 1,000,000.
[0030] The nano-tube composite polymer electrolyte of the present invention comprises the polymer substrate, the metal salt and the nano-tube modifier. The enhancement of the conductivity of the polymer electrolyte results from the dissociation of the metal salt at the disordered area of the polymer substrate. Under the interaction between the ions and atoms of the polymer, the ions diffuses within the polymer following the direction of the magnetic filed for conduction.
[0031] Moreover, because of the addition of the nano-tube modifier into the composite polymer electrolyte, the nano-tube composite polymer electrolyte of the present invention exhibits better mechanical and process properties than those composites with ordinary nano particles. The conductivity of the nano-tube composite polymer electrolyte can be improved under room temperature. Because the interaction force formed by the nano-tubes with metal salt is larger than that formed by nano particles, the dissociation of the metal salt is enhanced and the space for Li ions is also increased. Therefore, the conductivity is enhanced.
[0032] Additionally, the nano-tube modifier added into the composite polymer electrolyte of the present invention enhances the dissociation of the metal salt. The ionized Li ions enter the crystal structure of the polymer substrate for forming a complex having a structure similar thereto and reducing the crystallization thereof. Therefore, the free space of the solid-state composite polymer electrolyte is increased and the dissociated metal salt goes into the hollow structure of the nano-tubes which establishes additional transporting channel for ions transport. Therefore, the conductivity of the nano-tube composite polymer electrolyte is better than that of composite polymer electrolyte with nano particles.
[0033] Moreover, when the solid-state composite polymer electrolyte film of the present invention is applied to an electrochemical cell, the composite polymer electrolyte film made of the polymer substrate, the metal salt and the nano-tube modifier can improve the isolation between electrodes and avoid electrode shortage resulting from the contact of dendrimers of the electrodes.
[0034] In addition, adding the nano-tube modifier into the composite polymer electrolyte not only improves the mechanical property thereof, but also enhances the dissociation of the metal salt as to improve the conductivity of the Li ions of the electrolyte.
[0035] The method for fabricating a nano-tube composite polymer electrolyte of the present invention comprises: mixing a nano-tube modifier and an anhydrous solvent, adding metal salt into the solution and then adding a polymer substrate therein; heating and completely stirring the mixed solution for generating a uniform polymer electrolyte; and coating the uniform polymer electrolyte on a plate electrode, a container or a surface of an object and removing the solvent for forming a polymer electrolyte film.
[0036] In the method for fabricating a nano-tube composite polymer electrolyte of the present invention, the anhydrous solvent can be, for example, tetrahydrofuran (THF) having a dielectric constant higher than 20. Other solvents with suitable solubility also served the purpose. During the step of stirring, it is performed with the assist of microwave or ultrasonic for completely mixing. After forming the polymer electrolyte film, an electrical field treatment is performed at a temperature higher than a Tg of the polymer and cooling down to room temperature for enhancing the conductivity thereof. The electrical field of the electrical filed treatment is from about 200 to about 10,000 V/cm, and the process time is from about 1 hr to about 90 hrs.
[0037] The method for fabricating a nano-tube TiO 2 of the present invention first forming nano-particle TiO 2 by Sol-Gel. A base refinement, such as using NaOH as a refiner, for forming nano-tube TiO 2 , wherein the temperature of the base refinement is from about 100° C. to about 300° C. and the heating time is from about 1 hr to about 50 hrs. When the refinement is done, the rate of the cooling down step is from about 30° C./hr to about 50° C./hr and it is cooled down to room temperature. This method is more simple and convenient than the traditional method for preparing the nano-tubes. The present invention uses a strong base solution, such as 10M NaOH solution, to break down the bonds of TiO 2 for forming Ti—O—Na and Ti—OH. At this moment, the nano-particles have a multilayer structure. An acid solution, such as HCl solution, is then used for reforming the bonds of TiO 2 . Finally, pillar type and hollow nano-tube TiO 2 is formed.
[0038] Following are the descriptions of the method for fabricating the nano-tube TiO 2 , the nano-tube composite polymer electrolyte and the fabrication method thereof.
[0039] This embodiment is the method for fabricating the nano-tube TiO 2 . First, nano-particle TiO 2 is formed by Sol-Gel preparation method. Then, the crystal structure of the particles, anatase, is identified by XRD. TEM serves to find out the shape, particle size and distribution thereof. FIG. 1 shows the nano-particles exists in chain. The nano-particle TiO 2 is oval and about 20˜50 nm.
[0040] Then, a base refinement method is performed for forming nano-tube TiO 2 . First, TiO 2 and a 10 M NaOH solution having 100 times volume of the TiO 2 are provided in a Teflon cup. It is preferred that the volume ratio of the NaOH solution to the TiO 2 is more than 200. They are stirred for an hour and then put into an auctoclave for baking 1˜50 hrs at 100˜300° C. When the reaction is complete, the rate of the cooling down step is from about 30° C./hr to about 50° C./hr and it is cooled down to room temperature. White powder sediments appear within the solution.
[0041] The powder is extracted by using a centrifuge. A 1N HCl solution is mixed with the powder, and the powder is then extracted again. The process is repeated for several times. De-ionized water is used to wash the powder until the PH of the solution is near to 7. The oval nano-particle TiO 2 transforms into hollow nano-tubes. The nano-tube TiO 2 is then dried at temperature lower than 50° C.
[0042] XRD is then used to identify the structure of the nano-tube TiO 2 , wherein the structure includes anatase and rutile. When the 10 M NaOH solution is added to the TiO 2 , the structure of the TiO 2 changes and is a disordered structure. When the 1N HCl solution is added thereto, the nano-tube TiO 2 is formed.
[0043] Then, the nano-tube TiO 2 is put into a solvent and shook by ultrasonic for avoiding clusters resulting because of the interaction of surface charges. The particle size, shape and distribution are found out by TEM as shown in FIG. 2. The arrangement of the nano-tube TiO 2 is disordered, and the shape is changed from particles into hollow tubes, which have a length/width ratio of about 8. The dimension and aspect ratio of the tube can be tailored by changing the reaction concentrations and growth temperature and pressure.
[0044] The following embodiment is the method for forming the polymer electrolyte. An anhydrous solution, such as THF, having a dielectric constant larger than 20 is added to the nano-tube TiO 2 , and shook the solution for about 40˜50 minutes for uniformly mixing the nano-tube TiO 2 therein. LiClO 4 is then added into the solution and stirred until full dissolution. A portion of LiClO 4 goes into the nano-tube TiO 2 . A PEO polymer with specific ration to Li is added into the solution for forming the polymer electrolyte. Then the solution is heated and stirred at 65˜75° C. for about 20˜24 hrs. PEO will completely dissolve therein. The polymer electrolyte is then put into a Teflon dish or Petri-dish and most of the solvent is removed at 40˜60° C. In order to make sure the removal of the solvent and water, the polymer electrolyte film is kept in a vacuum baker for 3˜7 days. Then the solid-state polymer electrolyte film is kept under Ar environment for measuring the conductivity thereof.
[0045] Following are the experiments 1˜19 for interpreting the properties of the polymer electrolyte of the present invention according to different processes.
[0046] In experiments 1˜7, PEO is added into nano-particle TiO 2 or nano-tube TiO 2 . A solvent, THF, is added into different types of TiO 2 powder and shook by sonication for 40˜50 minutes. POE with a specific ratio is added thereto, and heated and stirred at 60° C. for about 20˜24 hrs. The solvent is then removed by using a vacuum baker for forming a polymer film with thickness 20˜400 μm. Thin film is kept in vacuum for 2˜3 days and then under Ar environment.
[0047] In experiments 8˜19, PEO and LiClO 4 are added into nano-particle TiO 2 or nano-tube TiO 2 . A solvent, THF, is added into different types of TiO 2 powder and shook by ultrasonic for 40˜50 minutes. LiClO 4 with a specific ratio is added thereto and stirred for about 10 minutes. POE with a specific ratio is added thereto, and heated and stirred at 60° C. for about 20˜24 hrs for full dissolution. The solution is then poured into a Teflon dish or Petri-dish. The solvent is then removed by using a vacuum baker for forming a polymer film with thickness 20˜400 μm. Thin film is kept in vacuum for 2˜3 days and then under Ar environment.
[0048] The compositions of the experiments 1˜19 are shown in Table 1. The crystallization and appearance of the polymer electrolyte of the experiments 1˜19 are summarized in Table 2. The polymer electrolyte films of the experiments 1˜19 are processed by a 1000V/cm electrical field at 80° C., and cooled down to room temperature. The changes of the conductivity and surface appearance of the films are shown in Table 3.
[0049] Following are the results of the experiments 1˜19. By TEM, the size of the nano-particle TiO 2 is about 20˜50 nm. The nano-tube TiO 2 processed by the NaOH solution bears a length of about about 100˜160 nm. In experiments 1˜7, PEO generates different crystallizations depending on different nano TiO 2 . When PEO is added to nano-particle TiO 2 or nano-tube TiO 2 which have the same ratio, the nano-tube TiO 2 destroys the crystallization of the polymer more efficiently than nano-particle TiO 2 . Therefore, a more elastic and uniform polymer film is formed. As shown in Table 3, by thermal and electrical treatments the dielectric constant and conductivity of the polymer film is increased because charges affect the nano-tube TiO 2 without changing the appearance and mechanical properties thereof.
[0050] In experiments 8˜19, the comparison of adding PEO and LiClO 4 into nano-particle TiO 2 or nano-tube TiO 2 is presented. When the ratio of LiClO 4 is less than 18%, the ionized LiClO 4 will not affect the crystallization of the polymer seriously. When the ratio of LiClO 4 is larger than 18%, the crystallization of PEO is totally destroyed and the electrolyte film will have bad mechanical properties. Then the nano-tube TiO 2 strengthens the mechanical properties of the film which can be performed by 3% nano-tube TiO 2 .
[0051] [0051]FIG. 3 is a relationship between temperature and conductivity of experiments 9 and 10 . FIG. 3 demonstrated that the nano-tube TiO 2 faciliated the storage and transmission of Li ions. At room temperature, they displayed similar results: 2.2×10 −6 S/cm for experiment 9 and 2.0×10 −6 S/cm for experiment 10. When temperature is up, the crystallization of the polymer electrolyte film is down and the mobility of Li ions is enhanced. Therefore, when the temperature is higher than the melting point of the polymer electrolyte, the conductivity will increase. The increase of the ion conductivity is more pronounced for the nano-tube TiO 2 composite polymer electrolyte because the electrical field applied thereto arranges nano-tubes in order and enhances couple effect, which improves the dielectric constant thereof. Under high temperature, Li ions stored in the nano-tube TiO 2 will move out and result in the increase of the dissociation of the metal salt. When the polymer electrolyte is cooled down to room temperature, the conductivity is enhanced. Accordingly, the conductivity of the polymer electrolyte with nano-tube TiO 2 as shown in experiment 10 is increased to 4.5×10 −5 S/cm; the conductivity of the polymer electrolyte with nano-particle TiO 2 as shown in experiment 9 is increased to 1.2×10 −5 S/cm. The similar results appear in experiments 12 and 17 which are polymer electrolyte with 5% nano-tube TiO 2 by weight. Invariably, better conductivity increase is found for those polymer electrolyte with nano-tube TiO 2 . After the treatment, the conductivity occurs in the range of 10 −4 S/cm. FIG. 4 is a relationship between temperature and conductivity of experiments 12, 15, 17 and 19. In FIG. 4, the conductivities of the electrolytes with different ratios of Li salt added with nano-tube TiO 2 can generate similar improvement. 3% nano-tube TiO 2 can make obvious improvement. Under 1000V/cm electrical field and at 80° C., they have the results similar to those measured by the variable temperature measurement. The best improvement of conductivity is over 20%. When the polymer electrolyte film is cooled down to room temperature, its mechanical properties can be recovered and the resistance thereof is also reduced because of the rearrangement of the nano-tubes. The devices using the electrolyte film can have long service time.
[0052] The nano-tubes of the composite polymer electrolyte of present invention are formed by a base treatment. During the process for fabricating the composite polymer electrolyte, the high uniformity and high particle dispersion is achieved by using ultrasonic. The nano-tubes of the solid-state composite polymer electrolyte, the metal salt, the Lewis base functional group form a complex which can improve the disordered area ratio of the polymer substrate, enhance the dissociation of the metal salt and increase the conductivity thereof.
[0053] Moreover, the dielectric constant of the nano-tubes of the composite polymer electrolyte of the present invention is higher than 183. By heating or electrical field treatment, the nano-tubes will be arranged in long range order and the dielectric constant of the composite polymer electrolyte will be increased as to enhance the conductivity thereof by one to three orders. It will have better performance than that of the traditional composite polymer electrolyte. Accordingly, the resistance of device using the electrolyte low resistance, better electrical properties at low temperature and longer service time.
TABLE 1 w % Nano- Nano- tube particle mmole ratio TiO 2 TiO 2 PEO LiClO 4 TiO 2 PEO LiClO 4 Experiment 0 0 100 0 0 5 0 1 Experiment 0 3 100 0 37.5 5 0 2 Experiment 3 0 100 0 37.5 5 0 3 Experiment 0 5 100 0 62.6 5 0 4 Experiment 5 0 100 0 62.6 5 0 5 Experiment 0 10 100 0 125.2 5 0 6 Experiment 10 0 100 0 125.2 5 0 7 Experiment 0 0 90 10 0 5 104.3 8 Experiment 0 3 90 10 41.7 5 104.3 9 Experiment 3 0 90 10 41.7 5 104.3 10 Experiment 0 5 90 10 69.5 5 104.3 11 Experiment 5 0 90 10 69.5 5 104.3 12 Experiment 0 0 82 18 0 5 206.1 13 Experiment 0 3 82 18 45.8 5 206.1 14 Experiment 3 0 82 18 45.8 5 206.1 15 Experiment 0 5 82 18 76.3 5 206.1 16 Experiment 5 0 82 18 76.3 5 206.1 17 Experiment 0 0 80 20 0 5 234.7 18 Experiment 3 0 80 20 46.9 5 234.7 19
[0054] [0054] TABLE 2 Enthalpy Crystallization (j/g) (%) Appearance Experiment1 134 100 translucent, tough, little-hard film Experiment2 130 97 low-transparent, soil, elastic film Experiment3 119 89 low-transparent, soft, elastic film Experiment4 103 77 low-transparent, soft, elastic film Experiment5 85 63 low-transparent, soft, elastic film Experiment6 68 51 low-transparent, soft, elastic film Experiment7 54 40 low-transparent, soft, elastic film Experiment8 72 54 translucent, soft, elastic film Experiment9 63 47 light-white, soft, elastic film Experiment10 70 52 light-white, soft, elastic film Experiment11 59 44 light-white, soft, elastic film Experiment12 62 46 light-white, soft, elastic film Experiment13 0 0 opaque, soft, fragile film Experiment14 0 0 white, soft, elastic film Experiment15 0 0 white, soft, elastic film Experiment16 0 0 white, soft, elastic film Experiment17 0 0 white, soft, elastic film Experiment18 0 0 opaque, soft, fragile film Experiment19 0 0 white, soft, elastic film
[0055] [0055] TABLE 3 Conductivity Conductivity at after thermal R.T. treatment Appearance after (S/cm) (S/cm) thermal treatment Experiment1 2.96 × 10 −10 3.5 × 10 −10 translucent, tough, little- hard film Experiment2 3.2 × 10 −8 6.8 × 10 −8 low-transparent, soft, elastic film Experiment3 9.3 × 10 −8 3.6 × 10 −7 low-transparent, soft, elastic film Experiment4 8.5 × 10 −8 1.3 × 10 −7 low-transparent, soft, elastic film Experiment5 9.7 × 10 −8 2.7 × 10 −7 low-transparent, soft, elastic film Experiment6 2.7 × 10 −7 4.9 × 10 −7 low-transparent, soft, elastic film Experiment7 7.2 × 10 −7 6.6 × 10 −7 low-transparent, soft, elastic film Experiment8 3.0 × 10 −6 8.2 × 10 −6 translucent, tough, little- hard film Experiment9 2.2 × 10 −6 1.2 × 10 −5 light-white, soft, elastic film Experiment10 2.0 × 10 −6 4.5 × 10 −5 light-white, soft, elastic film Experiment11 6.3 × 10 −6 2.1 × 10 −5 light-white, soft, elastic film Experiment12 5.4 × 10 −6 5.3 × 10 −5 light-white, soft, elastic film Experiment13 1.2 × 10 −5 6.8 × 10 −5 opaque, soft, fragile film Experiment14 1.6 × 10 −5 0.5 × 10 −4 white, soft, elastic film Experiment15 1.7 × 10 −5 2.4 × 10 −4 white, soft, elastic film Experiment16 1.3 × 10 −5 0.7 × 10 −4 white, soft, elastic film Experiment17 1.1 × 10 −5 2.7 × 10 −4 white, soft, elastic film Experiment18 4.3 × 10 −5 7.4 × 10 −5 opaque, soft, fragile film Experiment19 4.7 × 10 −5 2.9 × 10 −5 white, soil, elastic film
[0056] Although the present invention has been demonstrated by exemplary embodiments, it is not limited thereto by these experiments. Rather, the appended claims should be constructed broadly to include other variants and embodiments of the invention, which may be made by those skilled in the field of this art without departing from the scope and range of equivalents of the invention. | This invention pertains to the composition and method for fabricating nano-tube compositepolymer electrolyte. The composite polymer electrolyte is made by blending suitable amount of highly dispersed, nano-tube, such as titanium dioxide (TiO 2 ), with highly amorphous polymer electrolyte, such as polyethylene oxide. The hollow nano-tube structure facilitates salt dissociation, serves temporarily storage for lithium ions, creates new conducting mechanism and improves the conductivity thereof. The subsequent thermal treatment and high electric field arrange the nano-tubes in order for increase of the dielectric constant thereof, which increased ion mobility at room temperature. The mechanical properties are also improved due to the physical cross-linking of the nano-tubes, suitable for industrial processing. | 8 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to an information recording/reproducing apparatus, and more particularly to an audio apparatus for automatically reproducing or playing back music and automatically recording the music reproduced in a storage device when an information recording medium storing music information recorded is loaded into a reproducing device for reproducing it.
[0003] 2. Description of the Related Art
[0004] An audio apparatus such as an in-vehicle audio apparatus has a storage-medium reproducing device such as a CD player, so that a user can enjoy the music reproduced or played back by the reproducing device. The audio apparatus also has a hard disk (hereinafter referred to as HD) with a large capacity of e.g. several tens G (giga) bytes and a hard disk drive (HDD) for driving HD, so that the user can enjoy any selected music program reproduced by a music reproducing system from the HD in which a large number of recording media such as CDs are copied (see JP-A-2000-207845).
[0005] According to such an audio apparatus, if contents of a large number of recording media, e.g. CD have been previously recorded in a built-in HD, a preferred piece of music read from among programmed pieces of music contained in a large number of CDs can be enjoyed with no loading/unloading thereof. Particularly, from the viewpoint of safety driving, this is preferred in an in-vehicle audio apparatus, which is mostly operated during driving because copying in HD makes it unnecessary to load/unload a recording medium such as CD.
[0006] In this way, in the in-vehicle apparatus, contents of a large number of CDs are often used in a form recorded in a storage device such as HD. Some audio apparatus, therefore, have been also proposed in which the reproducing/recording of CD is automatically started when CD is loaded into a reproducing device.
SUMMARY OF THE INVENTION
[0007] When the recording/reproducing of the recording medium is automatically started when the recording medium is loaded into the reproducing device, audio of the recording medium is not output from a reproducing system. For this reason, a user may forget recording and eject the recording medium. This gives rise to a problem that the recording medium will be ejected without completing recording.
[0008] Further, in the case of the audio apparatus appended to a car navigation device, when the operation/display panel of the car navigation device is opened, the recording medium such as CD is ejected. Therefore, when the user forgets that recording is being automatically performed and opens the operation display panel, a problem likewise occurs that the recording medium will be ejected without completing the recording.
[0009] Further, if music is not output from the recording system during automated recording as described above, the user does not notice that sound skip has occurred. Therefore recording will be completed in sound-skipped state. In this case, it is possible to detect the sound-skip and automatically perform re-recording. This, however, leads to a problem that the recording time will be lengthened without the user's noticing. Another problem will occur in the automated recording that if the user is not seeing the display panel, he/she cannot know when the recording has been completed.
[0010] Further, it is also possible to output music being reproduced during the automated recording. However, the user, who often records content of a recording medium such as CD into a built-in HD in advance and enjoys his/her preferable programmed music from the built-in HD, may carry out automated recording while he/she listens to broadcasting from a tuner. In such a case, simultaneously when the recording operation is started, the recording medium is reproduced and the reproduced audio is produced. After completion of the recording, therefore, it is necessary for a user to return the source of audio output from a speaker to the state where the recording medium has been loaded. This is very troublesome.
[0011] The invention has been made in view of the problems described above. An object of the invention is to provide an information recording/reproducing apparatus capable of preventing a recording medium from being ejected during automated recording of the recording medium and saving a user's labor during the automated recording.
[0012] In order to achieve the above-described object, an information recording/reproducing apparatus (1) includes a reproduction unit, an operation unit, a storage unit, and a control unit. The reproduction unit reads information recorded in a recording medium. The operation unit instructs the reproduction unit to eject the recording medium. The storage unit stores the information read by the reproduction unit therein. When the recording medium is loaded into the reproduction unit, the control unit controls the reproduction unit to read the information and controls the storage unit to store the information read by the reproduction unit therein automatically. When the operation unit instructs the reproduction unit to eject the recording medium during the storage unit being storing the information read, the control unit informs a user that the storage unit is storing the information read.
[0013] In addition to (1), in an information recording/reproducing apparatus (2), when the operation unit instructs the reproduction unit to eject the recording medium during the storage unit being storing the information read, the control unit displays time to storage completion on a display.
[0014] In addition to (1), in an information recording/reproducing apparatus (3), when the operation unit instructs the reproduction unit to eject the recording medium during the storage unit being storing the information read, the control unit displays attribute information of the information, which has been stored in the storage unit, on a display.
[0015] An information recording/reproducing apparatus (4) includes an operation/display panel, a reproduction unit, a storage unit, and a control unit. A recording medium is lodable into the reproduction unit, when the operation/display panel is opened. The reproduction unit reads information recorded in the recording medium. The storage unit stores the information read by the reproduction unit. When the recording medium is loaded into the reproduction unit, the control unit controls there production unit to read the information and controls the storage unit to store the information read therein automatically. When an opening operation of the operation/display panel is performed during the storage unit being storing the information read, the control unit informs a user that the storage unit is storing the information read.
[0016] In addition to (4), in an information recording/reproducing apparatus (5), when the opening operation of the operation/display panel is performed during the storage unit being storing the information read, the control unit displays time to storage completion on a display.
[0017] In addition to (4), in an information recording/reproducing apparatus (6), when the opening operation of the operation/display panel is performed during the storage unit being storing the information read, the control unit displays attribute information of the information, which has been stored in the storage unit, on a display.
[0018] In addition to any one of (1)-(6), in an information recording/reproducing apparatus (7), when the storage unit completes the storing of the information read, the control unit ejects the recording medium from the reproduction unit automatically.
[0019] In addition to any one of (1)-(6), in an information recording/reproducing apparatus (8), when an error occurs during the storage unit being storing the information read, the control unit notifies the occurrence of the error.
[0020] An information recording/reproducing apparatus (9) includes a reproduction unit, a storage unit, an audio output unit, a control unit, and a reception unit. The reproduction unit reads information recoded in a recording medium. The storage unit stores the information read by the reproduction unit therein. The audio output unit outputs audio. The reception unit receives external information from external. When the recording medium is loaded into the reproduction unit, the control unit controls the reproduction unit to read the information and controls the storage unit to store the information read therein automatically. The audio output unit is able to output the external information received. When the recording medium is loaded into the reproduction unit and the audio output unit outputs audio other than the information recorded in the recording medium, the control unit controls the storage unit to begin storing the information read without changing the audio output from the audio output unit.
[0021] An information recording/reproducing apparatus (10) includes a reproduction unit, a storage unit, an audio output unit, a control unit, a reception unit, and a selection unit. The reproduction unit reads information recorded in a recording medium. The storage unit stores the information read by the reproduction unit therein. The audio output unit outputs audio. The reception unit receives external information from external. When the recording medium is loaded into the reproduction unit, the control unit controls the reproduction unit to read the information and controls the storage unit to store the information read therein automatically. The audio output unit is able to output the external information received. The selection unit selects one of: (a) a first mode in which when the recording medium is loaded into the reproduction unit and the audio output unit outputs audio other than the information recorded in the recording medium, the control unit controls the storage unit to begin storing the information read without changing the audio output from the audio output unit; and (b) a second mode in which when the recording medium is loaded into the reproduction unit and the audio output unit outputs audio other than the information recorded in the recording medium, the control unit changes the audio output from the audio output unit to the information read.
[0022] According to the information recording/reproducing apparatus (1), when the operation unit instructs the reproduction unit to eject the recording medium during the storage unit being storing the information read, the control unit informs a user that the storage unit is storing the information read. Therefore, even if a user erroneously performs the operation of ejecting the recording medium, the user recognizes that the information is being stored, thereby continuing the storage. For example, if the user sees a display during the automated recording, it can be prevented that the user erroneously instructs to eject the recording medium.
[0023] According to the information recording/reproducing apparatus (2) or (3), when the operation unit instructs the reproduction unit to eject the recording medium during the storage unit being storing the information read, the control unit displays time to storage completion or attribute information of the information, which has been stored in the storage unit, on a display. Therefore, a user can know the remaining time until completion of the storage at that time or e.g. song names of music storage-completed.
[0024] According to the information recording/reproducing apparatus (4) to (6), likewise as described above, when an opening operation of the operation/display panel is performed during the storage unit being storing the information read, the control unit: informs a user that the storage unit is storing the information read; displays time to storage completion on the display; or displays attribute information of the information, which has been stored in the storage unit, on the display. Therefore, even if a user erroneously performs the operation of opening the operation/display panel, the user can recognize that the information is being stored and know e.g. song names of the music storage-completed at that time.
[0025] According to the information recording/reproducing apparatus (7), when the storage unit completes the storing of the information read, the control unit ejects the recording medium from the reproduction unit automatically. This saves the labor of the operation by the user.
[0026] According to the information recording/reproducing apparatus (8), when an error occurs during the storage unit being storing the information read, the control unit notifies the occurrence of the error. Therefore, the user can select whether the storage should be interrupted or the storage should be continued.
[0027] According to the information recording/reproducing apparatus (9), when the recording medium is loaded into the reproduction unit and the audio output unit outputs audio other than the information recorded in the recording medium, the control unit controls the storage unit to begin storing the information read without changing the audio output from the audio output unit. Therefore, for example, even when the storage is performed while the user listens to broadcasting from a tuner, the user can continuously listen the broadcasting of the tuner without performing the operation of changing the audio output.
[0028] According to the information recording/reproducing apparatus (10), the selection unit selects one of: (a) a first mode in which when the recording medium is loaded into the reproduction unit and the audio output unit outputs audio other than the information recorded in the recording medium, the control unit controls the storage unit to begin storing the information read without changing the audio output from the audio output unit; and (b) a second mode in which when the recording medium is loaded into the reproduction unit and the audio output unit outputs audio other than the information recorded in the recording medium, the control unit changes the audio output from the audio output unit to the information read. Therefore, the audio to be output during the storage can be previously set according to a user's request, so that the operation during the storage can be simplified.
BRIEF DESCRIPTION OF THE DRAWINGS
[0029] FIG. 1 is an appearance view of a car navigation device according to an embodiment of the invention.
[0030] FIG. 2 is a schematic diagram showing the configuration of a control system of the car navigation device.
[0031] FIG. 3 is a flowchart showing an operation when music information recorded in CD is automatically recorded in HD.
[0032] FIG. 4 is a view showing an example of display of recording not-completed.
[0033] FIG. 5 is a view showing an example of display of occurrence of sound skip.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0034] Now referring to the drawings, an explanation will be given on an audio apparatus according to the invention with taking an embodiment where the invention is applied to a car navigation device. FIG. 1 is an appearance view of the car navigation device. As seen from FIG. 1 , an operation/display panel 2 is provided on the front face of an device body 1 . At the center of the operation/display panel 2 , an LCD display portion is arranged. On the periphery thereof, plural operation keys 4 are provided.
[0035] When opening the operation/display panel 2 is designated through the pertinent operation key 4 or a touch panel of the LCD display portion 3 , the operation/display panel 2 descends with rotating. Then, a recording medium insertion portion (not shown) of a CD player or MD player appears so that the recording medium can be inserted thereinto.
[0036] FIG. 2 is a schematic diagram showing the configuration of a control system of the car navigation device. In FIG. 2 , only audio-related portions are shown. As seen from FIG. 2 , the audio-related portions of the car navigation device include a CPU 11 , a ROM (Read Only Memory) 12 , a RAM (Random Access Memory) 13 , a HDD 14 , an encoder 15 , a decoder 16 , a CD-ROM drive 17 , an MD drive 18 , a tuner 19 , a selector 20 , an amplifier (AMP) 21 , a speaker 22 , a display portion 23 , a display controller 24 , an entry portion 25 , a graphic controller 26 and a graphic memory 27 . These elements are connected to one another through a bus 28 .
[0037] The CPU 11 controls the respective hardware portions of the car navigation device through the bus 28 and executes various programs on the basis of programs stored in the ROM 12 . The ROM 12 previously stores the various programs necessary for the operation of the car navigation device. The RAM 13 may be e.g. an SRAM, which stores temporary data generated during execution of the programs.
[0038] The HDD 14 drives HD that is a storage medium for storing music recorded in a recording medium such as CD. The encoder 15 compresses a signal supplied from the recording medium such as CD, and the compressed signal is stored in the HD. The decoder 16 decodes the signal read from the HD, and then the decoded signal is output. Further, the CD-ROM drive 17 /MD drive 18 reproduces and outputs music information recorded in the CD/MD. The tuner 19 receives and outputs audio broadcasting such as FM, AM and a television broadcasting. The selector 20 selects audio to be output from the speaker 22 . Under the control by the CPU 11 , the selector 20 selects one of: (a) read-output of the HDD 14 ; (b) output of the CD-ROM drive 17 ; (c) output of the MD drive 18 ; and (d) output of the tuner 19 to output the selected one to the AMP 21 . Then, the selected audio is output from the speaker 22 .
[0039] The display portion 23 displays a map, the operating status of the car navigation device, or operation screens for various functions. The display portion 23 includes a large-scale LCD display portion (large-sized display screen) 3 provided on the operation/display panel 2 shown in FIG. 1 , and is controlled by the display controller 24 . A touch panel switch is provided on the LCD display portion 3 . When an item segment displayed on the LCD display portion 3 is depressed, the corresponding item can be selected or the corresponding function can be executed. The entry portion 25 includes the operation keys 4 provided on the operation/display panel 2 and the touch panel on the LCD display portion 3 .
[0040] The CPU 11 controls the graphic controller 26 . The graphic controller 26 reads out content displayed on the display portion 23 from the graphic memory 27 , and sends the contents read to the display controller 24 .
[0041] The audio apparatus of this car navigation device has an automated recording function that when a CD is loaded in the CD-ROM drive 17 , the CD is automatically reproduced and the reproduced output is automatically stored in the HD by the HDD 14 through the encoder 15 . Further, the audio apparatus is configured so that an operation mode of the output produced from the speaker 22 during the automated recording can be set. Specifically, the audio apparatus can select: mode 1 in which the automated recording is started without changing audio being output from the speaker 22 at the time of loading CD, e.g. broadcast output from the tuner 19 ; or mode 2 in which the automated recording is started with changing audio being output from the speaker 22 to the reproduction output of the CD-ROM drive 17 . At the time of the mode selection, a user makes the LCD display portion 3 display a menu thereon and select audio output mode setting with using the operation keys 4 . By depressing “mode 1 ” or “mode 2 ” displayed on the screen of the audio output mode setting at the LCD display portion 3 , either mode can be set. The output operation mode set by a user can be stored in the RAM 13 .
[0042] Referring to the flowchart of FIG. 3 , an explanation will be given on an operation when music information recorded in CD is automatically recorded in the HD. Incidentally, this operation is performed under the control of the CPU 11 on the basis of the program stored in the ROM 12 .
[0043] In the case of automated recording, when a user designates the opening of the operation/display panel 2 from the operation keys 4 or touch panel on the LCD display portion 3 , the operation/display panel 2 descends with rotating. Then, the recording medium insertion portion of the CD-ROM drive 17 /the MD drive 18 appears. In this state, when a user loads CD in CD loading portion (the recording medium insertion portion) of the CD-ROM drive 17 , the CPU 11 initiates a program shown in the flowchart of FIG. 3 .
[0044] When CD is loaded, the CPU 11 closes the operation/display panel 2 and thereafter starts the reproduction of the CD by the CD-ROM drive 17 . The music information reproduced by the CD-ROM drive 17 is automatically recorded in the HD by the HDD 14 through the encoder 15 (step 101 ). Next, the CPU 11 determines whether or not the audio output mode (output operation mode), which is set by a user and stored in the RAM 13 , is the mode 2 (step 102 ). If the audio output mode is the mode 1 , audio being output from the speaker 22 at this time, e.g. broadcast output from the tuner 19 is continuously output as it is. On the other hand, if the audio output mode (output operation mode) set by the user is the mode 2 , the CPU 11 reproduces the music information recorded in the HD by the HDD 14 and also controls the selector 20 so that the output from the selector 20 is changed into the output from the decoder 16 (Step 103 ). Thus, the music information is automatically recorded in the HD and simultaneously, the music information stored therein is read and supplied to the speaker 22 through the decoder 16 , selector 20 and AMP 21 . In this way, the music recorded in the CD output from the speaker 22 .
[0045] Next, the CPU 11 controls the graphic controller 26 and the display controller 24 to display the output operation mode such as “CD is being reproduced”, “FM broadcasting”, etc. according to the output operation mode set as described above (step 104 ).
[0046] The CPU 11 determines whether or not a user designates the operation of ejecting the CD or the operation of opening the operation/display panel 2 through the operation keys 4 or touch panel on the LCD display portion 3 during the automated recording (step 105 ). If the ejecting operation or the panel opening operation is performed during the automated recording, the CPU 11 controls the graphic controller 26 and the display controller 24 to display message indicating that the recording is not still completed on the LCD display portion 3 as shown in FIG. 4 , thereby informing a user that the recording is now being performed (step 106 ).
[0047] On the other hand, CD previously digitally stores music signals in a programming area for each track and TOC (Table of Contents) information such as information indicating a position of each track in a lead-in area. During CD reproduction, the CPU 11 first reads and stores the TOC information in the RAM 13 . The TOC information contains numbers of respective pieces of music in the CD and their playing times. The CPU 11 , therefore, calculates the remaining playing time and the recording-completed music number when the ejecting operation is performed, thereby displaying them on the screen indicating “recording not-completed”, as shown in FIG. 4 . On this screen, the CPU 11 also displays icons “YES” and “NO” for allowing a user to select whether or not the automated recording is interrupted.
[0048] Next, the CPU 11 determines which “YES” or “NO” has been depressed on this screen (step 107 ). When a user depresses “YES” on this screen, the CPU 11 interrupts the automated recording (step 108 ), and then the operation/display panel 2 is opened and the CD is ejected (step 109 ). Thereafter, the program is terminated. When a user depresses “NO” on the screen indicating “recording not-completed”, the CPU 11 returns to step 105 , and then the automated recording is continued.
[0049] On the other hand, in step 105 , if the CPU 11 determines that the ejecting operation or the panel opening operation has not been performed, the CPU 11 further determines whether or not sound skip (data skip) has occurred (Step 110 ). The CPU 11 always checks the data number (address) of the CD data that is being reproduced by the CD-ROM drive 17 . When the data number has greatly changed, the CPU 11 determines that the sound skip has occurred. In this case, the CPU 11 controls the graphic controller 26 and the display controller 24 to display a message indicating the occurrence of the sound skip and icons for selecting the recording interruption (step 111 ).
[0050] The CPU 11 determines which icon “YES” or “NO” has been depressed on this screen (step 112 ). When a user depresses “YES” on this screen, the CPU 11 interrupts the automated recording (step 113 ), and then the operation/display panel 2 is opened and CD is ejected (step 109 ). Thereafter, the program is terminated. When a user depresses “NO” on this screen, the CPU 11 returns to step 105 .
[0051] In step 110 , if the CPU 11 determines that the sound skip has not occurred, the CPU 11 further determines whether or not the recording has been completed (step 114 ). If not completed (NO), the CPU 11 returns to step 105 . If completed (YES), the CPU 11 opens the operation/display panel 2 and ejects CD (step 109 ). Thereafter, the program is terminated.
[0052] As described above, in the case where the ejecting operation or the panel opening operation is performed during the automated recording of the music information of CD, a user is reminded that the recording is being performed. Therefore, the recording interruption against the user's will can be prevented. Also in the case where the sound skip occurs, user's attention is called. Therefore, the automated recording accompanied with sound skip can be prevented.
[0053] In the embodiment described above, the example is explained where the audio output mode for the automated recording can be selected. However, the function of selecting the audio output mode may not be given. Namely, during the automated recording, audio being output at that time can be continuously output without outputting reproduced audio of the recording medium.
[0054] In the embodiment described above, when the ejecting operation has been performed or the sound skip has occurred during the automated recording, the message for calling the user's attention is displayed on the LCD display portion 3 . However, the audio apparatus may inform the user of the fact that the recording being performed or the occurrence of the sound skip by voice.
[0055] Further, in the embodiment described above, the audio apparatus according to the invention is applied to the car navigation device. However, the invention can be applied to an ordinary audio apparatus equipped with a CD player and MD player. Further, the invention can also be applied to an audio apparatus equipped with the CD player alone or the MD player alone.
[0056] Further, in the embodiment described above, music information of CD is recorded in the HD. However, the invention can be applied to a case where music information is automatically recorded from various recording media into various storage devices other than HD. The invention can be applied to a case where information contained in a recording medium includes various information such as music and an image. | An information recording/reproducing apparatus includes a reproduction unit, an operation unit, a storage unit, and a control unit. The reproduction unit reads information recorded in a recording medium. The operation unit instructs the reproduction unit to eject the recording medium. The storage unit stores the information read by there production unit therein. When the recording medium is loaded into the reproduction unit, the control unit controls the reproduction unit to read the information and controls the storage unit to store the information read by there production unit therein automatically. When the operation unit instructs the reproduction unit to eject the recording medium during the storage unit being storing the information read, the control unit informs a user that the storage unit is storing the information read. | 6 |
TECHNICAL FIELD
[0001] The present invention relates to a method for producing an atropisomer of a pyrrole derivative having excellent mineralocorticoid receptor antagonistic activity, and a production intermediate thereof.
BACKGROUND ART
[0002] A mineralocorticoid receptor (MR) (aldosterone receptor) is known to play an important role in regulating electrolyte balance and blood pressure in the body, and MR antagonists having a steroidal structure such as spironolactone and eplerenone are known to be useful for the treatment of hypertension and heart failure.
[0003] 1-(2-Hydroxyethyl)-4-methyl-N-[4-(methylsulfonyl)-phenyl]-5-[2-(trifluoromethyl)phenyl]-1H-pyrrole-3-carboxamide, which is a pyrrole derivative, is disclosed in PTL 1. Further, an atropisomer thereof is disclosed in PTL 2 and is known to be useful for the treatment of hypertension, diabetic nephropathy, and the like.
CITATION LIST
Patent Literature
[0004] PTL 1: WO 2006/012642 (US Patent Application No. US 2008-0234270)
[0005] PTL 2: WO 2008/126831 (US Patent Application No. US 2010-0093826)
SUMMARY OF INVENTION
Technical Problem
[0006] Substances to be used for pharmaceutical products are required to have particularly strictly high purity so as not to cause unpredicted side effects (for example, toxicity, etc.) due to their impurities. Further, in their industrial production methods (mass production methods), impurities are required to be removed by simpler operations.
[0007] In addition, it is important that pharmaceutical drug substances or production intermediates can be stored for long periods of time while maintaining their quality. In the case where it is necessary to store such substances under low temperature conditions, a large-scale refrigeration facility is needed for maintaining quality, and therefore, it is industrially meaningful to find stable crystals which can be stored at room temperature or higher.
[0008] Under such circumstances, the present inventors made intensive studies for developing a method for producing (S)-1-(2-hydroxyethyl)-4-methyl-N-[4-(methylsulfonyl)-phenyl]-5-[2-(trifluoromethyl)phenyl]-1H-pyrrole-3-carboxamide (hereinafter sometimes referred to as “Compound A)”), which is an atropisomer of a pyrrole derivative having excellent MR antagonistic activity, with higher quality in higher yield by using a more industrially advantageous operation method with lower environmental impact. As a result, they found a method for efficiently resolving an atropisomer of a novel synthetic intermediate, and based on this finding, they established a method for producing an atropisomer of a pyrrole derivative with high quality in high yield by using an industrially advantageous operation, and thus completed the present invention.
Solution to Problem
[0009] The present inventors intensively studied a production intermediate of an atropisomer of 1-(2-hydroxyethyl)-4-methyl-N-[4-(methylsulfonyl)phenyl]-5-[2-(trifluoro-methyl)phenyl]-1H-pyrrole-3-carboxamide, which is a pyrrole derivative having excellent mineralocorticoid receptor antagonistic activity, and an efficient method for producing the same so as to improve solubility, purity, stability, and the like for enhancing the medical usefulness of the atropisomer of the pyrrole derivative.
[0010] Hereinafter, the present invention will be described in detail.
[0011] The present invention is directed to:
[0012] (1) a pyrrole compound represented by the following formula (B):
[0000]
[0000] [wherein R 1 represents a C1-C4 alkyl group, and R 2 represents a 2-hydroxyethyl group or a carboxymethyl group];
[0013] (1-2) the pyrrole compound according to the above (1), wherein R 1 is an ethyl group;
[0014] (1-3) the pyrrole compound according to the above (1), wherein R 2 is a 2-hydroxyethyl group;
[0015] (1-4) the pyrrole compound according to the above (1), wherein R 2 is a carboxymethyl group;
[0016] (1-5) (S)-2-[4-ethoxycarbonyl-3-methyl-2-[2-(trifluoromethyl)phenyl]-1H-pyrrol-1-yl]acetic acid;
[0017] (2) ethyl (S)-1-(2-hydroxyethyl)-4-methyl-5-[2-(trifluoromethyl)phenyl]-1H-pyrrole-3-carboxylate represented by the following formula (Ia):
[0000]
[0018] (3) a method for producing a compound represented by the following formula (Ib):
[0000]
[0000] [wherein R 1 represents a C1-C4 alkyl group], characterized by resolving an atropisomer of the following formula (IB):
[0000]
[0000] in a solvent in the presence of an acyl donor using one enzyme selected from a lipase and a protease;
[0019] (4) a method for producing ethyl (S)-1-(2-hydroxyethyl)-4-methyl-5-[2-(trifluoromethyl)-phenyl]-1H-pyrrole-3-carboxylate represented by the following formula (Ia):
[0000]
[0000] characterized by resolving an atropisomer of ethyl (RS)-1-(2-hydroxyethyl)-4-methyl-5-[2-(trifluoromethyl)-phenyl]-1H-pyrrole-3-carboxylate in a solvent in the presence of an acyl donor using one enzyme selected from a lipase and a protease;
[0020] (5) the method according to the above (3) or (4), wherein the enzyme is a lipase;
[0021] (6) the method according to the above (3) or (4), wherein the enzyme is an immobilized lipase;
[0022] (6-1) the method according to the above (6), wherein the immobilized lipase is one immobilized lipase selected from Chirazyme L-2, Chirazyme L-2 carrier-fixed C3, Chirazyme L-6 Pseudomonas sp., and Novozyme 435;
[0023] (6-2) the method according to any one selected from the above (4) to (6), wherein the acyl donor is vinyl propionate, vinyl acetate, vinyl butyrate, or vinyl laurate;
[0024] (7) the method according to the above (3) or (4), wherein the solvent is an organic solvent;
[0025] (8) a method for resolving an atropisomer of the following general formula (C):
[0000]
[0000] [wherein R 1 represents a C1-C4 alkyl group], characterized by using an optically active amine;
[0026] (9) the method according to the above (8), wherein the optically active amine is one compound selected from the group of the following compounds:
[0000]
[0027] (10) the method according to the above (8), wherein the optically active amine is (R)-(+)-1-(1-naphthyl)ethylamine;
[0028] (11) a method for producing the following intermediate compound (Ia):
[0000]
[0000] including:
[0029] (i) a step of obtaining an optically active amine salt of a desired atropisomer by resolving the following compound (C):
[0000]
[0000] in a solvent using an optically active amine;
[0030] (ii) a step of removing the optically active amine from the optically active amine salt of the atropisomer obtained in (i) under a hydrochloric acid condition; and
[0031] (iii) a step of reducing the atropisomer obtained in (ii) using a reducing agent;
[0032] (12) a method for producing ethyl (S)-1-(2-hydroxyethyl)-4-methyl-5-[2-(trifluoromethyl)-phenyl]-1H-pyrrole-3-carboxylate, including the following steps of:
[0033] (i) obtaining an optically active amine salt of (S)-2-[4-ethoxycarbonyl-3-methyl-2-[2-(trifluoromethyl)-phenyl]-1H-pyrrol-1-yl]acetic acid by resolving (RS)-2-[4-ethoxycarbonyl-3-methyl-2-[2-(trifluoromethyl)-phenyl]-1H-pyrrol-1-yl]acetic acid in a solvent using an optically active amine;
[0034] (ii) removing the optically active amine under an acidic condition; and thereafter
[0035] (iii) performing reduction using a reducing agent;
[0036] (13) the method according to the above (11) or (12), wherein the reducing agent is sodium borohydride;
[0037] (14) the method according to any one selected from the above (11) to (13), wherein the optically active amine is quinine, cinchonine, or R-1-(1-naphthyl)ethylamine;
[0038] (15) the method according to any one selected from the above (11) to (13), wherein the optically active amine is cinchonine;
[0039] (16) the method according to any one selected from the above (11) to (15), wherein the solvent is an organic solvent;
[0040] (17) a method for producing the following compound (A):
[0000]
[0000] characterized by reacting ethyl (S)-1-(2-hydroxyethyl)-4-methyl-5-[2-(trifluoromethyl)-phenyl]-1H-pyrrole-3-carboxylate represented by the following formula (Ia):
[0000]
[0000] with 4-(methylsulfonyl)aniline in the presence of one reagent selected from a metal alkoxide and a Grignard reagent;
[0041] (18) the production method according to the above (17), wherein the reagent is a Grignard reagent;
[0042] (18-1) the production method according to the above (17), wherein the Grignard reagent is ethylmagnesium bromide;
[0043] (19) ethyl (S)-1-(2-hydroxyethyl)-4-methyl-5-[2-(trifluoromethyl)phenyl]-1H-pyrrole-3-carboxylate represented by the following formula (Ia):
[0000]
[0000] which is an intermediate for producing the following compound (A):
[0000]
[0044] (20-0) a pyrrole compound represented by the following compound (C) or an atropisomer thereof:
[0000]
[0000] [wherein R 1 represents the same meaning as described above], which is an intermediate for producing (S)-1-(2-hydroxyethyl)-4-methyl-N-[4-(methylsulfonyl)-phenyl]-5-[2-(trifluoromethyl)phenyl]-1H-pyrrole-3-carboxamide;
[0045] (20-1) an optically active amine salt of (S)-2-[4-ethoxycarbonyl-3-methyl-2-[2-(trifluoromethyl)-phenyl]-1H-pyrrol-1-yl]acetic acid, which is an intermediate for producing (S)-1-(2-hydroxyethyl)-4-methyl-N-[4-(methylsulfonyl)phenyl]-5-[2-(trifluoromethyl)phenyl]-1H-pyrrole-3-carboxamide;
[0046] (20-2) the salt according to the above (20-1), wherein the optically active amine is one compound selected from cinchonine, quinine, and (R)-(+)-1-(1-naphthyl)ethylamine; and
[0047] (20-3) the salt according to the above (20-1), wherein the optically active amine is (R)-(+)-1-(1-naphthyl)ethylamine.
[0048] (S)-1-(2-Hydroxyethyl)-4-methyl-N-[4-(methyl-sulfonyl)phenyl]-5-[2-(trifluoromethyl)phenyl]-1H-pyrrole-3-carboxamide represented by the following formula (A):
[0000]
[0000] is sometimes referred to as Compound (A) in this description.
[0049] Examples of the “lipase” as used herein include Lipase AK “Amano” 20, Lipase A “Amano” 6, Lipase AS “Amano”, a lipase derived from Candida Antarctica Type B, and a lipase derived from Pseudomonas sp. The lipase is preferably a lipase derived from Pseudomonas sp.
[0050] The “immobilized lipase” as used herein is a lipase which is brought into a state where its catalytic activity is maintained by immobilizing the lipase on a resin or confining the lipase in a small space so as to convert it to a solid form, and examples thereof include Chirazyme L-2 and Chirazyme L-2 carrier-fixed C3 (Roche) using a lipase derived from Candida Antarctica Type B, and Chirazyme L-6 Pseudomonas sp. and Novozyme 435 using a lipase derived from Pseudomonas sp. The immobilized lipase is preferably Novozyme 435.
[0051] Examples of the “protease” as used herein include Protease N “Amano” and Proleather FG “Amano”, and further, the protease is preferably Protease N “Amano”.
[0052] The “optically active amine” as used herein is preferably an amine compound having an asymmetric point such as quinine, cinchonine, (R)-1-(1-naphthyl)ethylamine, (R)-(+)-1-(4-chlorophenyl)ethylamine, or (R)-(+)-1-phenylethylamine, more preferably quinine, cinchonine, or (R)-1-(1-naphthyl)ethylamine, and particularly preferably cinchonine.
[0053] The “metal alkoxide” as used herein is preferably potassium t-butoxide, sodium t-butoxide, sodium methoxide or potassium ethoxide.
[0054] Examples of the “C1-C4 alkyl group” as used herein include methyl, ethyl, n-propyl, i-propyl, n-butyl, i-butyl, and t-butyl groups. The C1-C4 alkyl group as R 1 is preferably a methyl, ethyl, n-propyl, or i-butyl group, more preferably an ethyl group.
[0055] R 1 is preferably a methyl, ethyl, n-propyl, or i-butyl group, more preferably an ethyl group.
[0056] R 2 is preferably a 2-hydroxyethyl group.
[0057] The compound represented by the above general formula (B) is preferably ethyl (S)-1-(2-hydroxyethyl)-4-methyl-5-[2-(trifluoromethyl)phenyl]-1H-pyrrole-3-carboxylate represented by the above formula (Ia) or (S)-2-[4-ethoxycarbonyl-3-methyl-2-[2-(trifluoromethyl)-phenyl]-1H-pyrrol-1-yl]acetic acid, more preferably ethyl (S)-1-(2-hydroxyethyl)-4-methyl-5-[2-(trifluoromethyl)-phenyl]-1H-pyrrole-3-carboxylate.
[0058] A method for producing Compound (A) using the production intermediate compound of the present invention will be described in detail below.
[0059] Compound (A) can be produced by using known compounds as starting materials and using the following production method of the present invention and intermediates.
Step A: Production of Intermediate Compound (IV)
[0060]
Step B: Production of Intermediate Compound (Ia)
[0061]
[0000] Step C: Production of Intermediate Compound (Ia) through Intermediate Compound (IIa)
[0000]
Step D: Production of Compound (A)
[0062]
[0063] Hereinafter, the respective steps will be described.
(Step A-1)
[0064] This step is a step of producing Compound (V) by reacting 2-bromo-1-[2-(trifluoromethyl)phenyl]propan-1-one, which is a known substance, with ethyl cyanoacetate in the presence of a base.
[0065] As a solvent, an organic solvent which does not inhibit the reaction and dissolves the starting material to some extent is used. The solvent is preferably an amide such as methylacetamide.
[0066] Examples of the base include alkali metal carbonates such as potassium carbonate.
[0067] The reaction temperature is from 0° C. to 100° C., preferably from 40° C. to 60° C.
[0068] The reaction time is from 0.5 to 12 hours, preferably from 1 to 3 hours.
(Step A-2)
[0069] This step is a step of producing Compound (IV) by cyclizing Compound (V) to form a pyrrole ring.
[0070] As a solvent, an organic solvent which does not inhibit the reaction and dissolves the starting material to some extent is used. The solvent is preferably an aromatic hydrocarbon such as toluene.
[0071] As a reagent, it is preferred to blow hydrogen chloride gas in the presence of thionyl chloride, and further concentrated sulfuric acid may be added.
[0072] The reaction temperature is from 0° C. to 40° C., preferably room temperature.
[0073] The reaction time is from 1 to 30 hours, preferably from 10 to 20 hours.
(Step B-1)
[0074] This step is a step of producing Compound (III) by removing the chlorine group of Compound (IV).
[0075] As a solvent, a mixed solvent of water and an organic solvent which does not inhibit the reaction and dissolves the starting material to some extent is used. The solvent is preferably a mixed solvent of ethanol, tetrahydrofuran, and water.
[0076] As a reagent, sodium formate and a 5% palladium-carbon catalyst are preferred.
[0077] The reaction temperature is from 0° C. to 100° C., preferably from 40° C. to 60° C.
[0078] The reaction time is from 0.5 to 12 hours, preferably from 0.5 to 2 hours.
(Step B-2)
[0079] This step is a step of producing Compound (I) by introducing a hydroxyethyl group on the nitrogen atom of the pyrrole group of Compound (III) in a solvent in the presence of a base.
[0080] As the solvent, an organic solvent which does not inhibit the reaction and dissolves the starting material to some extent is used. The solvent is preferably an amide such as N,N-dimethylacetamide.
[0081] Examples of the base include metal alkoxides such as potassium t-butoxide and organic bases such as 4-dimethylaminopyridine.
[0082] A reagent for introducing a hydroxyethyl group is preferably bromoethanol or ethylene carbonate.
[0083] As a combination of the base and the reagent for introducing a hydroxyethyl group, a combination of 4-dimethylaminopyridine and ethylene carbonate is preferred.
[0084] The reaction temperature is from room temperature to 150° C., preferably from 100° C. to 120° C.
[0085] The reaction time is from 1 to 20 hours, preferably from 5 to 15 hours.
(Step B-3)
[0086] This step is a step of obtaining Compound (Ia) by optical resolution of an atropisomer through stirring of the above Compound (I) and a lipase or a protease in the presence of an acyl donor.
[0087] This method is usually performed in a solvent. The solvent is preferably a ketone such as acetone or methyl isobutyl ketone, an acetate ester such as isopropyl acetate, or a nitrile such as acetonitrile, more preferably a nitrile such as acetonitrile.
[0088] Examples of the lipase in this method include enzymes such as Lipase AK “Amano” 20, Lipase A “Amano” 6, and Lipase AS “Amano”, and immobilized lipases such as Chirazyme L-2, Chirazyme L-2 carrier-fixed C3, Chirazyme L-6 Pseudomonas sp., and Novozyme 435. The lipase is preferably Novozyme 435.
[0089] The amount of the enzyme to be used in this method is preferably from 0.005 g to 1 g of the enzyme with respect to 1 g of a substrate, preferably 1 g of the enzyme, and the amount of the immobilized lipase to be used is preferably from 0.005 to 1 equivalent with respect to Compound (I).
[0090] The protease in this method is preferably Protease N “Amano”.
[0091] The acyl donor in this method is preferably vinyl propionate, vinyl acetate, vinyl butyrate, vinyl laurate, or the like, and particularly preferably vinyl propionate.
[0092] The reaction temperature is from 0° C. to 50° C., preferably room temperature.
[0093] The enantiomeric excess of the obtained atropisomer can be determined according to conventional methods.
(Step C-1)
[0094] This step is a step of producing Compound (II) by introducing a carboxymethyl group on the nitrogen atom of the pyrrole group of Compound (III) in a solvent in the presence of a base using ethyl bromoacetate.
[0095] As the solvent, an organic solvent which does not inhibit the reaction and dissolves the starting material to some extent is used. The solvent is preferably an amide such as N,N-dimethylacetamide.
[0096] Examples of the base include metal alkoxides such as potassium t-butoxide.
[0097] The reaction temperature is from 0° C. to 100° C., preferably from 10° C. to room temperature.
[0098] The reaction time is from 0.5 to 12 hours, preferably from 1 to 3 hours.
(Step C-2)
[0099] This step is a step of producing Compound (IIa) by optical resolution of the atropisomer through stirring of Compound (II) and an optically active amine in a solvent.
[0100] This method is usually performed in a solvent. The solvent is preferably an acetate ester, a nitrile, a ketone, an ether, or a mixed solvent of a solvent selected therefrom and water, more preferably t-butyl methyl ether or di isopropyl ether.
[0101] In this method, the optically active amine is preferably one compound selected from quinine, cinchonine, R-1-(1-naphthyl)ethylamine, R-(+)-1-(4-chlorophenyl)-ethylamine, and R-(+)-1-phenylethylamine, more preferably R-1-(1-naphthyl)ethylamine, quinine, or cinchonine.
[0102] The amount of the optically active amine to be used in this method is preferably 0.5 equivalents with respect to Compound (II).
[0103] The reaction temperature is from room temperature to 50° C., preferably 50° C.
[0104] The diastereomeric excess of the obtained atropisomer can be determined according to conventional methods.
[0105] An amine salt of Compound (IIa) obtained in this step can also be converted to the free form using an acid. The acid to be used at this time is not particularly limited as long as it is an acid (an inorganic acid such as hydrochloric acid) usually used for removing an amine salt.
(Step C-3)
[0106] This step is a step of producing Compound (Ia) by reduction of the carboxymethyl group of Compound (IIa) to a hydroxyethyl group in the presence of boron trifluoride using a reducing agent.
[0107] As a solvent, a mixed solvent of water and an organic solvent which does not inhibit the reaction and dissolves the starting material to some extent is used. The solvent is preferably a mixed solvent of an ester such as ethyl acetate and water.
[0108] The reducing agent is not particularly limited as long as it is a reagent which reduces a carboxyl group to a hydroxymethyl group, but is preferably an alkali metal borohydride such as sodium borohydride.
[0109] The reaction temperature is from 0° C. to 100° C., preferably room temperature.
[0110] The reaction time is from 0.5 to 12 hours, preferably from 0.5 to 2 hours.
(Step D-1)
[0111] This step is a step of producing Compound (A) by reacting Compound (Ia) with 4-(methylsulfonyl)aniline in the presence of a Grignard reagent.
[0112] As the solvent, an organic solvent which does not inhibit the reaction and dissolves the starting material to some extent is used. The solvent is preferably an ether such as tetrahydrofuran.
[0113] The Grignard reagent is preferably a tetrahydrofuran solution of ethylmagnesium bromide, ethylmagnesium chloride, isopropylmagnesium chloride, methylmagnesium bromide, or phenylmagnesium bromide, more preferably a tetrahydrofuran solution of ethylmagnesium bromide.
[0114] The reaction temperature is from room temperature to 150° C., preferably from 60° C. to 100° C.
[0115] The reaction time is from 0.5 to 5 hours, preferably from 0.5 to 2 hours.
[0116] In this step, Compound (A) can also be produced by reacting Compound (Ia) with 4-(methylsulfonyl)aniline in the presence of a metal alkoxide such as potassium t-butoxide, sodium t-butoxide, sodium methoxide, or potassium ethoxide.
[0117] As a reaction solvent, an organic solvent which does not inhibit the reaction and dissolves the starting material to some extent is used. The solvent is preferably tetrahydrofuran, toluene, dimethyl sulfoxide, or N,N-dimethylacetamide.
[0118] The reaction temperature is from room temperature to 70° C., preferably from 40° C. to 70° C.
[0119] The reaction time is from 0.5 to 5 hours, preferably from 1 to 2 hours.
[0120] A racemate of a pyrrole compound represented by the following formula (B):
[0000]
[0000] [wherein R 1 represents a C1-C4 alkyl group, and R 2 represents a 2-hydroxyethyl group or a carboxymethyl group] can be produced according to the above steps A and B.
[0121] A compound represented by the following formula (IB):
[0000]
[0000] [wherein R 1 represents a C1-C4 alkyl group] can be produced by alkylation of (RS)-1-(2-hydroxyethyl)-4-methyl-5-[2-(trifluoromethyl)phenyl]-1H-pyrrole-3-carboxylate produced in Example 6 under conventional conditions.
[0122] After completion of the reactions of the above-mentioned respective steps, the target compounds can be collected from the reaction mixture according to conventional methods. For example, the reaction mixture is appropriately neutralized, or in the case where insoluble matter is present, after the insoluble matter is removed by filtration, an organic solvent immiscible with water such as ethyl acetate is added thereto, followed by washing with water or the like. Thereafter, the organic layer containing the target compound is separated and dried over anhydrous magnesium sulfate or the like, and then, the solvent is distilled off, whereby the target compound can be obtained.
[0123] If necessary, the thus obtained target material can be separated and purified by conventional methods, for example, by appropriately combining recrystallization, reprecipitation, or a method conventionally used for separation and purification of an organic compound, for example, a method using a synthetic adsorbent such as adsorption column chromatography or partition column chromatography, a method using ion exchange chromatography, or normal-phase or reverse-phase column chromatography using silica gel or alkylated silica gel, and performing elution with a suitable eluent.
[0124] Compound (A) obtained according to the present invention can be used in a pharmaceutical or a pharmaceutical composition containing Compound (A) as an active ingredient.
[0125] The pharmaceutical containing Compound (A) as an active ingredient is preferably provided in the form of a pharmaceutical composition containing Compound (A) and one or more pharmaceutically acceptable carriers. The administration form of the pharmaceutical of the present invention is not particularly limited, and the pharmaceutical can be administered orally or parenterally, but is preferably administered orally.
[0126] The pharmaceutical composition containing Compound (A) as an active ingredient contains Compound (A) and a pharmaceutically acceptable carrier, and can be administered in the form of any of various injections through intravenous injection, intramuscular injection, subcutaneous injection, or the like, or through any of various methods such as oral administration or transdermal administration. The pharmaceutically acceptable carrier refers to a pharmaceutically acceptable material (for example, an excipient, a diluent, an additive, a solvent, etc.) which is involved in transport of Compound (A) from a given organ or viscus to another organ or viscus.
[0127] As a method for preparing a formulation, an appropriate formulation (for example, an oral preparation or an injection) is selected according to the administration method, and can be prepared by a conventionally used preparation method for various formulations. Examples of the oral preparation can include a tablet, a powder, a granule, a capsule, a pill, a troche, a solution, a syrup, an elixir, an emulsion, and an oily or aqueous suspension. In the case of an injection, a stabilizer, a preservative, a solubilizing agent, or the like can also be used in the formulation. It is also possible to form a solid preparation as a formulation to be prepared before use by placing a solution which may contain such a pharmaceutical aid or the like in a container, followed by lyophilization or the like. In addition, a single dosage may be packed in one container, or multiple dosages may be packed in one container.
[0128] Examples of a solid preparation include a tablet, a powder, a granule, a capsule, a pill, and a troche. These solid preparations may contain a pharmaceutically acceptable additive along with Compound (A). Examples of the additive include a filler, an expander, a binder, a disintegrant, a solubilization enhancer, a wetting agent, and a lubricant, and the solid preparation can be prepared by selecting an additive therefrom according to need and mixing.
[0129] Examples of a liquid preparation include a solution, a syrup, an elixir, an emulsion, and a suspension. These liquid preparations may contain a pharmaceutically acceptable additive along with Compound (A). Examples of the additive include a suspending agent and an emulsifying agent, and the liquid preparation can be prepared by selecting an additive therefrom according to need and mixing.
[0130] For example, in the case of a tablet, in the entire pharmaceutical composition, the content of a binder is generally from 1 to 10 parts by weight (preferably from 2 to 5 parts by weight), the content of a disintegrant is generally from 1 to 40 parts by weight (preferably from 5 to 30 parts by weight), the content of a lubricant is generally from 0.1 to 10 parts by weight (preferably from 0.5 to 3 parts by weight), and the content of a fluidizing agent is generally from 0.1 to 10 parts by weight (preferably from 0.5 to 5 parts by weight).
[0131] The pharmaceutical composition containing Compound (A) as an active ingredient can be administered to a warm-blooded animal (particularly a human being). The dose of Compound (A) or a pharmacologically acceptable salt thereof which is an active ingredient varies depending on the various conditions such as symptoms, age, and body weight of a patient, however, in the case of, for example, oral administration, it can be administered to a human being at a single dose of 0.1 mg/body to 20 mg/body (preferably 0.5 mg/body to 5 mg/body) one to six times per day depending on the symptoms.
Advantageous Effects of Invention
[0132] According to the present invention, a method for producing (S)-1-(2-hydroxyethyl)-4-methyl-N-[4-(methyl-sulfonyl)phenyl]-5-[2-(trifluoromethyl)phenyl]-1H-pyrrole-3-carboxamide (Compound (A)) having mineralocorticoid receptor antagonistic activity and a production intermediate compound thereof are provided. Compound (A) obtained according to the present invention has excellent stability and is useful as a pharmaceutical such as an antihypertensive drug.
DESCRIPTION OF EMBODIMENTS
[0133] Hereinafter, the present invention will be described in more detail by showing Examples of the present invention and the like, however, the scope of the present invention is not limited thereto.
EXAMPLES
Example 1
2-Bromo-1-[2-(trifluoromethyl)phenyl]propan-1-one
[0134]
[0135] To 1-[2-(trifluoromethyl)phenyl]propan-1-one (75 g (370 mmol)), t-butyl methyl ether (750 mL) and bromine (1.18 g (7.4 mmol)) were added. The resulting mixture was stirred at 15 to 30° C. for about 30 minutes, and after it was confirmed that the color of bromine disappeared, the mixture was cooled to 0 to 5° C. While maintaining the temperature at 0 to 10° C., bromine (59.13 g (370 mmol)) was added thereto, and the resulting mixture was stirred. After the mixture was stirred for about 2.5 hours, a 10 w/v % aqueous potassium carbonate solution (300 mL) was added thereto while maintaining the temperature at 0 to 25° C., and sodium sulfite (7.5 g) was further added thereto, followed by heating to 20 to 30° C. This solution was subjected to liquid separation, and to the obtained organic layer, water (225 mL) was added to wash the organic layer. Thereafter, the organic layer was concentrated under reduced pressure, whereby a t-butyl methyl ether solution (225 mL) of the title compound was obtained.
[0136] 1 H NMR (400 MHz, CDCl 3 ) δ: 1.91 (3H, d, J=4.0 Hz), 4.97 (1H, q, J=6.7 Hz), 7.60-7.74 (4H, m.
Example 2
Ethyl 2-cyano-3-methyl-4-oxo-4-[2-(trifluoro-methyl)phenyl]butanoate
[0137]
[0138] To the 2-bromo-1-[2-(trifluoromethyl)phenyl]-propan-1-one/t-butyl methyl ether solution (220 mL) obtained in Example 1, dimethylacetamide (367 mL), ethyl cyanoacetate (53.39 g (472 mmol)), and potassium carbonate (60.26 g (436 mmol)) were sequentially added, and the resulting mixture was heated to 45 to 55° C. and stirred. After the mixture was stirred for about 2 hours, the mixture was cooled to 20 to 30° C., and then water (734 mL) and toluene (367 mL) were added thereto to effect extraction. Then, water (513 mL) was added to the resulting organic layer to wash the organic layer (washing was performed twice). Thereafter, the obtained organic layer was concentrated under reduced pressure, whereby a toluene solution (220 mL) of the title compound was obtained.
[0139] 1 H NMR (400 MHz, CDCl 3 ) δ: 1.33-1.38 (6H, m), 3.80-3.93 (2H, m), 4.28-4.33 (2H, m), 7.58-7.79 (4H, m).
Example 3
Ethyl 2-chloro-4-methyl-5-[2-(trifluoro-methyl)phenyl]-1H-pyrrole-3-carboxylate
[0140]
[0141] To the toluene solution (217 mL) of ethyl 2-cyano-3-methyl-4-oxo-4-[2-(trifluoromethyl)phenyl]-butanoate obtained by the production method of Example 2, ethyl acetate (362 mL) and thionyl chloride (42.59 g (358 mmol)) were added at 20 to 30° C., and the resulting mixture was cooled to −10 to 5° C. Then, hydrogen chloride gas (52.21 g (1432 mmol)) was blown into the mixture, and concentrated sulfuric acid (17.83 g (179 mmol)) was further added thereto, and the resulting mixture was heated and stirred at 15 to 30° C. After the mixture was stirred for about 20 hours, ethyl acetate (1086 mL) was added thereto, followed by heating to 30 to 40° C., and water (362 mL) was added thereto, and then, the resulting mixture was subjected to liquid separation. To the organic layer obtained by liquid separation, water (362 mL) was added, followed by liquid separation, and then, a 5 w/v % aqueous sodium hydrogen carbonate solution (362 mL) was added thereto, followed by liquid separation.
[0142] Subsequently, the organic layer was concentrated under reduced pressure, and toluene (579 mL) was further added thereto, followed by concentration under reduced pressure, and then, toluene (72 mL) was added thereto, and the resulting mixture was cooled to 0 to 5° C. After the mixture was stirred for about 2 hours, the deposited crystal was filtered and washed with toluene (217 mL) cooled to 0 to 5° C. The obtained wet crystal product was dried under reduced pressure at 40° C., whereby the title compound was obtained (97.55 g, yield: 82.1%).
[0143] 1 H NMR (400 MHz, CDCl 3 ) δ: 1.38 (3H, t, J=7.1 Hz), 2.11 (3H, s), 4.32 (2H, q, J=7.1 Hz), 7.39 (1H, d, J=7.3 Hz), 7.50-7.62 (2H, m), 7.77 (1H, d, J=8.0 Hz), 8.31 (1H, br).
Example 4
Ethyl 4-methyl-5-[2-(trifluoromethyl)phenyl]-1H-pyrrole-3-carboxylate
[0144]
[0145] To ethyl 2-chloro-4-methyl-5-[2-(trifluoromethyl)-phenyl]-1H-pyrrole-3-carboxylate (97.32 g (293 mmol)) obtained by the production method of Example 3, ethanol (662 mL), tetrahydrofuran (117 mL), water (49 mL), sodium formate (25.91 g (381 mmol)), and a 5% palladium-carbon catalyst (water content: 52.1%, 10.16 g) were added at room temperature, and the resulting mixture was heated to 55 to 65° C. and stirred. After the mixture was stirred for about 1 hour, the mixture was cooled to 40° C. or lower, and tetrahydrofuran (97 mL) and a filter aid (KC Flock, Nippon Paper Industries) (4.87 g) were added thereto. Then, the catalyst was filtered, and the residue was washed with ethanol (389 mL). The filtrate and the ethanol solution used for washing were combined, and the combined solution was concentrated under reduced pressure. Thereafter, water (778 mL) was added thereto and the mixture was stirred at 20 to 30° C. for 0.5 hours or more. The deposited crystal was filtered and washed with a mixed solution of ethanol/water=7/8 (292 mL). The thus obtained wet crystal product was dried under reduced pressure at 40° C., whereby the title compound was obtained (86.23 g, yield: 98.9%).
[0146] 1 H NMR (400 MHz, CDCl 3 ) δ: 1.35 (3H, t, J=7.1 Hz), 2.18 (3H, s), 4.29 (2H, m), 7.40-7.61 (4H, m), 7.77 (1H, d, J=7.9 Hz), 8.39 (1H, br).
Example 5
Ethyl (S)-1-(2-hydroxyethyl)-4-methyl-5-[2-(trifluoromethyl)phenyl]-1H-pyrrole-3-carboxylate
(5-1) Production Method 1
(5-1-1) Ethyl (RS)-1-(2-hydroxyethyl)-4-methyl-5-[2-(trifluoromethyl)phenyl]-1H-pyrrole-3-carboxylate
[0147]
[0148] To ethyl 4-methyl-5-[2-(trifluoromethyl)phenyl]-1H-pyrrole-3-carboxylate (65.15 g (219 mmol)) obtained by the production method of Example 4, N,N-dimethylacetamide (261 mL), ethylene carbonate (28.95 g (328.7 mmol)), and 4-dimethylaminopyridine (2.68 g (21.9 mmol)) were sequentially added at room temperature, and the resulting mixture was heated to 105 to 120° C. and stirred. After the mixture was stirred for about 10 hours, the mixture was cooled to 20 to 30° C., and toluene (1303 mL) and water (326 mL) were added thereto, and the organic layer was extracted. Then, water (326 mL) was added to the organic layer to wash the organic layer (washing was performed three times). The obtained organic layer was concentrated under reduced pressure, and ethanol (652 mL) was added thereto, and the resulting mixture was further concentrated under reduced pressure. Thereafter, ethanol (130 mL) was added thereto, whereby an ethanol solution (326 mL) of the title compound was obtained.
[0149] 1 H NMR (400 MHz, CDCl 3 ) δ: 1.35 (3H, t, J=7.1 Hz), 1.84 (1H, broad singlet), 2.00 (3H, s), 3.63-3.77 (4H, m), 4.27 (2H, m), 7.35-7.79 (5H, m).
(5-1-2) (S)-Ethyl 1-(2-hydroxyethyl)-4-methyl-5-[2-(trifluoromethyl)phenyl]-1H-pyrrole-3-carboxylate
[0150] After ethyl (RS)-1-(2-hydroxyethyl)-4-methyl-5-[2-(trifluoromethyl)phenyl]-1H-pyrrole-3-carboxylate (5.00 g (14.6 mmol)) produced according to (5-1-1) was dissolved by adding acetonitrile (50 mL) thereto, vinyl propionate (4.8 mL (43.9 mmol)) and an immobilized lipase, Novozyme 435 (Novozymes Japan Ltd.) (50 mg) were added thereto, and the resulting mixture was stirred at 20 to 30° C. for about 7 hours. After stirring, the immobilized lipase was filtered off, and the filtrate was concentrated under reduced pressure. Subsequently, the concentrated residue was dissolved by adding toluene (25 mL) thereto, and then, silica gel (for example, 60N, Kanto Chemical Co., Inc., spherical and neutral, 40 to 50 μm mesh was used) (10.00 g) was added thereto, and the resulting mixture was stirred for about 1 hour. After stirring, the silica gel was filtered with toluene (50 mL) (this filtrate was discarded), and subsequently, the silica gel was washed with ethyl acetate (50 mL), and the obtained filtrate was concentrated under reduced pressure. Then, to the obtained concentrated residue, toluene (10 mL) and ethylcyclohexane (10 mL) were added thereto, and the resulting mixture was cooled to −17 to −15° C. and stirred for 0.5 hours or more. Thereafter, ethylcyclohexane (100 mL) was slowly added thereto while keeping the temperature at −17 to −5° C., and the resulting mixture was stirred for 1 hour or more. The resulting crystal was filtered and washed with ethylcyclohexane (10 mL) cooled to −17 to −15° C., and the obtained wet crystal product was dried under reduced pressure, whereby the title compound (1.16 g) was obtained (yield: 23.2%). The enantiomeric excess of the obtained crystal was about 92.4% ee (calculated according to Example 5-1-3).
[0151] 1 H NMR (400 MHz, CDCl 3 ) δ: 1.35 (3H, t, J=7.1 Hz), 1.84 (1H, broad singlet), 2.00 (3H, s), 3.63-3.77 (4H, m), 4.27 (2H, m), 7.35-7.79 (5H, m).
(5-1-3) HPLC Determination Method for Enantiomeric Excess
[0152] About 10 mg of a sample was collected and diluted with a mobile phase to 10 mL, whereby a sample solution was prepared.
Column: DAICEL CHIRALPAK AD-H (4.6 mm I.D.×250 mm)
[0153] Mobile phase: n-hexane:ethanol=95:5
[0154] Detection: UV 254 nm
[0155] Flow rate: about 1.0 mL/min
[0000] Column temperature: constant temperature of around 40° C.
Measurement time: about 10 min
Injection volume: 5 μL
[0156] The enantiomeric excess was calculated according to the following formula using the peak area ratios of the S form (retention time: about 11 min) and the R form (retention time: about 9 min).
[0000] % ee ={[(the peak area ratio of the title compound ( S form))−(the peak area ratio of the R form)]÷[(the peak area ratio of the title compound ( S form))+(the peak area ratio of the R form)]}×100
(5-2) Production Method 2
(5-2-1) (RS)-2-[4-Ethoxycarbonyl-3-methyl-2-[2-(trifluoromethyl)-phenyl]-1H-pyrrol-1-yl]acetic acid
[0157]
[0158] To ethyl 4-methyl-5-[2-(trifluoromethyl)phenyl]-1H-pyrrole-3-carboxylate (20.00 g (67.3 mmol)) produced according to Example 4, N,N-dimethylacetamide (190 mL) was added at room temperature, and subsequently, potassium t-butoxide (9.06 g (80.8 mmol)) was added thereto using N,N-dimethylacetamide (10 mL). After the resulting mixture was cooled to about 15° C., ethyl bromoacetate (9.0 mL (80.8 mmol)) was added thereto. After the resulting mixture was stirred for about 1 hour, a 5 N aqueous sodium hydroxide solution (27 mL) and water (40 mL) were added thereto, and the resulting mixture was stirred at room temperature for about 1 hour. Thereafter, water (300 mL) and ethyl acetate (200 mL) were added thereto, and the resulting mixture was stirred, followed by liquid separation. To the aqueous layer, ethyl acetate (400 mL) and 5 N hydrochloric acid (41 mL) were added to effect extraction, and the obtained organic layer was washed 5 times with water (100 mL) and further washed with a saturated sodium chloride solution (100 mL), and then dried over anhydrous sodium sulfate. The insoluble matter was filtered off, and the filtrate was concentrated under reduced pressure, and the resulting residue was purified by column chromatography (silica gel 200 g, methylene chloride/methanol=100/0 to 9/1), whereby (RS)-2-[4-ethoxycarbonyl-3-methyl-2-[2-(trifluoro-methyl)phenyl]-1H-pyrrol-1-yl]acetic acid (22.49 g, (63.3 mmol, yield: 94.1%)) was obtained.
[0159] On the other hand, in the case where purification is desired, it is also possible to isolate (RS)-2-[4-ethoxycarbonyl-3-methyl-2-[2-(trifluoromethyl)-phenyl]-1H-pyrrol-1-yl]acetic acid as an amine salt by using dicyclohexylamine. For example, (RS)-2-[4-ethoxycarbonyl-3-methyl-2-[2-(trifluoromethyl)phenyl]-1H-pyrrol-1-yl]-acetic acid (20.00 g (56.3 mmol)) was dissolved in diisopropyl ether (600 mL), and dicyclohexylamine (10.21 g (56.3 mmol)) was added thereto. After the resulting mixture was stirred at room temperature for about 24 hours, the deposited crystal was filtered and washed with diisopropyl ether (100 mL). The wet crystal product was dried under reduced pressure, whereby (RS)-2-[4-ethoxycarbonyl-3-methyl-2-[2-(trifluoromethyl)-phenyl]-1H-pyrrol-1-yl]acetic acid dicyclohexylamine salt (28.23 g (yield: 93.5%)) was obtained.
(5-2-2) (S)-2-[4-Ethoxycarbonyl-3-methyl-2-[2-(trifluoro-methyl)phenyl]-1H-pyrrol-1-yl]acetic Acid Cinchonine Salt (Entry 4 in Table 2)
[0160] (RS)-2-[4-Ethoxycarbonyl-3-methyl-2-[2-(trifluoro-methyl)phenyl]-1H-pyrrol-1-yl]acetic acid (500.8 mg (1.41 mmol)) was dissolved by adding t-butyl methyl ether (7.5 mL) thereto at room temperature, and further cinchonine (207.8 mg (0.706 mmol)) was added thereto at room temperature, and the resulting mixture was stirred for about 19 hours. The deposited crystal was filtered and washed with t-butyl methyl ether (1.5 mL). The wet crystal product was dried under reduced pressure, whereby (S)-2-[4-ethoxycarbonyl-3-methyl-2-[2-(trifluoromethyl)phenyl]-1H-pyrrol-1-yl]acetic acid cinchonine salt (344.4 mg (yield: 37.6%)) was obtained. The diastereomeric excess of the obtained crystal was about 94.8% de.
[0161] 1 H NMR (400 MHz, CDCl 3 ) δ: 0.80-0.94 (m, 1H), 1.26-1.40 (m, 3H), 1.50-2.23 (m, 7H), 2.51-2.53 (m, 1H), 2.98-3.39 (m, 4H), 3.96-4.55 (m, 5H), 5.05-5.26 (m, 2H), 5.91-6.00 (m, 1H), 6.12-6.15 (m, 1H), 6.57 (broad singlet), 6.91-7.19 (m, 2H), 7.24-7.95 (m, 8H), 8.03-8.11 (m, 1H), 9.00-9.11 (m, 1H).
(5-2-3) HPLC Determination Method for Diastereomeric Excess
[0162] About 10 mg of a sample is collected and diluted with a mobile phase to 10 mL, whereby a sample solution is prepared.
Column: DAICEL CHIRALCEL OD-RH (4.6 mm I.D.×150 mm)
[0163] Mobile phase: Mobile phase A: a 0.1 v/v % acetic acid solution:acetonitrile=1:9
[0164] Mobile phase B: water:acetonitrile=2:8
[0165] Mobile phase A: Mobile phase B=1:1
Detection: UV 254 nm
[0166] Flow rate: about 1.0 mL/min
Column temperature: constant temperature of around 40° C.
Measurement time: about 10 min
Injection volume: 5 μL
[0167] The diastereomeric excess was calculated according to the following formula using the peak area ratios of the S form (retention time: about 5 min) and the R form (retention time: about 4 min)
[0000] % de ={[(the peak area ratio of the title compound ( S form))−(the peak area ratio of the R form)]÷[(the peak area ratio of the title compound ( S form))+(the peak area ratio of the R form)]}×100
(5-2-4) Effect of Optically Active Amine
[0168] After (RS)-2-[4-ethoxycarbonyl-3-methyl-2-[2-(trifluoromethyl)phenyl]-1H-pyrrol-1-yl]acetic acid (25 mg (0.07 mmol)) was dissolved in diisopropyl ether (0.5 mL), each of the various optically active amines (0.5 equivalents) was added thereto, and the resulting mixture was stirred at room temperature for about 19 hours. After stirring, the mixture was centrifuged, and the diastereomeric excess in the supernatant was determined by HPLC. The diastereomeric excess and yield of the precipitate (crystal, the target compound was in the S form) were calculated from the measured values (solubility and diastereomeric excess) of the supernatant and shown in Table 1.
[0000]
TABLE 1
Entry
Optically active amine
Supernatant % de
Precipitate % de
Yield (%)
1
(R)-(+)-1-phenylethylamine
10 (R form)
7 (S form)
58.6
2
(R)-(+)-1-(4-chlorophenyl)ethylamine
19 (R form)
22 (S form)
46.7
3
(R)-1-(1-naphthyl)ethylamine
84 (R form)
85 (S form)
49.5
4
quinine
67 (R form)
71 (S form)
48.7
5
cinchonine
76 (R form)
84 (S form)
47.3
[0169] Among the optically active amines, high selectivity was observed in the case of R-1-(1-naphthyl)ethylamine, quinine, and cinchonine. On the other hand, in the case of R-(+)-1-(p-tolyl)ethylamine and cinchonidine, a different isomer (R form) was obtained as a precipitate.
[0170] Subsequently, by using cinchonine (0.5 equivalents), the type of solvent was examined, and the results are shown in Table 2. The amount of solvent was 15 times (v/v) the amount of sample, and the stirring time was about 19 hours at room temperature. The calculation methods for the diastereomeric excess and yield are the same as those for Table 1.
[0000]
TABLE 2
Entry
Solvent
% de
Yield (%)
1
isopropyl acetate
98.5
23.5
2
t-butyl acetate
97.6
26.3
3
cyclopentyl methyl ether
97.1
30.7
4
t-butyl methyl ether
94.8
37.6
[0171] In each of the solvents, good results with respect to selectivity were obtained.
(5-2-5) Ethyl (S)-1-(2-hydroxyethyl)-4-methyl-5-[2-(trifluoromethyl)phenyl]-1H-pyrrole-3-carboxylate
[0172] To an amine salt, for example, a R-1-(1-naphthyl)ethylamine salt of (S)-2-[4-ethoxycarbonyl-3-methyl-2-[2-(trifluoromethyl)phenyl]-1H-pyrrol-1-yl]acetic acid (101.3 mg (0.19 mmol)), ethyl acetate (2 mL), water (0.5 mL), and 1 N hydrochloric acid (0.23 mL) were added at room temperature, and the resulting mixture was stirred, followed by liquid separation. The organic layer was washed with a saturated sodium chloride solution (0.5 mL), and then dried over anhydrous sodium sulfate. The insoluble matter was filtered off, and the filtrate was concentrated under reduced pressure. After the residue was dissolved by adding tetrahydrofuran (1 mL) thereto, sodium borohydride (22 mg, 0.582 mmol) was added thereto, and the resulting mixture was stirred at room temperature for about 1 hour. Subsequently, a boron trifluoride-ether complex (0.0586 mL, 0.48 mmol) was added thereto, and the resulting mixture was stirred for about 1 hour. The reaction mixture was subjected to an analysis by HPLC, the production ratio of the title compound was 97.7% (HPLC peak area ratio).
Example 6
(RS)-1-(2-Hydroxyethyl)-4-methyl-5-[2-(trifluoromethyl)phenyl]-1H-pyrrole-3-carboxylic acid
[0173]
[0174] To the solution of ethyl (RS)-1-(2-hydroxyethyl)-4-methyl-5-[2-(trifluoromethyl)phenyl]-1H-pyrrole-3-carboxylate/ethanol solution (321 mL) obtained by the production method of Example 5, water (128.6 mL) and sodium hydroxide (21.4 g (519 mmol)) were added at room temperature, and the resulting mixture was heated and stirred at 65 to 78° C. After stirring for about 6 hours, the mixture was cooled to 20 to 30° C., and water (193 mL) was added thereto, and then, the pH of the mixture was adjusted to 5.5 to 6.5 with 6 N hydrochloric acid while keeping the temperature at 20 to 30° C. To the mixture whose pH was adjusted, (RS)-1-(2-hydroxyethyl)-4-methyl-5-[2-(trifluoromethyl)-phenyl]-1H-pyrrole-3-carboxylic acid (6.4 mg) was added as a seed crystal, and water (193 mL) was further added thereto. Then, the mixture was cooled to 0 to 5° C., and again, the pH of the mixture was adjusted to 3 to 4 with concentrated hydrochloric acid, and the mixture was stirred for about 1 hour. Thereafter, the deposited crystal was filtered and washed with a 20% aqueous ethanol solution (93 mL) cooled to 0 to 5° C. The thus obtained wet crystal product was dried under reduced pressure at 40° C., whereby the title compound was obtained (64.32 g, yield: 95.00).
[0175] 1 H NMR (400 MHz, DMSO-d 6 ) δ: 1.87 (3H, s), 3.38-3.68 (4H, m), 7.43-7.89 (5H, m).
Example 7
(S)-1-(2-Hydroxyethyl)-4-methyl-5-[2-(trifluoromethyl)phenyl]-1H-pyrrole-3-carboxylic acid quinine salt
(7-1) (S)-1-(2-Hydroxyethyl)-4-methyl-5-[2-(trifluoro-methyl)phenyl]-1H-pyrrole-3-carboxylic acid quinine salt
[0176] Acetone (1,150 mL) was added to quinine (21.23 g (65.5 mmol)), and the resulting mixture was heated and stirred under reflux (about 50° C.). After it was confirmed that quinine was dissolved, (RS)-1-(2-hydroxyethyl)-4-methyl-5-[2-(trifluoromethyl)phenyl]-1H-pyrrole-3-carboxylic acid (41.00 g (130.9 mmol)) was added thereto using acetone (82 mL). After stirring for about 1 hour, the resulting mixture was slowly cooled to 0 to 5° C. (adequate cooling rate: about 0.3° C./min) and stirred for about 0.5 hours at that temperature. The resulting crystal was filtered and washed with acetone (205 mL) cooled to 0 to 5° C., whereby a crude wet crystal product (59.52 g) of the title compound was obtained (when a portion of the crude wet crystal product was dried under reduced pressure and the entire amount thereof was converted to a dry weight basis, the amount of the dry product was 35.35 g, and the yield was 42.2%). The diastereomeric excess of the obtained salt was about 94.8% de. Subsequently, to the obtained wet crystal product (59.52 g), ethanol (53 mL) and ethyl acetate (71 mL) were added, and the resulting mixture was heated and stirred under reflux (about 78° C.). After the mixture was stirred for about 1 hour, ethyl acetate (583 mL) was added thereto, and the resulting mixture was stirred under reflux again. Thereafter, the mixture was slowly cooled to 0 to 5° C. and stirred for about 0.5 hours at that temperature. The resulting crystal was filtered and washed with ethyl acetate (141 mL) cooled to 0 to 5° C. The obtained wet crystal product was dried under reduced pressure, whereby the title compound (32.48 g) was obtained (overall yield: 41.5%). The diastereomeric excess of the obtained salt was about 99.3% de.
[0177] 1 H NMR (400 MHz, DMSO-d 6 ) δ: 1.87-1.89 (1H, m), 1.30-2.20 (9H, m), 2.41-2.49 (2H, m), 2.85-3.49 (6H, m), 3.65-3.66 (1H, m), 3.88 (3H, s), 4.82 (1H, broad singlet), 4.92-5.00 (2H, m), 5.23-5.25 (1H, m), 5.60 (1H, br), 5.80-6.00 (1H, m), 7.36-7.92 (9H, m), 8.67 (1H, d, J=4.6 Hz).
(7-2) HPLC Determination for Diastereomeric Excess (% de) of (S)-1-(2-hydroxyethyl)-4-methyl-5-[2-(trifluoromethyl)-phenyl]-1H-pyrrole-3-carboxylic acid quinine salt
[0178] About 10 mg of a sample was collected and diluted with a mobile phase to 20 mL, whereby a sample solution was prepared.
Column: DAICEL CHIRALCEL OD-RH (4.6 mm I.D.×150 mm, 5 μm)
[0179] Mobile phase: a 0.1 v/v % aqueous acetic acid solution (prepared by mixing 1 mL of acetic acid in 1000 mL of distilled water):acetonitrile=75:25
[0180] Detection: UV 220 nm
[0181] Flow rate: about 1.0 mL/min
[0000] Column temperature: constant temperature of around 40° C.
Measurement time: about 25 min
Injection volume: 5 μL
[0182] The diastereomeric excess (% de) was calculated according to the following formula using the peak area ratios of the S form (retention time: about 14.5 min) and the R form (retention time: about 15.5 min).
[0000] % de ={[(the peak area ratio of the title compound ( S form))−(the peak area ratio of the R form)]÷[(the peak area ratio of the title compound ( S form))+(the peak area ratio of the R form)]}×100
Example 8
Ethyl (S)-1-(2-hydroxyethyl)-4-methyl-5-[2-(trifluoromethyl)phenyl]-1H-pyrrole-3-carboxylate
(8-1) Production Method 1
[0183] To the (S)-1-(2-hydroxyethyl)-4-methyl-5-[2-(trifluoromethyl)phenyl]-1H-pyrrole-3-carboxylic acid quinine salt (32.00 g (50.2 mmol)) obtained in Example (7-1), ethyl acetate (480 mL) and a 2 N aqueous hydrochloric acid solution (160 mL) were added, and the resulting mixture was stirred, followed by liquid separation. The obtained organic layer was concentrated under reduced pressure (to 160 mL or less), ethyl acetate (160 mL) was added thereto, and the resulting mixture was further concentrated under reduced pressure. After completion of the concentration under reduced pressure, the amount of the liquid was adjusted (to 320 mL) by adding ethyl acetate, and the resulting mixture was cooled to 0 to 5° C. Subsequently, to this mixture, oxalyl chloride (11.2 mL (130.5 mmol)) was added while keeping the temperature at 0 to 10° C., and then, the resulting mixture was heated to 20 to 30° C. and stirred for about 1 hour. Ethanol (16 mL) was further added thereto, and the resulting mixture was heated and stirred under reflux for about 0.5 hours (about 78° C.) Thereafter, the mixture was cooled to 40° C. or lower, and a 5 w/v % aqueous sodium bicarbonate solution (160 mL) was added thereto, and the resulting mixture was stirred, followed by liquid separation. The resulting organic layer was concentrated under reduced pressure (to 96 mL), and methanol (160 mL) and a 5 w/v % aqueous sodium bicarbonate solution (64 mL) were added thereto, and the resulting mixture was stirred for 1 hour or more. Subsequently, toluene (800 mL) and a 20 w/v % aqueous sodium chloride solution (64 mL) were added thereto, and the resulting mixture was stirred, followed by liquid separation. To the resulting organic layer, a 20 w/v % aqueous sodium chloride solution (160 mL) was further added, and the resulting mixture was stirred, followed by liquid separation. The obtained organic layer was concentrated under reduced pressure (to 64 mL), and ethylcyclohexane (64 mL) was added thereto, and the resulting mixture was cooled to −17 to −15° C. and stirred for 0.5 hours or more. Thereafter, ethylcyclohexane (640 mL) was slowly added thereto while keeping the temperature at −17 to −5° C., and the resulting mixture was stirred for 1 hour or more. The resulting crystal was filtered and washed with ethylcyclohexane (64 mL) cooled to −17 to −15° C., and the obtained wet crystal product was dried under reduced pressure, whereby the title compound (14.20 g) was obtained (yield: 81.4%). The enantiomeric excess of the obtained crystal was about 99.3% ee (the enantiomeric excess was calculated according to Example (5-1-3)).
[0184] 1 H NMR (400 MHz, CDCl 3 ) δ: 1.35 (3H, t, J=7.1 Hz), 1.84 (1H, broad singlet), 2.00 (3H, s), 3.63-3.77 (4H, m), 4.27 (2H, m), 7.35-7.79 (5H, m).
(8-2) Production Method 2
[0185] To the (S)-1-(2-hydroxyethyl)-4-methyl-5-[2-(trifluoromethyl)phenyl]-1H-pyrrole-3-carboxylic acid quinine salt (20.00 g (31.4 mmol)), ethyl acetate (300 mL) and a 2 N aqueous hydrochloric acid solution (100 mL) were added, and the resulting mixture was stirred, followed by liquid separation. The obtained organic layer was concentrated under reduced pressure. After completion of the concentration under reduced pressure, the resulting residue was dissolved by adding N,N-dimethylacetamide (50 mL) thereto, and then, potassium carbonate (6.51 g (47.1 mmol)) and ethyl iodide (3.0 mL (37.6 mmol)) were added thereto, and the resulting mixture was heated to about 60° C. and stirred for about 2 hours. Thereafter, the mixture was cooled to 40° C. or lower, and toluene (350 mL) was added thereto, and the resulting mixture was further cooled to 0 to 5° C. Subsequently, a saturated sodium chloride solution (100 mL) was added thereto, and the resulting mixture was heated to room temperature. Then, toluene (150 mL) and water (100 mL) were further added thereto, and the resulting mixture was stirred, followed by liquid separation. The obtained organic layer was washed by adding a saturated sodium chloride solution (100 mL), and then concentrated under reduced pressure.
[0186] Ethylcyclohexane (40 mL) was added thereto at room temperature, and the resulting mixture was cooled to −17 to −15° C. and stirred for 0.5 hours or more. Thereafter, a seed crystal was added thereto, and further ethylcyclohexane (400 mL) was slowly added thereto while keeping the temperature at −17 to −5° C., and the resulting mixture was stirred for 1 hour or more. The resulting crystal was filtered and washed with ethylcyclohexane (40 mL) cooled to −17 to −15° C., and the obtained wet crystal product was dried under reduced pressure, whereby the title compound (8.79 g) was obtained (yield: 82.10).
Example 9
(S)-1-(2-Hydroxyethyl)-4-methyl-N-[4-(methylsulfonyl)phenyl]-5-[2-(trifluoromethyl)phenyl]-1H-pyrrole-3-carboxamide
[0187] Tetrahydrofuran (45 mL) was added to ethyl (S)-1-(2-hydroxyethyl)-4-methyl-5-[2-(trifluoromethyl)-phenyl]-1H-pyrrole-3-carboxylate (3.00 g (8.8 mmol)) obtained in Example 8 and 4-(methylsulfonyl) aniline (2.56 g (15.0 mmol)), and the resulting mixture was heated and stirred (60° C. or higher). To this liquid, a tetrahydrofuran solution of ethylmagnesium bromide (about 1 mol/L) (32.37 g (30.8 mmol)) was slowly added while keeping the temperature at 60° C. or higher. The resulting mixture was stirred for about 1 hour and then cooled to 0 to 5° C., and a 2 N aqueous hydrochloric acid solution (30 mL) and isobutyl acetate (75 mL) were added thereto, and the resulting mixture was stirred, followed by liquid separation. Subsequently, the resulting organic layer was washed with a 2 N aqueous hydrochloric acid solution (15 mL) (washing was repeated 4 times), and further washed with a 20 w/v % aqueous sodium chloride solution (30 mL). After the organic layer was concentrated under reduced pressure, the amount of the liquid was adjusted (to 30 mL) by adding isobutyl acetate, and the resulting mixture was stirred at room temperature for about 1 hour. Thereafter, the mixture was cooled to −15 to −10° C. and stirred for about 1 hour at that temperature. Thereafter, methylcyclohexane (15 mL) was added thereto, and the resulting mixture was further stirred for about 1 hour. The deposited crystal was filtered and washed with methylcyclohexane (12 mL) cooled to −15 to −10° C., and the obtained wet crystal product was dried under reduced pressure, whereby the title compound (3.90 g) was obtained (yield: 92.4%). The enantiomeric excess of the obtained crystal was about 99.8% ee.
Formulation Example 1
Capsule
[0188] The crystal (5 g) obtained in Example 9, lactose (115 g), cornstarch (58 g), and magnesium stearate (2 g) are mixed using a V-type mixer, and the resulting mixture is filled in a capsule (180 mg per capsule), whereby a capsule is obtained.
Formulation Example 2
Tablet
[0189] The crystal (5 g) obtained in Example 9, lactose (90 g), cornstarch (34 g), crystalline cellulose (20 g), and magnesium stearate (1 g) are mixed using a V-type mixer, and the resulting mixture is tableted (a mass of 150 mg per tablet) using a tableting machine, whereby a tablet is obtained.
Formulation Example 3
Suspension
[0190] A dispersion medium in which methyl cellulose is dispersed or dissolved in purified water is prepared. The crystal obtained in Example 9 is weighed and placed in a mortar and kneaded well while adding the above-mentioned dispersion medium thereto in small portions, and then, purified water is added thereto, whereby a suspension (100 g) is prepared. | The present invention provides a method for producing an atropisomer of a pyrrole derivative having excellent mineralocorticoid receptor antagonistic activity, and an intermediate thereof. A method for producing an atropisomer of a pyrrole derivative using a compound represented by (B) [wherein R 1 represents a C1-C4 alkyl group, and R 2 represents a 2-hydroxyethyl group or a carboxymethyl group] as a production intermediate. | 2 |
BACKGROUND OF THE INVENTION
This is a continuation-in-part of application Ser. No. 887,298 filed on or about Mar. 15, 1978, now abandoned, which in turn is a continuation of application Ser. No. 764,033 filed Jan. 31, 1977, now abandoned.
The invention in general relates to foamed plastic food containers having an integral dish and cover interconnected by a hinge at one end and a latching means at the other end. More particularly the invention relates to deformable containers that provide secure, positive locking means that automatically latch upon closing the containers.
Economical but sturdy containers are of great importance in the food service industry because they permit food to be handled, stored, and reheated routinely.
Early containers used tab type latching mechanisms and had the disadvantage that they required two operations and generally two hands to close. This is a decided disadvantage in fast food operations where speed and efficiency are essential.
Second generation food containers may be easily closed with one hand but have other disadvantages. This prior art is described in U.S. Pat. Nos. 3,876,130 and 3,935,962 which are hereby incorporated by reference. U.S. Pat. No. 3,876,130 describes a foamed plastic food container having a dish and cover interconnected along a portion of their rims by a hinge. Both the dish and cover have a flat flange integrally connected to that portion of their rim that is not contiguous to the hinge. The cover has a skirt integrally molded to and extending down and away from the flange. A recessed surface, or flute, is molded across the face of the skirt opposite the hinge. A slot is cut through the flute within the vertical area defined by the skirt. When the container is closed the flange on the dish rides up on the inclined plane of the skirt until it slips into the slot. In the closed position the skirt fits around the flange of the dish providing a loose "seal" of the container.
U.S. Pat. No. 3,935,962 in its relevant embodiment (i.e. the embodiment having a hinge) is similar to the U.S. Pat. No. 3,876,130 prior art described above except that it does not have a skirt on its cover, and the indentation is formed in the wall of the dish. As in the U.S. Pat. No. 3,876,130 prior art, the indentation is formed in the container in the side opposite the hinge and a slot is cut in the indentation. When this container is closed the flange, or lip, of the cover rides along the inclined plane formed by the indentation in the wall of the dish until it slips into the slot.
Both of the above-described containers have the advantage that they may be closed with one hand. However, opening either of these containers with one hand is quite difficult, and in the case of U.S. Pat. No. 3,935,962 opening with one hand will result in food spillage unless the container is supported with the other hand or with other means.
Both the prior art containers described above have the disadvantage that after molding they must be trimmed and slotted in two separate operations either on separate machines or on a very expensive die that has cutting capabilities in two directions at 90° to one another. The trimming operation is performed by a die moving downward over the molded container in a direction perpendicular to the base wall and top wall. The slotting operation is performed by a punch or knife moving in a direction parallel to the top wall or base wall. If both the trimming and slotting could be performed on the same operation by cutting dies moving in a single direction, much simpler and much less expensive equipment could be used in the manufacturing process. Furthermore the two-step process of the prior art normally requires additional mechanical handling of the molded container.
SUMMARY OF THE INVENTION
The invention provides a deformable container of the type having a bottom dish and a top cover interconnected by a hinge at one end and a latching means at the other end, the latching means having a male and a female portion. The container can be easily closed and opened with one hand, provides a secure, tight, positive seal between the dish and cover and can be manufactured with only a single cutting and trimming operation.
The container is preferably composed of foam plastic and molded in one piece. The bottom dish comprises a base wall and side walls outwardly inclined from the base wall and terminating at their edges remote from the base wall in a flared first rim. At one end of the dish the rim is integrally molded to the hinge and at the opposite end the first rim terminates at and is integrally molded to the male portion of the latching means. The top cover comprises a top wall and side walls outwardly inclined from the top wall and also terminating in a flared second rim. At one end of the cover the second rim is integrally molded to the hinge and at the opposite end the second rim terminates at and is integrally molded to the female portion of the latching means.
The male portion of the latching means comprises a central segment lying in a plane substantially parallel to the base and displaced above the level of the first rim in a direction away from the base, and supporting segments interconnecting the central segment and the first rim on each side of the central segment. The female portion of the latching means comprises an outwardly protruding chamber extending on the side of the second rim toward the top wall and forming a shelf where it meets the side wall. An inwardly protruding indentation is formed in the chamber toward the inner portion of the shelf. A U-shaped slot is cut into the chamber with the outer circumference of the U being formed in the shelf and the inner circumference of the U being formed in the inwardly protruding indentation. This design of the latching means permits the slot to be formed by a punch, knife, or die moving in a direction perpendicular to the plane of the top wall, bottom wall, and rims. This is possible because the shelf provides a plane parallel to the bottom and top walls and perpendicular to the movement of the die by which the cut may be made. In addition the raised central segment of the male portion of the latching means combined with the extension of the protrusion of the side of the second rim towards the base wall permit such a cut to be made without seriously affecting the structural integrity of the latching means. As a result the slot may be formed on the same machine by a die which moves in the same direction as the die which trims the containers from the sheet. Thus the invention may be manufactured with much simpler machinery than the prior art food containers. Furthermore one operation in which the molded container must be mechanically handled is eliminated, thus reducing the probability of misalignments which produce defective containers.
The hinge, bottom dish, top cover, and the male and female portions of the latching means are designed so that as the cover is rotated about the hinge toward the closed position the central segment of the male portion of the latching means rides on the inwardly sloping indentation until it snaps into the slot. Preferably the width of the slot in a direction perpendicular to the shelf is substantially greater than the thickness of the central segment so that the central segment easily slips into the slot even when the parts are subject to normal distortion. Preferably the hinge is biased so that upon release of the latching means the cover is urged away from the dish to bring the container into its open configuration.
In the preferred form of this invention, the slot is essentially free of radii and rather all sides of the slot are straight. This eliminates all problems of machining and maintaining the punch and die that form the slot. When radii are formed at the corners of the slot it is very difficult to achieve the proper curvature and at the same time provide the precise clearance between the punch and die to make a clean cut of the slot.
The container provided by the invention can be easily closed and opened with one hand. The height of the slot enables the central segment to easily slip into the slot even though the central segment and slot may be distorted due to closing pressure. The bias in the hinge causes the cover to pop open when the central segment is disengaged from the slot by applying pressure to the dish wall just below the central segment.
The invention also provides containers with no undercut or reverse tapers so that they may be easily removed from the mold and nested for efficient distribution and storage, and they may be easily denested by the user.
Numerous other features, objects and advantages of the invention will now become apparent from the following detailed description when read in conjunction with the accompanying drawing, in which:
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a side view of a closed container according to the invention with the hinge on the left and the latching mechanism on the right;
FIG. 2 is a view of the same container as in FIG. 1 showing the end having the latching mechanism (the front end);
FIG. 3 is a top view of the same container as in FIGS. 1 and 2;
FIG. 4 is a cross sectional view of the invention taken through the line 4--4 of FIG. 3;
FIG. 4A is an enlarged fragmentary view of a portion of FIG. 4 which also shows in ghost the position of the latching mechanism during the closing operation;
FIG. 4B is a fragmentary cross sectional view of one side of the container according to the invention taken through line 4B--4B of FIG. 4;
FIG. 5 is a top plane view of the container according to the invention, in the open position;
FIG. 6 is a cross sectional view of two containers according to the invention showing the manner in which one nests within the other;
FIG. 7 is a fragmentary perspective view looking down upon the female portion of the latching mechanism of the cover of the container; and
FIG. 8 is a fragmentary plan view of a portion of the cover showing the preferred configuration of slot.
DETAILED DESCRIPTION
Directing attention to the drawings, the invention will now be described in more detail. FIG. 1 shows the container according to the invention in its closed position. It comprises a top cover 10, a bottom dish 20, interconnected by hinge 30 at one end, and having a latching mechanism 40 at the other end. The invention resides primarily in the latching mechanism and in the intersection of the latching mechanism with other parts of the container, and thus the detailed description will be limited to these aspects, while the rest of the container will be described only generally.
The one piece molded construction of the container is best shown in FIG. 5. The bottom dish 20 comprises a base wall 22, and side walls 24 outwardly inclined from the base wall and terminating at their edges remote from the base wall in a flared first rim 26. At one end of dish 20 rim 26 broadens into a generally flat portion 34 which forms part of hinge 30. At the other end of dish 20 rim 26 terminates at and is integrally molded to the male portion 50 of latching means 40.
Top cover 10 comprises a top wall 12 and side walls 14 outwardly inclined from top wall 12 and terminating in flared second rim 16. At one end of cover 10 rim 16 broadens into generally flat portion 32 which forms part of hinge 30. At the other end of cover 10 rim 16 terminates at and is integrally molded to female portion 60 of latching means 40.
The male portion 50 of latching means 40 (FIG. 5) comprises a central segment 52 which lies in a plane substantially parallel to base 22 and rim 26, and is displaced above the level of rim 26 in a direction away from base 22, and supporting segments 54 which interconnect central segment 52 and rim 26 on each side of the central segment 52. Preferably rim 26 broadens in the area 56 where it joins supporting segments 54, thus strengthening this critical area.
Female portion 60 of latching means 40 includes an outwardly protruding chamber 62 (FIGS. 1, 4 and 7) having a portion 63 which extends above rim 16 (i.e. on the side of rim 16 toward top wall 12), and forming a shelf 64 where it meets side wall 14. Shelf 64 is substantially parallel to top wall 12 and rim 16. Chamber 62 preferably also has a portion 61 extending below rim 16 which serves to strengthens this part of the latch. An inwardly protruding indentation 68 is formed in chamber 62. Indentation 68 angles from the outer edge of chamber 62 toward the inner portion of shelf 64. The angle which indentation 68 makes with the vertical plane is such that the overlap between central segment 52 and indentation 68 (FIG. 4A) is sufficient to provide a secure lock. However, it is not so great as to prevent central segment 52 from riding easily on the inclined plane of indentation 68 while the container is being closed. Preferably the angle which indentation 68 makes with the vertical plane is somewhat greater than the angle side wall 14 makes with the same plane.
The female portion 60 of the latching means also includes a U-shaped slot 70 (FIG. 5) cut into chamber 62 with the outer edge 72 of slot 70 cut into shelf 64 and the inner edge 74 of slot 70 cut into indentation 68. As can be best seen in FIG. 5 slot 70 may be cut by a knife, die, or punch moving in a vertical plane (i.e. perpendicular to top wall 12). The width of slot 70 is such that when viewed in the vertical plane (FIG. 2) slot 70 is substantially wider than the thickness of central segment 52. Typically slot 70 may be about 3 times the thickness of central segment 52. It should be noted that if such a slot were cut in side wall 14 rather than shelf 64 the width of slot 70 when viewed in the vertical plane would be many times the preferred width which would substantially decrease the structural integrity of the container and increase the probability of the contents and/or vapors escaping from the container.
In FIG. 8, a modified slot configuration is shown which is the preferred form of this invention. The slot 70a is generally U-shaped in plan view, as is the slot 70 shown in FIG. 7. However, unlike the slot 70, slot 70a is defined by straight inner and outer edges 100 and 102, straight inner and outer side edges 104 and 106, and straight front edges 108. The several edges are not joined by radii but rather meet at square corners. Consequently, the punch and die used to cut the slot 70a is made with readily machinable parts. The clearance between the punch and die necessary to accurately cut the slot must be in the order of 0.001 inch, and it will be recognized that the machining tolerances necessary to provide that clearance can be achieved without great difficulty. However, if the slot is to have the shape shown in FIGS. 5 and 7 the curved surfaces must be very carefully machined and maintained if the cutting operation is to be done effectively.
Hinge 30, dish 20, cover 10, and male portion 50 and female portion 60 of the latching means 40 are such that as cover 10 is rotated about hinge 30 toward the closed position, central segment 52 aligns with indentation 68. As the closing motion continues central segment 52 rides on indentation 68, the container being sufficiently deformable so that indentation 68 moves out over central segment 52. Finally as rims 16 and 26 come in contact central segment 52 slips into slot 70 and indentation 68 snaps back under indentation 52 securely locking the cover. The vertical extent of slot 70 and the memory of the material at the hinge which urges the container open cooperate to produce a click sound when the container is closed, which signals that the container is properly latched. In addition, preferably, the relative thickness of strip 36 and slots 31 and 33 forming hinge 30 are such that in this closed position there is also a slight compression of the parts of the hinge creating a bias in the hinge. If side wall 24 is pressed inward at a point just below central segment 52 so that central segment 52 disengages from indentation 68, the bias in hinge 30 will cause top 10 to move away from dish 20; thus the container may be opened with one hand.
Skirt 80 of cover 18 extends downwardly from rim 16 and forms a continuation of lower portion 61 of chamber 62 (FIG. 1). In the preferred embodiment the lower edge 82 of skirt 80 is flared outward and at the front of the container broadens into a flat projection 83 which serves to strengthen the female portion 60 of latching mechanism 40 and also to protect the latching mechanism 40 from being accidentally opened. The forming of protrusion 62 in two segments 61 and 63, and the U-shape of slot 70 and indentation 68 (FIG. 2) also serve to strengthen the latching mechanism. Ridge 25, which is described below serves as a stacking shoulder, may be formed just below rim 26 of dish 20 in order to strengthen that area of the container. Raised ribs 28 may be formed in base wall 22 so that material placed in the container will be raised slightly from the base wall 22. This prevents the hamburger bun from becoming soggy by permitting air to circulate under it and also strengthens the base of the container.
FIG. 4B shows the manner in which skirt 80 overlaps the edge of rim 26 to form a more effective closure for the container. Skirt 80 also serves as a guide to align cover 10 and dish 20 as the container is closed. The angled supporting segments 54 of the male portion 50 of the latching means also help to maintain the parts in correct alignment upon closing.
The nesting feature of the containers is shown in FIG. 6. It can be seen in that figure that the lack of undercuts or reverse tapers in the containers allow sone to fit snugly into another. The vertical heights of ridge 25, skirt 80 and protrusion portion 61 provide positive stacking by virtue of the stock thickness of the material so that adjacent nested containers may be readily separated.
There has been described a novel deformable food container that can be easily closed and opened with one hand, provides a secure, tight, positive lock, can be trimmed and slotted during manufacture on the same machine, and has numerous other features. It is evident that those skilled in the art may now make numerous uses and modifications of and departures from the specific embodiments described herein without departing from the inventive concepts. For example cover 10 and dish 20, chamber 62, indentation 68, central segment 52, etc. may take on various shapes and dimensions, providing the critical relationships between the parts remain as described. The container may be composed of any suitable materials such as pressed fiber, pulp, etc. rather than the preferred plastic foam. Also the container may be inverted in the sense that the male portion 50 of the latching means may be located on cover 10 and the female portion 60 of the latching means may be located on dish 20. This embodiment of the invention would require dish 20 to be independently supported when the container is opened with one hand, but would retain the other advantages discussed above. Consequently the invention is to be construed as embracing each and every novel feature and novel combination of the features present in or possessed by the container herein described. | A foamed plastic food container having a dish and cover interconnected by a hinge at one end and a latching means at the other end. The hinge is biased towards the open position. The latching means comprises a male flange-like member raised above the rim of the dish and a female member on the cover. The female member comprises an outwardly protruding chamber having an indentation sloping inward toward a shelf, with a U-shaped slot being cut into the indentation and shelf. The slot is substantially wider than the width of the flange thereby permitting easy closing and opening. | 1 |
CROSS REFERENCE TO RELATED APPLICATION
[0001] This application is a continuation of U.S. patent application Ser. No. 12/932,880, which was filed on Mar. 9, 2011, which claimed priority to the provisional patent application having Ser. No. 61/340,995, having a filing date Mar. 25, 2010.
FIELD OF THE DISCLOSURE
[0002] This disclosure relates primarily to fluid or fuel dispensing nozzles, and more specifically pertains to a modularized components assembled fluid dispensing nozzle, wherein the detailed operative components of the nozzle such as its poppet valve assembly, the automatic shutoff assembly, and other components are designed and assembled as modularized components, and can be easily removed and replaced intact in their entirety, for purposes of service, cleaning, repair, or replacement.
BACKGROUND
[0003] This disclosure relates to a dispensing nozzle. Many nozzles have been designed, developed, patented, and used in the past, that incorporate the usual operating components, such as poppet valves, hand lever assemblies, automatic shutoff components, and various spout designs, and many of such prior developments have been undertaken by the assignee of the current disclosure herein, who has been in the business of manufacturing and marketing dispensing nozzles for many, many years. For example, the assignee's prior U.S. Pat. No. 5,127,451, upon a dispensing nozzle improvement, in its main embodiment, shows the balanced pressure type of nozzle, that does incorporate a poppet valve, an automatic shutoff and its diaphragm assembly, including an operating hand lever system, to provide for dispensing of fuel when the nozzle has been conveniently applied to the fill pipe of a gasoline tank for automobiles, and other machines. The United States patent to the same assignee, U.S. Pat. No. 5,474,115, shows a related style of poppet valve, and a shutoff assembly, for a nozzle, as can be noted. Most of these earlier nozzles, and the various components as identified that are fitted into their structure, require a complete assembly of these components for the nozzle, from a myriad of individual parts, which must be assembled into the nozzle body, during constructing of the nozzle. Or, if several of these components need servicing or cleaning in a well used fuel nozzle, these components must be individually removed, all the parts disassembled, in order to provide for servicing of the subject nozzle. This not only requires a service person of high engineering and mechanical skill, but is very time consuming to service such a used nozzle, frequently requiring a replacement of the entire dispensing nozzle, and returning the used nozzle back to the manufacturing plant, for rebuilding. Thus, one of the primary objects of the current disclosure is to provide for a modularization of select of these components for a nozzle, so that the service person, even in the field, can simply remove a poppet modularized component, or an automatic diaphragm operated shutoff component, and simply replace it with a modularized new component, directly in the field, in a minimum of time, to substantially reduce the complexity of the nozzle handling, and to significantly reduce the amount of time involved in servicing such a product.
[0004] The assignee's U.S. Pat. No. 5,562,133, shows another dispensing nozzle, and how all of the individual parts that make up the operating components for the shown nozzle, such as the poppet valve 20, and the automatic shutoff assembly 70, are located within the nozzle structure, as shown assembled. The assignee's U.S. Pat. No. 6,394,139 shows how an elliptical expansion plug has been applied to a universal nozzle casting body, so as to facilitate its servicing when it is taken apart, or even when the nozzle is initially assembled, during its building. Finally, the assignee's U.S. Pat. No. 6,585,014 shows an easy opening dispensing nozzle, but more specifically pertains to a novel lever assembly that regulates the flow of the fuel through the nozzle.
[0005] The current disclosure is designed to significantly improve upon the structure of the various components that make up the assembled dispensing nozzle, and more particularly to modularize the various operative components, so that they can be easily removed from the nozzle, replaced with a new like modular component, to greatly facilitate and reduce the amount of time involved in servicing of a dispensing nozzle in the field.
SUMMARY OF THE DISCLOSURE
[0006] This disclosure relates primarily to a dispensing nozzle, as previously alluded to, and more particularly involves the modularization of select operating components for a dispensing nozzle, so that the mod units, as a whole, can be easily removed, and replaced, during servicing, all of which may take place within the field.
[0007] Anyone familiar with dispensing nozzles knows that the nozzle is made up of nozzle housing, having at its frontal end and applied thereto its dispensing spout, held to the housing body by means of gland, and retention nut, which rigidly affixes the spout to the nozzle, during assembly, and for usage. Such a nozzle body also includes an inlet, at its back end, normally at the rear end of the portion of the nozzle that is grasped and held by the hand, in preparation for dispensing. Furthermore, the nozzle body includes a flow path there through, which is blocked, during shutoff, by means of the poppet valve part. It is known in the art that such poppet valves include a valve that seals internally of the nozzle body, to prevent the further flow there through, and the poppet valve is normally held into tight closure position by means of the poppet spring. And, to attain an operating opening of the poppet valve, when fluid is to be dispensed, a valve stem extends downwardly from the poppet valve, and is contacted by the operating lever for the nozzle, which when the hand lever is actuated and raised, the poppet stem biases against the force of the poppet spring, to allow for an opening of the main poppet valve for the nozzle, providing for the dispensing of fluid. Furthermore, since nozzles of these type currently are constructed of rather sophisticated technology, containing many, many operating parts, there is also an automatic shutoff means provided within the nozzle housing body, and that shutoff means operates in accordance with the various vacuums generated within the nozzle, during the flow of fluid through its housing, and which vacuums operate upon the shutoff means diaphragm, to provide for release of the automatic shutoff plunger, which provides for a lowering of the hand operating lever, which provides for a shutoff of the poppet valve, to curtail further flow of fluid through the dispensing nozzle.
[0008] The current disclosure, and what are believed to be its improved features, provides a nozzle that has the unique ability to remove modular cartridges from the functional areas of the nozzle for their ease of cleaning, replacement, and servicing, particularly when dispensing different or alternative fluids. Thus, with a modularization of the poppet valve assembly, into a cartridge configuration, this disclosure provides for the ability to remove the same by simply making a minor turn of the poppet valve retaining cap, so that the entire poppet valve assembly can be pulled upwardly, and out of the housing body, and a new modular cartridge for a poppet valve simply inserted therein, which greatly expedites the servicing of the poppet valve component of the dispensing nozzle.
[0009] Another advantage is to provide means for holding the spout assembly, as previously identified, with a unique spout nut that requires only an approximate quarter turn for its removal, and separation of the spout from the nozzle body housing, when the spout needs to be replaced or serviced.
[0010] Another advantage is the modularization of the design of the automatic shutoff means, and its diaphragm assembly, so that once the diaphragm cap is removed the entire diaphragm and plunger assembly as a unit can be removed, for immediate servicing, or replacement with a new modularized unit, furnishing a quick and expedited servicing of the nozzle, at this location of its component assembly, as required. Thus, it is the design of the modular cartridge components that facilitate their ease of removal, and replacement, when servicing, in the field, as required.
[0011] Another benefit is the capability of holding the plunger spring to the vacuum cap and the diaphragm assembly to assist with its assembly and disassembly, during servicing.
[0012] Another benefit of this disclosure is that the poppet structure, and the venturi for the nozzle, is combined into the same area to facilitate its modularity.
[0013] Finally, the hand guard as assembled with its binding post fasteners assists with the ease of assembly, and disassembly, during servicing, of the hand operating lever, even in the field. This has not been capable of consistent performance, previously, and quickly by a service man, at the site of servicing of a nozzle at a service station or other location.
[0014] It is, therefore, the principal object of this disclosure to provide a unique dispensing nozzle, where several of its operating components are modularized, can be removed intact, and replaced by a new mod component, for servicing directly in the field.
[0015] Another object of this disclosure to provide a dispensing nozzle where its various operating components are of a modularized assembly, and therefore, these various components can be assembled separately, as both at the plant, and simply added into the nozzle in the field, to greatly facilitate and expedite the assembly of a new nozzle, even at the manufacturing plant, at the site of its assembly and construction.
[0016] Another object of this disclosure is to provide components for fluid dispensing nozzle that have been well thought out as modularized of assembly, and can be applied or removed intact, when the nozzle is being manufactured, or serviced.
[0017] These and other objects may become more apparent to those skilled in the art upon review of the summary of the disclosure as provided herein, and upon undertaking a study of the description of its preferred embodiment, in view of the drawings.
DESCRIPTION OF THE DRAWINGS
[0018] In referring to the drawings,
[0019] FIG. 1 provides a side view of the assembled dispensing nozzle of this disclosure;
[0020] FIG. 2 provides a sectional view, along the length and through the center of the nozzle, showing its various operating components, the sectional view being taken of the nozzle as disclosed in FIG. 1 ;
[0021] FIG. 3 shows an exploded view of the modularized poppet component being inserted or removed from the nozzle housing body during its assembly or servicing;
[0022] FIG. 4 shows an exploded view of the automatic shutoff diaphragm and its component assembly in the process of being applied, or removed, from the nozzle housing body during its assembly or servicing;
[0023] FIG. 5 shows a new style of spout, gland, and retaining nut as removed from the front of the nozzle housing body;
[0024] FIG. 6 discloses how the hand operating lever assembly for the fuel dispensing nozzle can be removed intact, as a modularized component;
[0025] FIG. 7 shows the poppet cap being removed from the nozzle housing body in the vicinity of the location of the poppet valve therein;
[0026] FIG. 8 provides a top view of the poppet cap of FIG. 7 ;
[0027] FIG. 9 shows a sectional view of the poppet cap taken along the line 9 - 9 of FIG. 8 ;
[0028] FIG. 10 shows a side view of the poppet cap;
[0029] FIG. 11 shows a side view of the poppet cap as it has been quarter turned from the view of the poppet cap in FIG. 10 ;
[0030] FIG. 12 shows the retaining nut as removed from the front of the nozzle housing body;
[0031] FIG. 13 is a front view of the retaining nut of FIG. 12 ;
[0032] FIG. 14 is a back view of the retaining nut for the spout and showing the spaced segments of threads applied internally thereof; and
[0033] FIG. 15 provides a sectional view of the retaining nut taken along the line 15 - 15 of FIG. 14 .
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0034] In referring to the drawings, and in particular FIG. 1 , a dispensing nozzle, as modified for the construction and installation of the modularized components assembled dispensing nozzle of this disclosure, is shown at N. The nozzle, as previously summarized, includes a nozzle housing body 1 , which includes it back end as at 2 , which is normally threaded internally, and to which the dispensing hose through its swivel connector attaches therewith, in a fluid sealed relationship. The nozzle body includes an integral upright segment 3 and it is within this segment that the poppet valve assembly locates, and which provides for the shutoff of the nozzle when dispensing is completed, or which can be elevated, to open the flow passage there through, so that fluid may traverse through the nozzle, for dispensing into the fill pipe of an automobile or other fluid receiving container. An operating hand lever 4 pivotally connects within the lever guard 5 and upon grasping the handle body portion 6 of the nozzle body, with the hand, and extending the fingers around the lever 4 , it can be raised, for opening the main poppet valve for the nozzle, when dispensing is to commence. Forwardly of the poppet valve portion of the nozzle is the automatic shutoff integral casing 7 for the nozzle, and it is herein that the diaphragm and the automatic shutoff means for the nozzle is provided, so as to furnish an instantaneous shutoff to the flow of fluid through the nozzle, when the fluid tank and the fill pipe have been filled with fluid, and the fluid blocks the tip end 8 of the spout 9 , as is well know in the art. The spout 9 is connected by means of the spout gland 10 and the spout retaining nut 11 to the integral frontal part of the nozzle housing 12 so as to complete the structure of the entire nozzle, and its integral components, into an operating dispensing nozzle. As shown in this model for the nozzle, is the elliptical expansion plug 13 , which allows the nozzle to be converted into different styles of dispensing nozzles, so that one casting can be used as a universal housing for the variety of nozzles that are fabricated, for dispensing select styles of fluid to the trade.
[0035] As to be seen in FIG. 2 , which is a sectional view throughout the length of the shown dispensing nozzle of FIG. 1 , the nozzle body 1 has its threaded means 14 provided at its back end, as previously described, and the poppet valve assembly, as noted at 15 , is embodied within the poppet valve portion 3 of the housing, as to be noted. A poppet cap 16 threadidly engages within the poppet housing 3 , at its upper end, and provides the means for biasing against the poppet spring 17 which forcefully presses down on the poppet seal holder 18 to normally maintain the poppet valve 15 in its closed position, as shown in FIG. 2 , as noted. As to be seen, the poppet stem 19 locates upwardly within the poppet 18 , while at the bottom end 20 the stem 19 biases against the operating lever 4 , at the vicinity of its forwardly extending end 21 , as to be noted. Thus, when the operating lever 4 is raised, the stem 19 is raised upwardly, by the lever pushing against the bottom end 20 of said stem, and forces the poppet holder or hat 18 and its valve 15 to rise upwardly; this allows fluid to pass through the flow path of the nozzle, on its way towards the spout 9 .
[0036] What is unique, though, about the structure of the specific nozzle as shown and described herein, and as to be seen in FIG. 3 , the entire poppet valve assembly 22 , as to be noted, has been modularized, once its cap 16 has been removed, and, if necessary, with its retainer latch pin which normally locates within the lower groove 23 is removed, the entire modularized poppet assembly, with its cap 16 can raise upwardly, and be easily removed from the formed poppet housing 24 of the poppet housing structure 3 as described, and as can be noted. Thus, it is a very easy function for the service person in the field, to simply remove the retainer latch as 23 , lift the poppet cap 16 by threadily unthreading it from the nozzle body, wherein the poppet spring 17 , in the poppet valve structure 18 , can be readily removed, and replaced, by a new mod unit, directly in the field. It is to be noted that the entire mod unit for the poppet assembly is tapered from its top to the bottom to ease its removal or installation during nozzle services. This may take a matter of minutes to complete that servicing function, which heretofore, required an entire disassembling of the nozzle, a removal of its component parts structured into the poppet valve assembly, which normally could not be done in the field, and had to be performed back at the manufacturing plant, where the nozzle is brought to for rebuilding.
[0037] Another means for engagement of the poppet cap 16 , through its threads 25 , as to be noted, is shown in FIG. 7 , and its engagement with the sectionalized threads 26 within the poppet structure 3 of the housing, discloses a uniquely designed thread pattern having spaced gaps, as at 27 and 28 provided between sections of the shown threads, which allows for the poppet cap to simply undertake a quarter turn, in order to achieve its removal from the nozzle housing, during a servicing function. Hence, this drastically reduces the amount of time involved in having to service the nozzle, particularly of this poppet structure, in the field. A socket, as shown at 29 , is provided within the upper exposed surface of the poppet cap 16 , and then a tool or wrench can be applied therein, turned for a quarter turn, which allows the entire cap to be removed, for prompt removal of the poppet spring, and the modularized poppet valve assembly, from the nozzle housing, for replacement.
[0038] As previously stated, the automatic shutoff part of the housing, as at 7 , is shown forwardly of the poppet valve assembly area, and it is within this portion of the nozzle that the automatic shutoff means 30 locates. As can also be seen in FIG. 4 , the shutoff means includes its cap 31 , that threadidly engages by means of fasteners, as at 32 , to the nozzle body, and provides for coverage eternally thereof of the entire automatic shutoff unit 30 , in its modular form, as to be noted. The diaphragm for the automatic shutoff is noted at 33 . This diaphragm assembly, with the cap, cooperates with the latch pin 34 that holds the plunger 35 fixed in position and held upwardly within the assembly structure, as known in the art, to allow dispensing of fuel to continue, until such time as the tip of the nozzle spout 9 becomes emersed in fluid as it fills the tank and fill pipe for the vehicle or fluid receiving container, which breaks the generated vacuum, and pulls the latch pin upwardly, for allowing the plunger 35 to shift downwardly to release the handle lever 4 to drop downwardly, allowing the poppet to lower within the nozzle housing body, and to shutoff the further flow of fluid through the dispensing nozzle. Many of these components are standard in the industry, with the exception that they have been modified to provide for their structuring into a modularized type of component, so that once the shutoff cap 31 is removed, through removal of its fasteners 32 , and the hand lever pin 36 is removed, the entire automatic shutoff means 30 can be shifted upwardly, pulled out of the nozzle housing, and be immediately replaced with a new automatic shutoff diaphragm unit, and allow the nozzle to be immediately put back into service, as can be understood. Note that the entire unit has a tapered configuration, to ease its rebuilding and replacement. All of this can be done by the service person in the field, at the service station, or at any other location where fluid is being dispensed, without requiring the nozzle to be removed, and shipped back to the manufacturing plant, for rebuilding. Thus, the modularized component for the diaphragm automatic shutoff means 30 , as to be seen, is of an integral structure, and can be lifted free from the nozzle body 7 as noted in said FIG. 4 .
[0039] Thus, this provides a second part of the modularized components for the dispensing nozzle of this disclosure, which can facilitate servicing of the nozzle, in the field, in a most prompt, efficient, and facile manner. The service man does not need to pick apart the entire structure of the automatic shutoff unit 30 , in the field, and separate all of its many functional components, but rather, can simply place the entire new modular unit, intact, directly into the cavity 37 of the nozzle body 7 , apply the shutoff cap 31 in place, fasten it into closure, and reapply the pivot pin 36 , for the hand lever, as noted. This provides a second form of modularized componentry for the dispensing nozzle of this disclosure.
[0040] As can further be seen in the structure of the dispensing nozzle of this disclosure, the operating hand lever 4 connects at two locations with the nozzle. The initial one is the biasing of the bottom end 20 of the poppet stem 19 against the forward lever component 21 , and secondly, the use of the pivot pin 36 , which holds the front of the hand lever pivotally to the bottom of the automatic shutoff plunger 35 , as previously explained. As can also be seen in FIG. 6 , even the hand lever 4 can be readily removed from the structure of the dispensing nozzle, with only a few minor disengagements. For example, the removal of a pin at the upper back part of the hand guard 5 , where the pin locates through the pair of apertures 38 and 39 , and the removal of a pin that locates through the aligned apertures 40 and 41 , the latter being located at the upper front of the hand guard 5 , allows for the hand guard to be removed. Then, if the operating hand lever 4 has been damaged, or worn-out, a simple removal of its pivot pin 36 provides for a release of the operating handle 4 , and its immediate replacement, with all of its various components that are attached thereto, such as the lever 4 , its latch clip 42 , and the various anti-rattle springs and clips, as noted at 43 , all may be replaced, as a modular type component, when any part of it becomes worn-out, or soiled to the extent that it must be replaced. Once again, this is a simple procedure to be preformed by the service person in the field, which makes this nozzle much more customer friendly, able to be immediately serviced in the field, and not require the customer to buy a new or rebuilt nozzle, at a substantial savings in cost and usage. This provides a third type of modular componentry for the dispensing nozzle of this disclosure.
[0041] Another improvement to the structured assembly of the dispensing nozzle of this disclosure, and which renders it efficient in its servicing particularly within the spout area of the nozzle, can also be seen in FIG. 2 . As noted, the spout gland 10 connects upon the upper end of the spout, and seals therewith, and is held in position rigidly affixed to the integral frontal end of the nozzle housing 12 by means of the spout retaining nut 11 . These elements can also be seen in greater detail in FIG. 5 . The tube 44 is the conventional vent tube that extends to the forward end of the spout, as can also be seen in FIG. 2 , which cooperates to provide for the automatic shutoff of the nozzle when the tank becomes filled. The retaining nut 11 can be seen in greater detail in FIGS. 12 through 15 , and said nut includes segments of threads 45 both extending approximately, or less, 90.degree. internally of the retaining nut, as can also be seen in FIG. 14 . In addition, the threaded end of the nozzle body 12 includes segments of threads, as at 46 , that extend also approximately 90.degree., or less, around the outer circumference of the shown body 12 . Hence, when the retaining nut, as affixed upon the spout gland 10 , and retains the spout 9 herein, said retaining nut is threadily engaged upon the nozzle body 12 , with the nut 11 being turned approximately a quarter turn, to provide for a very firm interconnection between the retaining nut, and the nozzle body, thereby holding the spout fixedly in place, upon the frontal portion of the nozzle, as to be noted in FIGS. 1 and 2 of the disclosure. Obviously, the outer surface of the retaining nut 11 includes a series of lands, as at 47 , to accommodate a wrench, that allows for the forceful application of the retaining nut in place, when the spout is being affixed to the front of the nozzle body, or to be turned counterclockwise, for its removal, when it is necessary to remove and replace the spout from the structure of the dispensing nozzle. Hence, this provides another facile manner in which the components of the dispensing nozzle can be immediately removed, in the field, and readily replaced, within a minimum of time and effort.
[0042] Thus, the concept of this disclosure is to transfer the servicing of various operating components of a dispensing nozzle, from the manufacturing plant, as where nozzles are normally manufactured or rebuilt, out into the field, at the location of their usage, usually at a service station, with a minimum of effort on the part of the service person. Furthermore, this allows the service person to remove the various modular cartridges from the functional areas of the nozzle, for ease of their cleaning or replacement, particularly when the nozzle may be used for dispensing alternate fluids, which may require different type of seals, and o-rings in the operating structures of the components, all of which can be done directly in the field, when a service station may be switching over from dispensing routine fluids, or for use for dispensing fluids that may be used on the farm, or elsewhere. Thus, the nozzle is designed for accommodating its revision and modification directly at the site of its usage, this makes the nozzle much more compatible for accommodating a variety of fluids, and to be modified in situ, when the owner selects the type of fluid to be dispensed, requiring the nozzle to be modified accordingly, to accommodate such different usage.
[0043] Variations or modifications to the subject matter of this disclosure may occur to those skilled in the art upon review of the development as described herein. The various components of the nozzle, and their embodiment into modular form, may be considered by others upon review of the disclosure as provided herein. Such variations, if within the spirit of this disclosure, are intended to be the encompassed with the scope of any claims to patent protection that may be provided herein. The specific structure of the nozzle, and its various components, as described in the application, and as depicted in the drawings, are set forth for illustrative purposes only. | Modularized components assembled dispensing nozzle, including operating components in the category of a poppet valve assembly, an automatic shutoff device, a hand operating lever for providing a turn on or shutoff of the dispensing of fluid through the nozzle, and a connected spout that delivers fluid to the fill pipe and fuel tank for a vehicle or fluid accepting container. Each of the identified components having been redesigned for assembly in modularized form, such as a modular cartridge for the poppet valve, a modular cartridge for the automatic shutoff device, a modularized operating hand lever, and a spout and its gland and retaining nut that provide for high speed interconnection with the nozzle body, during assembly, or servicing. Each of these modularized components can be installed, during assembly of the manufactured nozzle, or can be replaced, out in the field, by a service person, as a modularized component or cartridge assembly. | 1 |
This application claims priority of PCT application PCT/CH2004/000337 having a priority date of Jun. 12, 2003, the disclosure of which is hereby incorporated herein by reference.
FIELD OF THE INVENTION
The invention relates to a loom.
BACKGROUND OF THE INVENTION
A loom of the type initially mentioned is known from WO 99/13145. The loom contains a warp thread tensioning device and a shedding device which has warp threads pretensioned into a first shedding position. A lifting device capable of being driven in oscillation is equipped with drivers for the warp threads, there being control means actuable by means of actuators, in order to bring the warp threads selectively into engagement with the drivers which move the warp threads into a second shedding position. There is the disadvantage that, in this loom, the lifting device equipped with the drivers has to move along the entire travel of the warp threads from the first shedding position as far as the second shedding position. The lifting device therefore has to execute a relatively long travel, which, on the one hand, is time-consuming and, on the other hand, requires higher drive forces. In order to avoid this, in WO 99/13145 there is a further exemplary embodiment, in which the warp threads assume a middle shedding position and there are two lifting devices which each have drivers in order to move the warp threads either into the top shedding position or into the bottom shedding position. This requires double the number of drivers, with the result that such a design variant is highly complicated and consequently cost-intensive.
SUMMARY OF THE INVENTION
The object of the invention is to improve a loom of the type initially mentioned.
The set object is achieved by means of the characterizing features of claim 1 . Since the loom has a second lifting device which is common to all the warp threads and which moves the warp threads out of the first shedding position into a switching position effective for the first lifting device, this results, for all the warp threads, in a very simple second lifting device which, moreover, appreciably reduces the switching travel for the first lifting device, so that the first lifting device has to move a warp thread only out of the switching position into the second shedding position. Both lifting devices have to execute only a limited travel for which they require less time.
Moreover, since the lifting devices can be active simultaneously, an appreciable increase in the performance of the loom is obtained. In addition, owing to this design, the useful life is also improved owing to the lower susceptibility to wear. The loom also results in lower noise emission. Advantageous refinements of the loom are described below.
The second lifting device may be a lifting beam extending over all the warp threads. The lifting travel of the second lifting device may vary greatly, and it is advantageous if, the latter executes at least half the lifting travel of the warp threads in the shed.
For the design of the first lifting device, there are various design variants which are already contained in WO 99/13145. An embodiment that is particularly advantageous, includes a first lifting device which has for each warp thread a control drop wire with a driver slot and an assigned driver, preferably of hook-shaped design, for the associated warp thread. The warp thread can be brought selectively into engagement with the driver by means of a control drop wire switchable by means of the actuator. In some embodiments, the driver slot is assigned to the displacement path of the driver and, in the switching region, is guided, via a control slot running obliquely with respect to the direction of displacement of the driver, out of the displacement path of the driver into a widened guide slot of the control drop wire. To facilitate the introduction of the warp thread into the control slot, the guide slot is provided with a run-on side.
In principle, the control drop wire may be configured as a sheet steel strip. In one advantageous design, the control drop wire is formed in the shape of a sleeve with two side walls, between which the driver is mounted displaceably. A reliable guidance of the warp thread from and to the driver is thereby achieved. To protect the warp thread, on the one hand, and to facilitate the run of the warp thread through the control drop wire, on the other hand, at least the guide slot and the control slot are offset relative to one another in the two side walls of the control drop wire in the direction of run of the warp thread, in such a way that a deflection of the running warp thread in the control drop wire is lower than 90°, preferably 10°.
There are various possibilities for driving the drivers, there being preference, for all the drivers of a row to be movable up and down by means of a common lifting knife. This affords a particularly simple and cost-effective solution.
Since the warp threads are moved in each case out of a first shedding position into the second shedding position, their displacement travel is such that the elasticity of the warp thread is not sufficient, as a rule, to ensure satisfactory functioning. It is therefore advantageous if, the warp thread tensioning device has an individual thread tensioner for each warp thread on the run-in side of the warp threads to the shedding device. The tension of the individual warp thread can thereby be adapted more closely to the respective position of the warp thread in the shed. The loom may have the conventional additional catch thread devices. It is more advantageous, however, if, the thread tensioner is at the same time also designed as a catch thread device.
In some embodiments, each warp thread is guided via two guide elements which are arranged at a distance from one another and between which is arranged the thread tensioner which engages on the warp thread and exerts a pretension on the warp thread. The pretension may be generated by a tensioning weight. In a more advantageous design, the pretension is generated by a tensioning spring. This also makes it possible, in particular, to arrange the thread tensioner in a position deviating from the vertical.
The thread tensioner may be provided with a closed eye. In a more advantageous design however, each thread tensioner has a lateral run-in eye for the warp thread. In some embodiments, each thread tensioner is provided with a guide orifice, by means of which it is mounted on a holder displaceably in the tensioning direction. Expediently, the thread tensioner is provided, in the direction opposite to the pretensioning direction, with a grip part which preferably has a signal part projecting out of the direction of displacement. Such a signal part may be, for example, a projecting head part of the thread tensioner. As a result, a thread tensioner on which a thread fault has occurred can be detected more easily, since it emerges from the plane of the thread tensioners which are operating satisfactorily.
It is particularly expedient if, the thread tensioner is arranged on a holder which has a middle contact part which projects on one side and which, insulated, is embedded into lateral contact parts cooperating with the sides of the guide orifice of the thread tensioner. In the event of a faulty warp thread tension, the contact parts come into touch with an end face of the guide orifice, this touch bridging the contacts and thus triggering a fault signal.
The thread tensioner can be used in the most diverse possible looms. It is preferably used, however, in a loom in which the warp thread tensioning device has a control device which is connected to the drive of a cloth take-up in such a way as to control the warp beam such that the warp threads as a whole are under a predeterminable tension force. The retaining force may be generated by means of a braking device at the warp let-off. To generate the retaining force in a more advantageous embodiment, the warp beam is provided with specific drive which contains a selflocking gear. The warp thread tensioning device can be further improved by means of the design, according to which it has a back bearer for the warp threads which is pretensioned by means of a tensioning spring device. The tensioning spring device is connected to the control device, so that the drives of the warp beam and of the cloth take-up can be controlled in such a way that the predeterminable tension force is maintained at the back bearer. Various variants may be envisaged for the design of the tensioning spring device. In a particularly advantageous embodiment, the tensioning spring device has a leaf spring with a flexion converter which delivers corresponding control signals to the control device. In addition, the warp thread tensioning device may be designed with a safety device which is operatively connected to the back bearer and which contains an emergency switch which responds when the force of the warp threads which occurs in the back bearer is greater than the set tension force by a determinable safety amount.
BRIEF DESCRIPTION OF THE DRAWINGS
Exemplary embodiments of the invention are described in more detail below with reference to the drawings in which:
FIG. 1 shows a diagram of a loom in a side view;
FIG. 2 shows a detail of the shedding device of the loom of FIG. 1 on a larger scale;
FIG. 3 shows the shedding device of FIG. 2 in the section III-III;
FIGS. 4-8 show various work stages of the shedding device of FIG. 2 ;
FIG. 9 shows the diagram of a further loom with individual thread tensioners in a side view;
FIG. 10 shows the thread tensioner of the loom according to FIG. 9 on a larger scale, and
FIG. 11 shows a detail of the device according to FIG. 10 .
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 shows diagrammatically a loom which, in general, has a warp let-off 2 which is designed, for example, as a warp beam, from which warp threads 4 arrive at the shedding device 12 via a back bearer 6 , individual thread tensioners 8 and catch thread devices 10 . In the shedding device 12 , the warp threads 4 are opened to form a shed 14 into which can then be introduced a weft thread 16 which is beaten up at the beating-up edge 18 , so that a cloth web 20 is obtained. The cloth web 20 , held by a cloth holder 22 , is taken up via a cloth take-up 24 . A control device 26 serves for controlling the loom.
The loom is provided with a thread tensioning device which primarily contains the cloth take-up 24 , the drive 28 of which is controlled by means of the control device 26 such that a predeterminable tension force common to all the warp threads 4 is given as a function of the retaining force of the warp let-off 2 . The retaining force of the warp let-off may be generated by means of a braking device 29 or a specific drive, in which a motor is connected to the warp let-off via a selflocking gear. The warp thread tensioning device additionally contains, for each warp thread 4 , an individual warp thread tensioner 8 which is arranged between two guide elements 30 and, in the example shown, individually pretensions, by means of a pretensioning spring 32 , the warp thread 4 which runs through an eye 34 .
In the shedding device 12 , the warp threads 4 are pretensioned into a first shedding position F 1 between a deflecting roller 36 and a cloth holder 22 which may also be designed as an expander. A first lifting device 38 serves for the individual control of the warp threads 4 , said lifting device having drivers 40 which can be moved out of a switching position F 2 into the second shedding position F 3 by means of a lifting beam 42 . With the aid of control means 46 controllable by actuators 44 , the warp threads 4 can be brought selectively into engagement with the drivers 40 when the warp threads have been moved out of the first shedding position F 1 into the switching position F 2 by means of a common second lifting device 48 , as is evident in detail in FIGS. 1 to 8 . The control means 46 contain control drop wires 50 which are pretensioned by means of a pretensioning spring 52 against a lifting beam 54 on which they stand via a stop 56 . The actuators 44 contain hook parts 58 which cooperate with hook parts 60 on the control drop wires 50 and, in the activated state, hold the control drop wire 50 in the lifted position. A nonactivated actuator 44 enables the displacement travel of the control drop wire 50 . In FIG. 1 , each control drop wire 50 is symbolized by its switching travel, as illustrated in detail by means of FIGS. 2 to 8 . Thus, the control drop wires contain a driver slot 62 which lies in the displacement travel of the warp thread 2 . The driver slot has adjoining it upwardly a control slot 64 which guides the warp thread out of the displacement travel of the driver into a widened guide slot 66 , so that it can no longer be grasped by the driver 40 .
As may be gathered from FIGS. 2 and 3 , the control drop wire is designed in the form of a sleeve and has side walls 68 , 70 which are connected by means of end walls 72 , 74 and which thus provide a cavity in which the driver 40 is mounted displaceably. In particular, the driver slots 62 a and 62 b are arranged in the side walls 68 , 70 so as to be offset in the direction of run of the thread in such a way that the warp thread, when it passes through the control drop wire, is inclined at an angle α from the vertical with respect to the control drop wire which is smaller than 90°, preferably 40°, in order to keep as low as possible the passage resistance of the warp thread through the control drop wire and consequently the wear of the warp thread, on the one hand, and of the control drop wire, on the other hand.
The functioning of the shedding device is illustrated in more detail with reference to FIG. 1 in conjunction with FIGS. 2 to 8 . When the control drop wire is in the lifted position, in which it is retained on the actuator, as may be gathered from FIG. 1 for the actuator on the right and from FIGS. 2 , 4 and 5 , the warp thread is guided by means of the second lifting device 40 out of the guide slot 66 via an oblique run-on side 76 into the control slot 64 and by means of the latter into the driver slot 62 in which the warp thread lies in the displacement travel of the driver 40 . During the downward movement of the driver 40 , the warp thread 4 is driven by the hook 40 a of the driver 40 out of the switching position F 2 into the second shedding position F 3 which is the bottom shedding position. As long as the control drop wire 50 remains in the lifted state, the warp thread 4 is moved to and fro by the amount of the height H 1 only between the switching position F 2 and the bottom shedding position F 3 , as is evident from FIGS. 2 and 4 to 6 .
As soon as the actuator 44 releases the control drop wire 50 and the latter is lowered by the amount of the switching quantity S, during the upward movement of the driver 40 the warp thread passes via the control slot 64 into the widened guide slot 66 and consequently outside the displacement travel of the driver 40 . Then, as may be gathered from FIGS. 7 and 8 , the warp thread passes again into the displacement travel of the second lifting device 48 and is moved over the height H 2 out of the switching position into the first shedding position F 1 which is the top shedding position.
FIG. 9 shows a loom with a special design of the warp thread tensioning device and of the thread tensioners, which loom may have, for example, a shedding device according to the loom of FIG. 1 . The loom contains a warp beam 2 a , from which warp threads 4 are guided via a back bearer 6 a to individual thread tensioners 8 a which are arranged upstream of a shedding device 12 a . The shedding device 12 a may be designed similarly to the shedding device 12 of the loom of FIG. 1 , but may also have other designs. The cloth web 20 produced is taken up via a cloth take-up 24 a and wound up on a cloth beam 80 . The loom contains a control device 26 a which is designed, in particular, for controlling the warp thread tensioning device. The warp beam 2 a is actuated by a drive 82 which has a selflocking gear 84 . The drive is controlled by the control device 26 a , specifically as a function of the drive 28 a of the cloth take-up 24 a and of a tensioning spring device 86 with which the back bearer 6 a stands against the warp threads 4 . The control is such that the cloth take-up 24 a is set as a function of the retaining force of the drive 82 of the warp beam 2 a such that a predetermined tension force can be maintained at the back bearer 6 a.
The warp beam 6 a is fastened to a rocker 88 which is supported via a supporting device 90 on a leaf spring 92 provided with a flexion converter 94 which transfers its data to the control device 26 a . The supporting device 90 comprises a safety device 96 containing a screw bolt 98 , the head 100 of which is arranged displaceably in a holding bell 102 . The holding bell 102 is connected to the rocker 88 . The head 100 is supported on a stop 104 of the holding bell. A pretensioning spring 106 arranged outside the holding bell 102 is supported, on the one hand, on the screw bolt 98 via a setscrew 108 and on the holding bell 102 via a washer 110 on the other hand so that the head 100 bears with a corresponding pretensioning force against the stop 104 of the holding bell 102 . The screw bolt 98 is connected, further, to the leaf spring 92 . If, then, a tension force higher than the tension force set as permissible on the leaf spring 92 occurs at the back bearer 6 a , the pretensioning spring 106 is compressed and the holding bell 102 is displaced on the screw bolt 98 , with the result that a switch 112 connected to the holding bell 102 is closed and transmits a fault signal to the control device 26 a.
FIGS. 10 and 11 show in detail the design of the thread tensioners 8 a which are at the same time also configured as catch thread devices. The thread tensioners 8 a are designed as drop wires and each have a guide orifice 114 , by means of which they are mounted on a holder 116 displaceably in the tensioning direction. The holders have a middle contact part 118 which projects on one side and which, insulated, is embedded into lateral contact parts 120 . The latter are connected to the sides of the guide orifice. In the event of a faulty warp tension, the thread tensioners 8 a are displaced by means of the pretensioning spring 32 a until the contact parts 118 , 120 of the holder 116 stand against an end face 124 of the guide orifice 114 and trigger a fault warning. The thread tensioners lie in each case between two guide elements 30 a for the warp thread 4 which is pieced up to the thread tensioners 8 a via run-in eyes 34 a . On the side facing away from the pretensioning spring 32 a , the thread tensioners each contain a grip part 126 with a signal part 128 which projects out of the displacement plane of the thread tensioners, so that it is possible to detect those thread tensioners which indicate a broken warp thread and for this reason are no longer in alignment with the remaining signal parts 128 . The signal part 128 is formed by a head part projecting out of the displacement plane.
List of reference symbols
F 1
First shedding position
F 2
Switching position
F 3
Second shedding
position
H 1
Lift height of the 1st
lifting device
H 2
Lift height of the 2nd
lifting device
S
Switching quantity
α
Deflection
2, 2a
Warp let-off (warp
beam)
4
Warp thread
6, 6a
Back bearer
8, 8a
Thread tensioner
10
Catch thread device
12, 12a
Shedding device
14
Shed
16
Weft thread
18
Beating-up edge
20
Cloth web
22
Cloth holder
24, 24a
Cloth take-up
26, 26a
Control device
28, 28a
Drive
29
Braking device
30, 30a
Guide element
32, 32a
Pretensioning spring
34, 34a
Eye
36
Deflecting roller
38
First lifting device
40
Driver
40a
Hook
42
Lifting beam
44
Actuator
46
Control means
48
Second lifting device
50
Control drop wire
52
Pretensioning spring
54
Lifting beam
56
Stop
58
Hook part of 44
60
Hook part of 50
62
Driver slot
62a
Driver slot
62b
Driver slot
64
Control slot
66
Guide slot
68
Side wall
70
Side wall
72
End wall
74
End wall
76
Run-on side
80
Cloth beam
82
Drive
84
Selflocking gear
86
Tensioning spring
device
88
Rocker
90
Supporting device
92
Leaf spring
94
Flexion converter
96
Safety device
98
Screw bolt
100
Head
102
Holding bell
104
Stop
106
Pretensioning spring
108
Setscrew
110
Washer
112
Switch
114
Guide orifice
116
Holder
118
Contact part
120
Lateral contact
parts
124
End face
126
Grip part
128
Signal part | The invention relates to a loom comprising a warp thread tensioning device and a shedding device ( 12 ), which comprises pre-tensioned warp threads ( 4 ) in a first shedding position (F 1 ). The loom also comprises a lifting device ( 38 ), which can be driven in an oscillating manner, and followers ( 40 ) for the warp threads ( 4 ), in addition to control means ( 46 ) that can be operated by actuators ( 44 ) in order to selectively engage the warp threads ( 4 ) in the followers ( 40 ) and that displace the warp threads ( 4 ) into a second shedding position (F 3 ). To simplify said loom, a second lifting device ( 48 ), which is common to all warp threads ( 4 ), is provided in order to displace said warp threads ( 4 ) from the first shedding position (F 1 ) into a selection position (F 2 ), in which the first lifting device ( 38 ) is active, and in order to displace non-selected warp threads in unison into the first shedding position (F 1 ) by the pre-tensioning of said warp threads ( 4 ). | 3 |
CROSS REFERENCE TO RELATED APPLICATIONS
This application claims the benefits of European application No. 07006095.9 filed Mar. 23, 2007 and is incorporated by reference herein in its entirety.
FIELD OF INVENTION
The invention relates to an apparatus and a process for coating a component, in which the position of coating material sources and/or the component to be coated can be aligned.
BACKGROUND OF THE INVENTION
During plasma spray or HVOF coating, a spray cone, i.e. the distribution of the material, is checked in order to check the alignment of nozzles. This is done by means of a steel plate which is coated and has to be removed from the coating installation and inspected. This entails an interruption to the coating process and means that the assessment of the alignment is of poor quality.
SUMMARY OF INVENTION
It is therefore an object of the invention to provide an apparatus and a process which overcome the problem of the prior art.
The object is achieved by the apparatus and the process as claimed in the claims.
The subclaims list further advantageous measures, which can be combined with one another in any desired way in order to bring about further advantages.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawing:
FIGS. 1 , 2 show an apparatus and a process according to the prior art,
FIGS. 3 , 4 , 5 show an apparatus according to the invention for carrying out the process according to the invention,
FIG. 6 shows a gas turbine,
FIG. 7 shows a perspective view of a turbine blade or vane,
FIG. 8 shows a perspective view of a combustion chamber
DETAILED DESCRIPTION OF INVENTION
FIG. 1 shows a coating installation 1 according to the prior art, in which a component 4 that is to be coated is present in a holder 7 .
The component 4 , 120 , 130 , 155 ( FIG. 6 , 7 , 8 ) is coated by means of a coating material source 10 , for example by means of a plasma nozzle (LPPS, APS, VPS, etc.), a nozzle of an HVOF coating installation or from a nozzle of a cold-spraying installation or another material source (for example a PVD or CVD material source).
To carry out checking by means of a spray cone, the coating material source 10 is moved into a position 13 indicated by dashed lines in FIG. 1 . Coating material is applied to a reference plate 16 , which is removed from the coating installation 1 and can only be examined outside the coating installation 1 .
This is illustrated in FIG. 2 , in which the coated reference plate 16 is present outside the coating installation 1 .
A coated surface 19 , for example a spray cone 19 , which may have deviations from a desired geometry 22 (indicated by dashed lines) of the spray cone, is present on the reference plate 16 . In the event of deviations, by way of example the coating material source 10 may have to be realigned or replaced.
FIG. 3 shows an apparatus 40 according to the invention which in addition to what is shown in FIG. 1 , as well as a reference plate 25 made from a coatable material, preferably also has a sensor 28 . The reference plate 25 is not part of the component 4 , 120 , 130 , 155 ( FIG. 6 , 7 , 8 ) that is to be coated. The reference plate 25 can be examined in the coating installation 10 without it being necessary to open the coating apparatus 40 , in particular by means of a sensor 28 .
Preferably, the reference plate 25 can be optically examined, and preferably the reference plate 25 is made from glass.
The reference plate 25 is preferably made from an optically transparent material, in particular from a glass.
The reference plate 25 is preferably coated and examined prior to commencement of the coating of the component 4 , 120 , 130 .
Equally preferably, the reference plate 25 can preferably in addition be coated and examined during or after complete coating of the component 4 , 120 , 130 , 155 , and retesting of the coating material source 10 is possible.
The reference plate 25 can preferably also be replaced within the apparatus 40 during the coating operation.
As in the prior art, the coating material source 10 is preferably moved into a position 13 (indicated by dashed lines) and coated, so as to produce a spray cone 19 on the reference plate 25 .
Equally preferably, however, it is also possible to displace the reference plate 25 , i.e. for example to move it between coating material source 10 and component 4 so as to be coated ( FIG. 4 ).
Then, it 25 is preferably moved back and preferably examined in a different position.
The front surface 26 or rear surface 27 of the reference plate 25 can be examined by the sensor 28 .
Then, the spray cone 19 on the reference plate 25 is examined within the installation 40 . This can be done by the sensor 28 , which preferably measures reflection. In a preferred exemplary embodiment, the reference plate 25 is illuminated by the sensor 28 and at the same time the reflection is recorded.
Equally preferably, the reference plate 25 can be irradiated by means of an illumination source 37 , with the sensor 28 then measuring the transmission of the illumination source 37 , so that the position of the spray cone 19 can be determined.
This information (see FIG. 5 ) can preferably be presented graphically and shown to an operator of the apparatus 40 outside the apparatus 40 . The operator can manually evaluate the information.
An evaluation unit 31 may preferably be present, to process and preferably assess the results from the sensor 28 .
The information obtained is preferably used to realign the coating material source 10 .
This alignment step can be carried out at any time during the coating process or prior to initial coating.
Deviations in the spray cone 19 from the desired geometry 22 may be caused by;
misalignment of the nozzle of the coating material source 10 wear to the nozzle of the coating material source 10 misalignment of the component 4 , 120 , 130 , 155 .
The method for evaluating the coated reference plate 25 is explained with reference to FIG. 5 .
FIG. 5 illustrates the reference plate 25 with a spray cone 19 .
The illumination source 37 emits beams 34 , which in the region of the spray cone 19 cannot reach the sensor 28 behind the reference plate 26 or can do so only to an attenuated extent. The percentage transmission 40 is measured, as illustrated on the right-hand side of FIG. 5 .
FIG. 5 shows only a section through the three-dimensional geometry (x, y transmission) of the spray cone 19 . However, the three-dimensional results are preferably used for the evaluation.
Misalignment of the material source 10 can be checked by means of auxiliary grid lines 29 on the reference plate 25 .
The apparatus 40 and the process have the advantage that the results of the alignment can be automatically evaluated and can even be stored and archived in digitized form. It is also possible to correct the plasma parameters or the plasma nozzle by means of a knowledge database.
The coating process can be interrupted if a misalignment is present, or alternatively on-time process control is possible.
FIG. 6 shows, by way of example, a partial longitudinal section through a gas turbine 100 .
In the interior, the gas turbine 100 has a rotor 103 with a shaft 101 which is mounted such that it can rotate about an axis of rotation 102 and is also referred to as the turbine rotor.
An intake housing 104 , a compressor 105 , a, for example, toroidal combustion chamber 110 , in particular an annular combustion chamber, with a plurality of coaxially arranged burners 107 , a turbine 108 and the exhaust-gas housing 109 follow one another along the rotor 103 .
The annular combustion chamber 110 is in communication with a, for example, annular hot-gas passage 111 , where, by way of example, four successive turbine stages 112 form the turbine 108 .
Each turbine stage 112 is formed, for example, from two blade or vane rings. As seen in the direction of flow of a working medium 113 , in the hot-gas passage 111 a row of guide vanes 115 is followed by a row 125 formed from rotor blades 120 .
The guide vanes 130 are secured to an inner housing 138 of a stator 143 , whereas the rotor blades 120 of a row 125 are fitted to the rotor 103 for example by means of a turbine disk 133 .
A generator (not shown) is coupled to the rotor 103 .
While the gas turbine 100 is operating, the compressor 105 sucks in air 135 through the intake housing 104 and compresses it. The compressed air provided at the turbine-side end of the compressor 105 is passed to the burners 107 , where it is mixed with a fuel. The mix is then burnt in the combustion chamber 110 , forming the working medium 113 . From there, the working medium 113 flows along the hot-gas passage 111 past the guide vanes 130 and the rotor blades 120 . The working medium 113 is expanded at the rotor blades 120 , transferring its momentum, so that the rotor blades 120 drive the rotor 103 and the latter in turn drives the generator coupled to it.
While the gas turbine 100 is operating, the components which are exposed to the hot working medium 113 are subject to thermal stresses. The guide vanes 130 and rotor blades 120 of the first turbine stage 112 , as seen in the direction of flow of the working medium 113 , together with the heat shield elements which line the annular combustion chamber 110 , are subject to the highest thermal stresses.
To be able to withstand the temperatures which prevail there, they may be cooled by means of a coolant.
Substrates of the components may likewise have a directional structure, i.e. they are in single-crystal form (SX structure) or have only longitudinally oriented grains (DS structure).
By way of example, iron-base, nickel-base or cobalt-base superalloys are used as material for the components, in particular for the turbine blade or vane 120 , 130 and components of the combustion chamber 110 .
Superalloys of this type are known, for example, from EP 1 204 776 B1, EP 1 306 454, EP 1 319 729 A1, WO 99/67435 or WO 00/44949.
The blades or vanes 120 , 130 may also have coatings which protect against corrosion (MCrAlX; M is at least one element selected from the group consisting of iron (Fe), cobalt (Co), nickel (Ni), X is an active element and represents yttrium (Y) and/or silicon, scandium (Sc) and/or at least one rare earth element or hafnium). Alloys of this type are known from EP0 486 489 B1, EP0 786 017 B1, EP0 412 397 B1 or EP 1 306 454 A1.
A thermal barrier coating, consisting for example of ZrO 2 , Y 2 O 3 —ZrO 2 , i.e. unstabilized, partially stabilized or completely stabilized by yttrium oxide and/or calcium oxide and/or magnesium oxide, may also be present on the MCrAlX. Columnar grains are produced in the thermal barrier coating by suitable coating processes, such as for example electron beam physical vapor deposition (EB-PVD).
The guide vane 130 has a guide vane root (not shown here), which faces the inner housing 138 of the turbine 108 , and a guide vane head which is at the opposite end from the guide vane root. The guide vane head faces the rotor 103 and is fixed to a securing ring 140 of the stator 143 .
FIG. 7 shows a perspective view of a rotor blade 120 or guide vane 130 of a turbomachine, which extends along a longitudinal axis 121 .
The turbomachine may be a gas turbine of an aircraft or of a power plant for generating electricity, a steam turbine or a compressor.
The blade or vane 120 , 130 has, in succession along the longitudinal axis 121 , a securing region 400 , an adjoining blade or vane platform 403 and a main blade or vane part 406 and a blade or vane tip 415 .
As a guide vane 130 , the vane 130 may have a further platform (not shown) at its vane tip 415 .
A blade or vane root 183 , which is used to secure the rotor blades 120 , 130 to a shaft or a disk (not shown), is formed in the securing region 400 .
The blade or vane root 183 is designed, for example, in hammerhead form. Other configurations, such as a fir-tree or dovetail root, are possible.
The blade or vane 120 , 130 has a leading edge 409 and a trailing edge 412 for a medium which flows past the main blade or vane part 406 .
In the case of conventional blades or vanes 120 , 130 , by way of example solid metallic materials, in particular superalloys, are used in all regions 400 , 403 , 406 of the blade or vane 120 , 130 .
Superalloys of this type are known, for example, from EP 1 204 776 B1, EP 1 306 454, EP 1 319 729 A1, WO 99/67435 or WO 00/44949.
The blade or vane 120 , 130 may in this case be produced by a casting process, by means of directional solidification, by a forging process, by a milling process or combinations thereof.
Workpieces with a single-crystal structure or structures are used as components for machines which, in operation, are exposed to high mechanical, thermal and/or chemical stresses.
Single-crystal workpieces of this type are produced, for example, by directional solidification from the melt. This involves casting processes in which the liquid metallic alloy solidifies to form the single-crystal structure, i.e. the single-crystal workpiece, or solidifies directionally.
In this case, dendritic crystals are oriented along the direction of heat flow and form either a columnar crystalline grain structure (i.e. grains which run over the entire length of the workpiece and are referred to here, in accordance with the language customarily used, as directionally solidified) or a single-crystal structure, i.e. the entire workpiece consists of one single crystal. In these processes, a transition to globular (polycrystalline) solidification needs to be avoided, since non-directional growth inevitably forms transverse and longitudinal grain boundaries, which negate the favorable properties of the directionally solidified or single-crystal component. Where the text refers in general terms to directionally solidified microstructures, this is to be understood as meaning both single crystals, which do not have any grain boundaries or at most have small-angle grain boundaries, and columnar crystal structures, which do have grain boundaries running in the longitudinal direction but do not have any transverse grain boundaries. This second form of crystalline structures is also described as directionally solidified microstructures (directionally solidified structures).
Processes of this type are known from U.S. Pat. No. 6,024,792 and EP 0 892 090 A1.
The blades or vanes 120 , 130 may likewise have coatings protecting against corrosion or oxidation e.g. (MCrAlX; M is at least one element selected from the group consisting of iron (Fe), cobalt (Co), nickel (Ni), X is an active element and represents yttrium (Y) and/or silicon and/or at least one rare earth element, or hafnium (Hf)). Alloys of this type are known from EP 0 486 489 B1, EP 0 786 017 B1, EP 0 412 397 B1 or EP 1 306 454 A1, which are intended to form part of the present disclosure with regard to the chemical composition of the alloy.
The density is preferably 95% of the theoretical density.
A protective aluminum oxide layer (TGO=thermally grown oxide layer) is formed on the MCrAlX layer (as an intermediate layer or as the outermost layer).
The layer preferably has a composition Co-30Ni-28Cr-8Al-0.6Y-0.7Si or Co-28Ni-24Cr-10Al-0.6Y. In addition to these cobalt-based protective coatings, it is also preferable to use nickel-based protective layers, such as Ni-10Cr-12Al-0.6Y-3Re or Ni-12Co-21Cr-11Al-0.4Y-2Re or Ni-25Co-17Cr-10Al-0.4Y-1.5Re.
It is also possible for a thermal barrier coating, which is preferably the outermost layer and consists for example of ZrO 2 , Y 2 O 3 —ZrO 2 , i.e. unstabilized, partially stabilized or fully stabilized by yttrium oxide and/or calcium oxide and/or magnesium oxide, to be present on the MCrAlX.
The thermal barrier coating covers the entire MCrAlX layer. Columnar grains are produced in the thermal barrier coating by means of suitable coating processes, such as for example electron beam physical vapor deposition (EB-PVD).
Other coating processes are possible, for example atmospheric plasma spraying (APS), LPPS, VPS or CVD. The thermal barrier coating may include grains that are porous or have micro-cracks or macro-cracks, in order to improve the resistance to thermal shocks. The thermal barrier coating is therefore preferably more porous than the MCrAlX layer.
Refurbishment means that after they have been used, protective layers may have to be removed from components 120 , 130 (e.g. by sand-blasting). Then, the corrosion and/or oxidation layers and products are removed. If appropriate, cracks in the component 120 , 130 are also repaired. This is followed by recoating of the component 120 , 130 , after which the component 120 , 130 can be reused.
The blade or vane 120 , 130 may be hollow or solid in form. If the blade or vane 120 , 130 is to be cooled, it is hollow and may also have film-cooling holes 418 (indicated by dashed lines).
FIG. 8 shows a combustion chamber 110 of a gas turbine. The combustion chamber 110 is configured, for example, as what is known as an annular combustion chamber, in which a multiplicity of burners 107 , which generate flames 156 , arranged circumferentially around the axis of rotation 102 open out into a common combustion chamber space 154 . For this purpose, the combustion chamber 110 overall is of annular configuration positioned around the axis of rotation 102 .
To achieve a relatively high efficiency, the combustion chamber 110 is designed for a relatively high temperature of the working medium M of approximately 1000° C. to 1600° C. To allow a relatively long service life even with these operating parameters, which are unfavorable for the materials, the combustion chamber wall 153 is provided, on its side which faces the working medium M, with an inner lining formed from heat shield elements 155 .
On the working medium side, each heat shield element 155 made from an alloy is equipped with a particularly heat-resistant protective layer (MCrAlX layer and/or ceramic coating) or is made from material that is able to withstand high temperatures (solid ceramic bricks).
These protective layers may be similar to the turbine blades or vanes, i.e. for example MCrAlX: M is at least one element selected from the group consisting of iron (Fe), cobalt (Co), nickel (Ni), X is an active element and stands for yttrium (Y) and/or silicon and/or at least one rare earth or hafnium (Hf). Alloys of this type are known from EP 0 486 489 B1, EP 0 786 017 B1, EP 0 412 397 B1 or EP 1 306 454 A1.
It is also possible for a, for example, ceramic thermal barrier coating to be present on the MCrAlX, consisting for example of ZrO 2 , Y 2 O 3 —ZrO 2 , i.e. unstabilized, partially stabilized or fully stabilized by yttrium oxide and/or calcium oxide and/or magnesium oxide.
Columnar grains are produced in the thermal barrier coating by means of suitable coating processes, such as for example electron beam physical vapor deposition (EB-PVD).
Other coating processes are possible, e.g. atmospheric plasma spraying (APS, LPPS, VPS) or CVD. The thermal barrier coating may include grains that are porous or contain micro-cracks or macro-cracks, in order to improve the resistance to thermal shocks.
Refurbishment means that after they have been used, protective layers may have to be removed from heat shield elements 155 (e.g. by sand-blasting). Then, the corrosion and/or oxidation layers and products are removed. If appropriate, cracks in the heat shield element 155 are also repaired. This is followed by recoating of the heat shield elements 155 , after which the heat shield elements 155 can be reused.
Moreover, a cooling system may be provided for the heat shield elements 155 and/or their holding elements, on account of the high temperatures in the interior of the combustion chamber 110 . The heat shield elements 155 are then, for example, hollow and may also have cooling holes (not shown) opening out into the combustion chamber space 154 . | Disclosed is an apparatus and process for coating a component with aligning device. Alignments or checking of the spray cone take place within the coating apparatus via an optically transparent reference plate which is optically evaluated. | 8 |
RELATED APPLICATION
[0001] The present application is a divisional application of U.S. patent application Ser. No. 13/662,129, by Luciana V. Mercer et al., filed on Oct. 26, 2012, the contents of which are incorporated herein.
FIELD OF THE INVENTION
[0002] The present invention relates to fastening systems for absorbent personal care articles. More particularly, it relates to absorbent personal care articles having foldable wings or flaps that can be employed to properly position and attach the absorbent articles to undergarments or other articles of clothing.
BACKGROUND
[0003] Absorbent personal care articles such as sanitary napkins, panty liners and incontinence pads commonly utilize a pair of wings or flaps which are used to help secure the article in place to the wearer's undergarments. Generally, the wings are folded around the outside of the wearer's undergarment and attach to the outside of the undergarment via adhesive or other fastening means. Once secured to the undergarment the wings help reduce the likelihood that the article will become dislodged and move out of position. Examples of such foldable wing fasteners are shown and described in U.S. Pat. No. 4,589,876 Van Tilberg; EP0511905B1 Pigneul; U.S. Pat. No. 5,401,268 Rodier; and EP1208823A1 Hohmann.
[0004] However, while wings of various size and shape have previously been used, there remain a number of drawbacks to these designs. First, many wings do not adequately prevent the article from bunching or twisting due to the stresses imparted on the article as the wearer moves. Second, misapplication of the article to the undergarment can also greatly increase the risk of leakage. In this regard, it can be difficult for wearers to place conventional wings properly onto their undergarment and when the wings are improperly fastened the absorbent article can be bunched or partially twisted as donned or more easily become twisted or bunched with the wearer's movement. Twisting of the article and/or the deformation of the article when worn can result in the article being at an angle relative to the wearer as opposed to being perpendicular to or flat against the wearer. When the article is sidewardly angled to the wearer the ability of the article to take in and absorb fluids can be reduced to an extent such that the article functions significantly less effectively than desired. Further, bunching of the article results in the article covering considerably less area under the vaginal region than desired. Thus, such unwanted twisting and bunching of the article can result in increased frequency of leakage and staining of the wearer's garments.
[0005] Thus, there exists a continued need for an absorbent personal care article having foldable wings that assist the wearer with proper placement and donning of the article.
[0006] There further exists a need for such an article wherein the foldable wings also help maintain the article in an uncontorted and/or generally flap shape in order to minimize the incidence of leakage.
SUMMARY OF THE INVENTION
[0007] The present invention addresses problems experienced with the flap designs of the prior art by providing an absorbent personal care article including (i) a left flap having first and second peaks and a furrow positioned there between, and (ii) a right flap having a first peak. The left and right flaps are positioned on opposed longitudinal sides of the article and sized such that, when the flaps are folded under the article and extended so that they lay flat against the liquid impermeable backsheet, the right flap peak extends across the longitudinal centerline of the article and into the left flap furrow.
[0008] In a further aspect of the invention, the left and right flaps can be integrally shaped and sized such that the wings substantially inter-mesh with or conform to one another when folded under and around the article. In still a further embodiment, the left and right flaps may define a space or gap between them along the substantial length of the flaps when the flaps are folded under the article lying flat adjacent the liquid impermeable backsheet. In an alternate embodiment, the left and right flaps can be sized and shaped so as to form one or more discrete areas of overlap when the flaps are folded under and around the article and lay flat against the liquid impermeable backsheet.
[0009] In a further aspect of the invention, the left and right flaps may include fasteners located on the garment facing side of the flap peaks such that the fastener extends across the longitudinal centerline of the article and either into the furrow of the opposed flap or over the opposed flap. This may be achieved, in one embodiment, by placing the fastener proximate the outer edges of the flap peaks.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] FIG. 1 is a representative partially cut away plan view of one embodiment of a sanitary napkin of the present invention in a flat and unfolded state.
[0011] FIG. 2 is a representative plan view of a sanitary napkin of an alternate embodiment of the present invention suitable for use with both traditional and tanga style underwear.
[0012] FIGS. 3-6 are enlarged views of individual embodiments of wings of the present invention shown in an inter-meshing relationship as folded directly under the personal care article lying flat against the backsheet.
DESCRIPTION OF THE INVENTION
[0013] In reference to FIGS. 1 and 2 , the drawings show absorbent personal care articles in a flat and unfolded state. Except as otherwise noted, discussion of dimensions of the article and/or the positions of individual components thereof are in reference to the article being in a flat and unfolded state and further, in the event elasticated components are utilized, dimensions are in reference to the article being in an uncontracted state. Further, as used herein, the terms “comprising” or “including” are inclusive or open-ended and do not exclude additional unrecited elements, compositional components, or method steps. Accordingly, the terms “comprising” or “including” encompass the more restrictive terms “consisting essentially of” and “consisting of.”
[0014] In reference to FIG. 1 , an absorbent personal care article 10 is provided comprising a liquid permeable topsheet 12 , a liquid impermeable backsheet 14 and an absorbent core 16 . The absorbent article 10 has a lengthwise or longitudinal direction and a widthwise or transverse direction. The longitudinal centerline of the article 10 is shown as line “L” and the transverse centerline of the article 10 is shown as line “T”. The absorbent article 10 can comprise any one of numerous elongate shapes including, but not limited to, triangular, rectangular, dog-bone and elliptical. In addition, it will often times be desirable for the article to have rounded corners and/or generally convex ends.
[0015] The absorbent article desirably has a length between about 80 mm and about 450 mm, and still more desirably a length between about 150 mm to about 250 mm. The absorbent article 10 desirably has a maximum width (excluding the wings) between about 40 and about 160 mm, and still more desirably a maximum width between about 65 mm and about 95 mm.
[0016] The absorbent article 10 further includes a first wing 20 and second wing 30 extending from opposite longitudinal sides of the article 10 . The first and second wings 20 , 30 desirably extend from about 20% to about 75% of the length of the article 10 . In a further aspect, the wings desirably have a length, in the longitudinal direction L, of from about 40 mm to about 160 mm, and still more desirably a length from about 95 mm to about 145 mm. The wings can be positioned about the transverse centerline or may be positioned either some distance forward or rear of the transverse centerline as may be desired to better accommodate the particular shape of the article and/or use on a particular style of garment. In addition, while not shown, it is noted that absorbent articles can, if desired, contain more than one set of opposed wings of the present invention.
[0017] A portion of the outside surface of the wings 20 , 30 include one or more fasteners 26 , 36 . The fastener will be selected to releasably engage either a garment or an overlapping portion of an opposed wing. Numerous adhesives and mechanical hook-type fasteners that releasably attach to itself or a user's garments are well known in the art and are suitable for use in connection with the present invention. Pressure sensitive adhesives are particularly well suited for use with the present invention. However, in order to protect the adhesive from contamination or drying prior to use, the adhesive is commonly protected by one or more releasable peel strips as is known in the art. A suitable releasable peel strip is a white Kraft paper having a silicone coating on one side so that it can be easily released from the adhesive. In addition, with respect to wing-to-wing attachment, examples of specific mechanical hook, adhesive and other fastening systems include but are not limited to those described in WO03/015682 to Hammonds et al.; WO03/015684 to Hammonds et al. and US20040133179 to Steger et al.
[0018] The first wing 20 includes at least a first peak 21 and a second peak 22 and a furrow base 24 spanning the peaks; the inner edges of the first and second peaks 21 , 22 and the furrow base 24 define a groove or furrow 24 A in the first wing 20 . The shapes of the peaks and furrow(s) can vary as desired including both rectilinear and curvilinear configurations. The wing 20 and components thereof are sized such that, when the wing 20 is folded around the underside of the article and the wing 21 lays flat against the backsheet 14 , portions of the first and second peaks 21 , 22 extend across the longitudinal centerline L whereas the furrow base 24 does not extend across or even to the longitudinal centerline. Thus, the specific dimensions for the wings will be selected in relation to the corresponding width of the absorbent article. In one aspect, the dimension of the peak in the transverse direction may be at least 50% of the width of the adjacent section of the absorbent core. In a further aspect, the distance from the middle of the first peak to the middle of the furrow base 24 is desirably at least about 20 mm and still more desirably between about 20 mm and about 60 mm. /
[0019] The second wing 30 includes at least a first peak 31 and first and second shoulders 38 , 39 positioned on opposite sides of the first peak 31 of the second wing 30 . Individual elements of the second wing 30 can have dimensions the same as or similar to those of the first wing 20 . However, as discussed in more detail below, desirably the peaks, furrows, and/or shoulders of the first and second wings are shaped so to coincide with one another. The second wing 30 and components thereof are sized such that, when second wing 30 is folded around the underside of the article and lays flat against the backsheet 14 , portions of the first peak 31 extend across the longitudinal centerline L io whereas the shoulders 38 , 39 do not extend across or even to the longitudinal centerline L. The shapes of the peak(s), furrow(s) and/or shoulders can vary as desired including both rectilinear and curvilinear configurations.
[0020] The first and second wings 20 , 30 are positioned along the longitudinal sides of the article 10 wherein the furrow base 24 of the first wing 20 lies in the same plane as the first peak 31 of the second wing. Stated differently, the first and second wings 20 , 30 are positioned along opposed longitudinal sides of the article 10 such that, when the first and second wings 20 , 30 are folded around the underside of the article 10 and extended to lay flat against the backsheet 14 , the first peak 31 of the second wing 30 extends into the furrow 24 A of the first wing 20 (the furrow 24 A of the first wing 20 being defined by the peaks 21 , 22 and furrow base 24 ).
[0021] In one embodiment and in reference to FIG. 3 , the first and second wings 20 , 30 can be sized and shaped so that, when folded around the underside of the article 10 and extended to lay flat against the backsheet 14 , the wings 20 , 30 do not overlap thereby leaving a space or gap “G” between them. In the embodiment shown, the wings 20 , 30 are sized and shaped so that they substantially intermesh but leave a substantially uniform gap “G” between them when folded around the underside of the article so as to lay flat against the backsheet 14 . Desirably in such embodiments the wings leave a gap “G” of less than about 20 mm and still more desirably less than about 15 mm. Thus, in use, the first wing 20 and second wing 30 extend around the crotch portion of the garment, and the first peak 31 of the second wing 30 extends into the furrow 24 A of the first wing 20 in a mating relationship. In a further aspect, the first and second peaks 21 , 22 of the first wing 20 and the shoulders 38 , 39 of the second wing 30 similarly lie in a corresponding relationship having a similar gap between the respective edges. Primary fasteners 26 , 36 , such as pressure sensitive adhesive, can be positioned adjacent the outer edges of the peaks such that, when the wings 20 , 30 are folded under the article so that the wings 20 , 30 lie flat against the backsheet 14 , the fasteners 26 , 36 lie on the opposite side of the longitudinal center line relative to which the wing is attached. The wings may also optionally include secondary fasteners 27 , 37 located proximate to outer edges of the furrow base 24 , shoulders 38 , 39 or base of the peaks 21 , 22 , 31 . The primary fasteners 26 , 36 may lie entirely or partially beyond the longitudinal center line when the wings 20 , 30 are folded around the underside of the article 10 and lay flat against the backsheet 14 . As shown in FIG. 3 , when the wings 20 , 30 are folded around the underside of the article 10 and lay flat against the backsheet 14 , the primary fasteners 26 , 36 are positioned entirely on the opposite side of the longitudinal center line “L” relative to the side that the wing extends from.
[0022] In a further embodiment, and in reference to FIGS. 4 and 5 , the first and second wings 20 , 30 are sized and shaped so that the wings form overlap regions 50 when folded around the underside of the article 10 and extended to lay flat against the backsheet 14 .
[0023] Thus, in use, the first wing 20 and second wing 30 can extend around the crotch portion of the garment and the first peak 31 of the second wing 30 extends over the furrow base 24 of the first wing 20 in an overlapping relationship. In this embodiment the wings are sized and shaped so as to inter-mesh in a manner such that the wings superpose one another. When the wings 20 , 30 are folded around the underside of the article 10 so as to lay flat against the backsheet 14 , individual overlap regions 50 formed by the superposed portions of the first wing 20 and second wing 30 desirably each comprise an area of at least about 50 mm 2 , more desirably between about 50-600 mm 2 and still more desirably between about 100-250 mm 2 . In a particular embodiment and in reference to FIG. 4 , the dimension of the wings relative to the width of the article 10 (exclusive of the wings) is such that the first and second wings 20 , 30 form overlap regions 50 adjacent the outer edges of the peaks 21 , 22 and 31 extending generally in the longitudinal direction. In a further particular embodiment and in reference to FIG. 5 , the shape and dimension of the wings 20 , 30 relative to the width of the article 10 (exclusive of the wings) is such that the first and second wings 20 , 30 form overlap regions 50 adjacent the side edges of the peaks 21 , 22 and 31 extending generally in the transverse direction T. The wings 20 , 30 can include fasteners (not shown) positioned on one or both areas of the wings intended to overlap and directly engage one another. Desirably the fasteners are positioned adjacent the edges of the peaks 21 , 22 , 31 . The wings may optionally include secondary fasteners such as pressure sensitive adhesive located in one or more areas of the wings 20 , 30 intended to overly the garment when worn.
[0024] In still a further embodiment and in reference to FIG. 6 , the second wing 30 can have a shape the same as or substantially similar to that of the first wing 20 . Thus, in this embodiment, the first wing 20 and second wing 30 each have first peaks 21 , 31 , second peaks 22 , 32 and furrow bases 24 , 34 respectively. The first peaks 21 , 31 and second peaks 22 , 32 are sized so as to extend beyond the longitudinal centerline “L” when the wings 20 , 30 are folded under the backside of the article and extended so as to lay flat against the backsheet 14 . In addition, the wings 20 , 30 are off-set from one another such that, when the wings are folded around the underside of the article and extended so that the wings 20 , 30 lay flat against the backsheet 14 , the first peak 31 of the second flap 30 extends into the furrow of the first wing 20 and the first peak 21 of the first wing 20 extends into the furrow of the second wing 30 . As will be readily understood by one skilled in the art, the multiple peaks of the wings can be configured to have non-overlapping relationships, overlapping relationships or both an overlapping and non-overlapping relationship. Accordingly, the wings will contain a plurality of fasteners in accord with the selected overlap scheme and fastening mechanism. In reference to FIG. 6 , the primary fasteners 26 , 36 traverse the longitudinal centerline “L.”
[0025] The front and rear halves of each wing can be symmetrical or asymmetrical as desired. For example, in one embodiment and in reference to FIG. 1 , the front and rear halves of the wings, i.e. the halves above and below the transverse centerline in the longitudinal direction, are symmetrical. The absorbent core in the embodiment of FIG. 1 is also symmetrical and commonly it will be desirable for the wings to be symmetrical when the absorbent core is symmetrical. In an alternate embodiment, and in reference to FIG. 2 , the absorbent core 16 is shaped having wider front (F) and narrower rear (R) sections in order to better conform to a tanga or thong type undergarments as well as for use in connection with certain overnight pads. The wings are therefore configured to correspond with the difference in the width of the article 10 . More specifically, the first peak 21 of first wing 20 , which is positioned adjacent a wider section of the absorbent core 16 , has a greater dimension in the transverse direction than the rearward second peak 22 of the first wing 20 . In the embodiment shown in FIG. 2 the wings 20 , 30 are centered about the transverse centerline “T” of the article however, as noted previously, the wings 20 , 30 can be positioned either forwardly or rearwardly relative to the transverse centerline as desired.
[0026] With respect to the general function and composition of the article 10 , the backsheet or outer cover 12 functions to isolate absorbed fluids from the wearer's garments and therefore comprises a liquid-impervious material. In one aspect the outer cover may optionally comprise a material that prevents the passage of liquids but allows air and water-vapor to pass there through. The outer cover can comprise a single layer or multiple layers and these one or more layers can themselves comprise similar or different materials. Suitable backsheet materials include, but are not limited to, polyolefin films, nonwovens and film/nonwoven laminates. The particular structure and composition of the outer cover may be selected from various known films and/or fabrics with the particular material being selected as appropriate to provide the desired level of liquid barrier, strength, abrasion resistance, tactile properties, aesthetics and so forth. Suitable outer covers include, but are not limited to, those described in U.S. Pat. No. 4,578,069 to Whitehead et al.; U.S. Pat. No. 4,376,799 to Tusim et al.; U.S. Pat. No. 5,695,849 to Shawver et al; U.S. Pat. No. 6,075,179 et al. to McCormack et al. and U.S. Pat. No. 6,376,095 to Cheung et al.
[0027] The topsheet 14 functions to receive and take in fluids, such as urine or menses, and therefore comprises a liquid permeable material. Additionally, topsheets can further function to help isolate the wearer's skin from fluids held in the absorbent core 16 . Topsheets can comprise a single layer or multiple layers and these one or more layers can themselves comprise similar or different materials. Topsheets are well known in the art and may be manufactured from a wide variety of materials such as, for example, porous foams, reticulated foams, apertured plastic films, woven materials, nonwoven webs, aperture nonwoven webs and laminates thereof. It is also well known that one or more chemical treatments can be applied to the topsheet materials in order to improve io movement of the fluid through the topsheet and into the article. Suitable topsheets include, but not limited to, those described in U.S. Pat. No. 4,397,644 to Matthews et al.; U.S. Pat. No. 4,629,643 to Curro et al.; U.S. Pat. No. 5,188,625 Van Iten et al.; U.S. Pat. No. 5,382,400 to Pike et al.; U.S. Pat. No. 5,533,991 to Kirby et al.; and 6,410,823 to Daley et al.
[0028] Between the liquid pervious topsheet 12 and liquid impervious backsheet 14 is positioned an absorbent core 16 . The absorbent core 16 functions to absorb and preferably “lock-up” the bodily fluids that pass into the absorbent article 10 through the topsheet 12 . The absorbent core can comprise a single layer or multiple layers and these one or more layers can themselves comprise similar or different materials. In order to efficiently and effectively utilize the absorbent capacity of the article, it is common for the absorbent core to include one or more liquid distribution layers or wicking layers in combination with a highly absorbent layer that preferentially absorbs and retains the liquids. Suitable wicking layers include, but are not limited to, bonded-carded webs, hydroentangled nonwoven webs, or spunbond webs containing fibers treated with or containing one or more topical agents that improve the contact angle with the bodily fluid and/or modify the flow properties of the bodily fluid. Highly absorbent layers often include, but not limited to, batts or webs containing wood pulp fibers, superabsorbent particles, synthetic wood pulp fibers, synthetic fibers and combinations thereof. The absorbent core may comprise any one of a number of materials and structures, the particular selection of which will vary with the desired loading capacity, flexibility, body fluid to be absorbed and other factors known to those skilled in the art. By way of example, suitable materials and/or structures for the absorbent core include, but are not limited to, those described in U.S. Pat. No. 4,610,678 to Weisman et al.; U.S. Pat. No. 6,060,636 to Yahiaoui et al.; U.S. Pat. No. 6,610,903 to Latimer et al.; US20100174260 to Di Luccio et al.; and U.S. Pat. No. 7,358,282 to Krueger t al.
[0029] The shape of the absorbent core can vary as desired and can comprise any one of various shapes including, but not limited to, generally triangular, rectangular, dog-bone and elliptical shapes. In one embodiment, the absorbent core 16 has a shape that generally corresponds with the overall shape of the article 10 such that the absorbent core terminates proximate the edge seal 18 and wings 20 , 30 . The dimensions of the absorbent core can be substantially similar to those referenced above with respect to the absorbent article 10 ; however it will be appreciated that the dimensions of the absorbent core 16 while similar will often be slightly less than those of the overall absorbent article 10 in order to be contained therein.
[0030] As previously indicated, the absorbent core 16 is positioned between the topsheet 12 and backsheet 14 . The individual layers comprising the article can be attached to one another using means known in the art such as adhesive, heat/pressure bonding, ultrasonic bonding and other suitable mechanical attachments. Commercially available construction adhesives usable in the present invention include, for example Rextac adhesives available from Huntsman Polymers of Houston, Tex., as well as adhesives available from Bostik Findley, Inc., of Wauwatosa, Wis. In one embodiment, and in reference to FIG. 1 , the absorbent core can be sealed between the topsheet 12 and backsheet 14 along the perimeter of the absorbent core 16 along edge seal 18 formed by the application of heat and pressure to melt thermoplastic polymers located in the topsheet 12 and/or backsheet 14 .
[0031] The wings can be constructed from materials described above with respect to the topsheet and backsheet. In one embodiment, the wings can comprise an extension of a layer of material within the topsheet and/or backsheet. By way of example and in reference to FIG. 1 , the wings 20 , 30 can be formed by an extension of the topsheet 12 and backsheet 14 that are welded together along edge seal 18 . Such wings can be integrally formed with the main portion of the absorbent article. Alternatively, the wings can be formed independently and separately attached to an intermediate section of the article. Wings that are made independent of the other components of the absorbent article can be welded onto or adhesively joined to a portion of the topsheet and/or backsheet. In addition, as is known in the art, when cutting materials to the desired shape it is preferable to arrange the components so as to minimize waste. Examples of processes for manufacturing absorbent articles and wings include, but are not limited to those described in U.S. Pat. No. 4,059,114 to Richards; U.S. Pat. No. 4,862,574 to Seidy et al., io WO1997040804 to Emenaker et al.; U.S. Pat. No. 5,342,647 to Heindel et al.; US20040040650 to Venturino et al.; and U.S. Pat. No. 7,070,672 to Alcantara et al.
[0032] In order to further assist with the maintenance of the article 10 in the desired location on the undergarment, garment adhesive (not shown) may be applied to the garment facing side of the backsheet 14 . The use of garment adhesive on the backsheet to help secure placement of an absorbent article on the garment is well known in the art and there are numerous adhesive patterns and releasable peel strips suitable for use with the present invention. Examples of suitable garment adhesives, patterns and release sheets include, but are not limited to, those described in DE700225U1; U.S. Pat. No. 3,881,490 to Whitehead et al.; U.S. Pat. No. 3,913,580 Ginocchio; U.S. Pat. No. 4,337,772 to Roeder et al.; GB1349962 Roeder; U.S. Pat. No. 4,556,146 to Swanson et al.; and US20070073255A1 to Thomas et al.
[0033] The absorbent articles of the present invention may further include one or more components or elements as may be desired. By way of example, the absorbent article may optionally include slits, voids or embossing on the topsheet and/or absorbent core in order to improve fluid intake, fluid distribution, stiffness (bending resistance) and/or aesthetic appeal. As a specific example and in reference to FIGS. 1 and 6 , embossing 17 can extend into both the topsheet 12 and absorbent core 16 . Examples of additional suitable embossing patterns and methods include, but are not limited to, those are described in U.S. Pat. No. 4,781,710 Megison et al.; EP769284A1 to Mizutani et al.; US20050182374 to Zander et al.; and U.S. Pat. No. 7,686,790 to Rasmussen et al.
[0034] The personal care articles can, optionally, contain one or more additional elements or components as are known and used in the art including, but not limited to, the use of fold lines, individual wrappers, elasticated flaps that extend above the plain of the topsheet in use, additional independent wings such as about the ends, odor control agents, perfumes, and the use of ink printing on one or more surfaces of the topsheet, backsheet, wings or absorbent core. Still further additional features and various constructions are known in the art. Thus, while the invention has been described in detail with respect to specific embodiments and/or examples thereof, it will be apparent io to those skilled in the art that various alterations, modifications and other changes may be made to the invention without departing from the spirit and scope of the same. It is therefore intended that the claims cover or encompass all such modifications, alterations and/or changes. | An absorbent personal care article, such as a sanitary napkin or incontinence pad, having a longitudinal centerline and a transverse centerline and including a pair of opposed first and second wings extending along the longitudinal sides of the article. The first wing includes two or more peaks with furrows there between and the second wing includes one or more peaks. The peaks of the first and second wings are sized and positioned on the article such that when folded under the article and around the wearer's undergarments, the peak of the second wing extends across the longitudinal centerline of the article and into the furrow of the first wing. The inter-meshing wings help wearer's properly don the articles, improve the attachment of the article to the wearer's garment and/or reduce unwanted twisting or bunching of the article during use. | 0 |
REFERENCE TO RELATED APPLICATIONS
This application is a continuation-in-part of U.S. patent application Ser. No. 410,650, filed Sep. 21, 1989 and now U.S. Pat. No. 5,019,174, entitled "Liposomal Cleaner," which is a continuation-in-part of Ser. No. 157,571, filed Mar. 3, 1988, now U.S. Pat. No. 4,911,928, issued Mar. 27, 1990, entitled "Paucilamellar Lipid Vesicles." This application is also a continuation-in-part of U.S. patent application Ser. No. 443,516, filed Nov. 29, 1989, also entitled "Paucilamellar Lipid Vesicles," which is a divisional of the aforementioned Ser. No. 157,571, now U.S. Pat. No. 4,911,928. The disclosures of all the above applications and patents are incorporated herein by reference.
BACKGROUND OF THE INVENTION
The present invention relates to a method of forming paucilamellar lipid vesicles which have amorphous central cavities substantially filled with a water immiscible material such as an oil. The invention is a "cold-loading" technique which allows incorporation of volatile and/or heat labile (heat degraded) materials which could not otherwise be incorporated into the vesicles.
U.S. Pat. No. 4,911,928 describes a "hot-loading" method of making paucilamellar lipid vesicles with water immiscible material substantially filling the amorphous central cavities. The lipid (and any oil or water immiscible material to be incorporated) is heated to an elevated temperature, e.g., a liquid or flowable form, so that it can be injected into an excess of an aqueous phase. This injection of the lipid into the aqueous phase causes the formation of small lipid micelles (probably spheroidal) which aggregate upon cooling with turbulent or shear mixing. The aggregated micelles fuse into vesicles with multiple bilayer shells surrounding a central, amorphous core. If an oil or a water immiscible material is also present, both lipid micelles and microemulsion oil droplets are formed. The microemulsion oil droplets act as nuclei about which the micelles aggregate, forming an oil-filled amorphous central cavity of the vesicle surrounded by the lipid bilayers. Preferably, a small amount of an indifferent surfactant is also included to stabilize the oil. The term "indifferent surfactant," as used herein, means a surfactant which will not form lipid vesicles but is able to emulsify the water immiscible materials to be encapsulated. Indifferent surfactants include most polyoxyethylene sorbitan ethers (Tweens), sodium dodecyl sulphate, and C 12 -C 18 fatty acids and their salts such as sodium oleate. If an indifferent surfactant is not used, a portion of the wall-forming lipid is cannibalized to stabilize the oil.
Although the "hot-loading" method is effective for a large number of water immiscible materials, the method is not useful for a variety of important water immiscible materials which are too volatile or heat labile at the vesicle forming temperatures. If the "hot-loading" methods are tried for these thermolabile materials, the majority of the water immiscible material is volatilized, leaving only a small portion to be incorporated into the vesicle. These volatile materials include insecticides such as diethyltoluamide (DEET), certain perfumes and fragrances, flavor oils, as well as many other materials such as mineral spirits. Since some fragrances are mixtures, release of one part of the mixture can change the overall properties dramatically. Further, even certain non-volatiles are more easily introduced into the amorphous central cavities of vesicles using the present "cold-loading" technique than the "hot-loading" technique. For example, the cleaning agent d-limonene can be incorporated into vesicles at a relatively low concentration using "hot-loading" but a much higher concentration can be achieved using the "cold-loading" technique.
Accordingly, an object of the invention is to provide a method of "cold-loading" the amorphous central cavities of paucilamellar lipid vesicles with water immiscible materials.
Another objection of the invention is to provide a means of incorporating volatiles into paucilamellar lipid vesicles.
A further object of the invention is to provide a generalized means of loading lipid vesicles with oily or water immiscible material which can be used with phospholipid, ionic, and nonionic lipid materials.
Further objects and features of the invention will be apparent from the description and the Drawing.
SUMMARY OF THE INVENTION
The present invention features a method of "cold-loading" the amorphous central cavities of paucilamellar lipid vesicles with water immiscible materials. The method is particularly important for volatile materials which cannot be loaded in significant quantities into the central cavities of paucilamellar lipid vesicles using a "hot-loading" technique.
The method of the invention commences with the formation of paucilamellar lipid vesicles having substantially aqueous-filled amorphous central cavities. The vesicles may be made by any classic technique but the methods and materials disclosed in U.S. Pat. No. 4,911,928 are preferred. Briefly, these methods require the injection of a flowable lipid, with or without a small portion of oil, into an excess of an aqueous phase using shear mixing techniques. The term "shear mixing," as defined in the aforementioned U.S. Pat. No. 4,911,928, means that the flow of the phases is equivalent to a relative flow of about 5-50 m/s through a 1 mm orifice. The resulting vesicles have the amorphous central cavity filled with an aqueous solution, possibly with some oil included.
After formation of the substantially aqueous-filled paucilamellar lipid vesicles, they are mixed with the water immiscible material, e.g., an oil, most preferably a volatile oil, to be incorporated into the amorphous central cavity under intermediate mixing conditions. The term "intermediate mixing conditions" means mixing of the preformed vesicles and the water immiscible material at or near room temperature under gentle conditions such as vortexing or syringing. Although flow conditions which yield a shear similar to that used to form the paucilamellar lipid vesicles initially could be used, it is unnecessary and may, in fact, be counterproductive.
Following this procedure, the amorphous central cavity of the lipid vesicles is filled with the water immiscible material, displacing the aqueous solution. The water immiscible material may act as a carrier for materials which are soluble or dispersed in it. The paucilamellar lipid vesicles are then separated from any excess oil, e.g., by centrifugation. Preferably, an indifferent surfactant is used in the process to stabilize the water immiscible material. The indifferent surfactant is normally aqueous soluble and carried in an external aqueous phase but a water insoluble indifferent surfactant can be incorporated in the amorphous center or walls of the paucilamellar lipid vesicles before the intermediate mixing. Preferred indifferent surfactants are selected from the group consisting of sodium dodecyl sulphate, C 12 -C 18 fatty acids, Tweens (polyoxyethylene sorbitan esters), and their salts, and mixtures thereof.
Although the preferred paucilamellar lipid vesicles of the invention have non-ionic materials such as polyoxyethylene fatty acid esters, Polyoxyethylene glycerol monostearate, polyoxyethylene steryl alcohols, and diethanolamides as the wall or bilayer forming lipid, other materials such as phospholipids, betaines, and other ionic or zwitterion materials may be used. The invention is particularly preferable for encapsulation of volatiles or heat labile materials which are not stable liquids at temperatures where the wall forming lipid is a liquid.
Further aspects and features of the invention will apparent from the following description.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1a and 1b are illustrations of micelle formation upon injection of a lipid phase into an excess of aqueous phase such as is used in the "hot-loading" technique;
FIGS. 2a and 2b are illustrations of micelle and microemulsion formation upon injection of a lipid and water immiscible material phase into an excess of aqueous phase such as is used in the "hot-loading" technique; and
FIG. 3 is a schematic of the endocytosis mechanism suggested for the "cold-loading" technique of the present invention.
DESCRIPTION OF THE INVENTION
The "cold-loading" method of the present invention is preferable to the "hot-loading" method where the material to be loaded into the amorphous central cavity of the vesicles is a volatile or heat labile water immiscible material. Further, even though the material to be incorporated in the central cavity may not be volatile, a higher concentration of the water immiscible material may be loaded using the methods of the present invention.
FIGS. 1a and 1b illustrate the critical step in the "hot-loading" technique without oil present, the formation of micelle structures by injection of the lipid phase into an excess of an aqueous solution. As noted previously, the micelles aggregate to form the bilayers of the paucilamellar lipid vesicle.
FIGS. 2a and 2b show the same mechanism with a water immiscible material added to the lipid. Both micelles and microemulsion oil droplets form. These microemulsion droplets are the nuclei about which the bilayers of the lipid vesicle form. Since these microemulsion oil droplets are necessary in this "hot-loading" technique, clearly a volatile material which will not form these microemulsions droplets are not appropriate for the "hot-loading" technique.
FIG. 3 illustrates the most likely mechanism of the "cold-loading" technique of the present invention. Once the substantially aqueous-filled paucilamellar lipid vesicles are formed, e.g., using the technique shown in FIG. 1, they are combined with the cargo material, e.g., the water immiscible material, preferably in the presence of a low concentration (approximately 1.5%) of an indifferent surfactant such as sodium dodecyl sulphate. Droplets of the water immiscible material (stabilized by the indifferent surfactant) enter the vesicles, presumably by a process resembling endocytosis.
Although the "cold-loading" technique is most preferred for volatile or thermolabile materials such as fragrance oils, flavor oils, and certain lipids or drugs, it is also particularly good for water immiscible materials which interfere with micelle formation and/or fusion. This latter group of materials includes diethyltoluamide, d-limonene, and certain water immiscible solvents such as petroleum distillates and aromatic solvents such as xylene. These materials, which cannot be encapsulated in lipid vesicles in any large quantity using the "hot-loading" techniques, can be incorporated in the amorphous central cavity of the paucilamellar lipid vesicles using the "cold-loading" technique of the present invention.
The following Examples will more clearly elucidate the present invention.
EXAMPLE 1
In this Example, aqueous-filled vesicles were made using the methods described in U.S. Pat. No. 4,911,928 from polyoxyethylene (9) glycerol monostearate, cholesterol, and a 1.5% solution of Tween 40 (polyoxyethylene 20 sorbitan monopalmitate). Briefly, the patent describes a technique whereby all of the lipid soluble materials (including any water immiscible materials if used), are blended together at elevated temperature until flowability. Normally, this requires a temperature of 60°-80° C. but in some cases as high as 90° C. The aqueous phase, which includes all the water soluble materials (including the indifferent surfactant, here the Tween), is also heated. The lipid phase in then injected into an excess of the aqueous phase through a moderate shear device and the mixture is sheared until vesicles form. While a device such as the mixing machine shown in U.S. Pat. No. 4,895,452, the disclosure of which is incorporated herein by reference, may be used, a pair of syringes connected by a three-way stopcock can provide shear sufficient for formation of the vesicles. The shear required is a relative flow of about 5- 50 m/s through a 1 mm orifice. Further details of this process are described in U.S. Pat. No. 4,911,928. Table 1 lists the formula used to make the vesicles.
TABLE 1______________________________________POE (9) glycerol monostearate 20.3 gCholesterol 3.5 gTween 40 (1.5% solution in water) 75 ml______________________________________
The preformed vesicles were then mixed with an excess of a water immiscible material by placing the vesicles in one syringe, an excess of the water immiscible material which was to act as the cargo in a second syringe, and the syringes are joined through a three-way stopcock. The solutions were mixed from one syringe to the other for approximately 40-50 strokes at ambient temperature. The resulting solution was then centrifuged at 3500 RPM for 30 minutes to separate the unencapsulated water immiscible material from the lipid vesicles. Table 2 lists the water immiscible material uptake for a variety of different water immiscible materials. All values are in ml of water immiscible material/ml vesicle.
TABLE 2______________________________________Mineral Oil 1.0 ml/mlButyl Cellosolve 0.11 ml/mlMineral Spirits 0.18 ml/mlIsodecyl Benzoate 1.0 ml/mlTricresyl Phosphate 1.0 ml/ml______________________________________
As can be seen, a large number of different materials can be incorporated at high concentration using this "cold-loading" procedure.
EXAMPLE 2
In this Example, a different wall forming material, polyoxyethylene 2 stearyl alcohol, and a different indifferent surfactant, sodium dodecyl sulphate (SDS), were used to form the vesicles. The amounts used to preform the vesicles are shown in Table 3.
TABLE 3______________________________________POE (2) Stearyl Alcohol 5.9 gCholesterol 2.1 g1.5% SDS in Water 41.5 ml______________________________________
The vesicles were formed in the same manner as described in connection with Example 1. The vesicles were then mixed with an excess of mineral oil (Drakeol #19) using the same syringe procedure as previously described and the oil-filled vesicles were separated by centrifugation. The uptake of mineral oil into the vesicles was greater than 0.7 ml oil/ml vesicle.
EXAMPLE 3
In this Example, a phospholipid, lecithin, was used to form the vesicles. The lecithin was dissolved in soybean oil, heated until a clear solution was formed, and then mixed with an excess of water, using the procedure described in Example 1, to form paucilamellar lipid vesicles. Table 4 shows the amounts of the different components used to form the vesicles. The vesicles included some oil in the aqueous center.
TABLE 4______________________________________Lecithin (98%, Emulpur N-P1 6.4 gLucas Meyer, Inc.)Soybean Oil 6.4 mlWater 26.0 ml______________________________________
The preformed phospholipid paucilamellar lipid vesicles were then mixed with an excess of additional soybean oil using the syringe technique previously described and centrifuged at 3500 RPM for 30 minutes. The uptake of the soybean oil in the second processing step was approximately 1 ml oil/ml vesicle. The same procedure has also been used with a 33% solution of cholesterol oleate in soybean oil being incorporated into the vesicles. The uptake was at least 0.67 ml/ml vesicle.
EXAMPLE 4
In this Example, additional oil was incorporated into the amorphous center of nonionic lipid vesicles which already had a small amount of oil therein. The procedures used were the same as those described in connection with Example 1 except mineral oil was incorporated into the heated lipid solution used to form the initial vesicles. Table 5 gives the ingredients used to preform the vesicles.
TABLE 5______________________________________POE (9) Glycerol Monostearate 20.3 gCholesterol 3.5 gMineral Oil (Drakeol #19) 25.0 ml1.5% SDS in Water 75.0 ml______________________________________
After the vesicles were formed, they were mixed using the syringe method with additional mineral oil and centrifuged at 3500 RPM for 15 minutes to separate the vesicles from the oil. Uptake of additional mineral oil was approximately 0.7 ml mineral oil/ml vesicle.
EXAMPLE 5
In this Example, the uptake of DEET (diethyltoluamide) into negatively charged vessels was tested. DEET interferes with vesicle forming using a "hot-loading" technique, so insufficient amounts of DEET can be incorporated into vesicles using the "hot-loading" procedure. Negatively charged vesicles were formed using the same procedures as described in Example 1, using the materials shown in Table 6.
TABLE 6______________________________________POE (9) Glycerol Monostearate 11.2 gCholesterol 1.9 gOleic Acid 0.2 gTween 40 0.9 mlWater 42.0 ml______________________________________
The preformed negatively charged vesicles were then mixed with an excess of DEET and centrifuged at 3500 RPM for 30 minutes. Uptake of DEET into the vesicles was approximately 0.4 ml DEET/ml vesicle.
Similar results have been obtained with a variety of flavor oils, fragrances, and the hand cleaner d-limonene. In addition, the 40-50 strokes of the syringe, mixing the vesicles and the water immiscible material, has been replaced by merely placing all the materials in a tube and blending with a vortex mixer, stirrer, or homogenizer thereby encapsulating the water immiscible material
Those skilled in the art may appreciate other methods which are within the scope of the present invention. Such other methods are included within the following claims. | A new "cold-loading" technique for filling the amorphous central cavity of paucilamellar lipid vesicles with a water immiscible material has been developed. Preformed, substantially aqueous filled paucilamellar lipid vesicles are mixed with the water immiscible material to be encapsulated under intermediate mixing conditions, thereby replacing the aqueous solution with the water-immiscible solution. The "cold-loading" technique is particularly useful for encapsulation of volatiles and heat labile materials. | 0 |
BACKGROUND OF THE INVENTION
This invention relates to an apparatus which is connected to a rollercard unit or carding machine upstream thereof for producing a fiber lap. The apparatus includes a feed chute into which fiber tufts are introduced at the top and are withdrawn as a fiber lap from the bottom. During this operation, an air stream enters the feed chute which exits therefrom through air exit openings provided in walls of the feed chute.
In practice, it is often a desideratum to obtain a fiber lap of different widths. If, for example, a changeover in the product occurs, it may be required to vary the lap width. According to known methods, the lap is brought to the desired width by cutting, blowing or suction, wherein the excessive material removed from the lap sides is reintroduced into the feed chute and is caused to participate again in the lap formation. It is a disadvantage of such an arrangement that it requires a certain additional technological input and further that the reintroduced lap edge portions pass more than once through lap formation and therefore may cause undesirable changes in the lap structure.
SUMMARY OF THE INVENTION
It is an object of the invention to provide an improved apparatus of the above-outlined type by means of which a fiber lap can be produced with easily variable width without removing material from the lap sides.
This object and others to become apparent as the specification progresses, are accomplished by the invention, according to which, briefly stated, the feed chute has at least one laterally displaceable wall element for varying the width of the fiber lap discharge opening of the feed chute, whereby the width of the delivered fiber tuft lap is varied.
By means of the arrangement according to the invention, it is feasible to produce fiber laps of different widths without the need of removing excessive marginal portions of the fiber lap. The laterally displaceable wall element is arranged immediately at the marginal zone of the lap and thus determines the width thereof.
According to a further feature of the invention, in a lap forming apparatus having an upper reserve chute and a lower feed chute, the lap width is expediently set in the lower feed chute. For this purpose, in the zone of the lateral feed chute wall, an obliquely downwardly oriented, angularly settable plate is provided which extends from the side wall to the air exit openings and the delivery rollers arranged at the discharge opening of the feed chute. The plate sealingly adjoins the lateral wall of the feed chute. The plate may have a U-shaped configuration whereby a sealing effect with respect to the front and rear walls of the lower feed chute is also achieved. By displacing the plate which practically in each position forms the hypotenuse of a triangle whose short sides are formed by the side wall and the delivery rollers, the position of the lap edge, that is, the lap width, may be varied in a stepless manner. Thus, the width and the position of the lap can be infinitely varied within the setting limits of the displaceable wall element.
In case the lap forming apparatus delivers divided laps, according to the invention several laps of variable width may be obtained. For such a case, the lap divider is provided with the obliquely oriented plates or the lap divider is itself so structured that the separating walls can be pivoted and displaced obliquely. The plates may be set and immobilized from the outside of the lower feed chute in case a constant lap width is required for a certain production period. For producing laps of predetermined shape, the wall elements can be displaced during operation. By coordinating the delivery roller speed with the motion of the wall elements, a desired number of different lap shapes may be obtained. This may lead to a reduction of waste during a subsequent lap cutting operation.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a schematic front elevational view of a preferred embodiment of the invention.
FIG. 2 is a schematic sectional elevational view of another preferred embodiment of the invention.
FIG. 3 is a schematic front elevational view of another preferred embodiment of the invention.
FIG. 4 is a schematic perspective view of still another preferred embodiment of the invention.
FIG. 5 is a schematic front elevational view of a further preferred embodiment of the invention.
FIG. 6 is a schematic front elevational view of still another preferred embodiment of the invention.
FIG. 7 is a schematic top plan view of one part of a further preferred embodiment of the invention and a fiber lap produced thereby.
FIG. 8 is a schematic front elevational view of a further preferred embodiment of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Turning to FIG. 1, there is shown a feed chute 1 which, at its upper inlet opening for the fiber tufts is in communication with a pneumatic conveyor duct 2 and which, at its lower output end is provided with two delivery rollers 3, 4. In at least one chute wall, preferably in the lower zone of the front or rear wall, up to a certain height air outlet openings 5 are provided which may be constituted by a comb-like structure known by itself and disclosed, for example, in German Auslegeschrift (Application Published after Examination) No. 1,286,436.
In the feed chute 1 there is arranged a wall element 6, for example, a sheet metal plate whose width extends from the front wall to the rear wall of the chute 1. The upper end 6' of the plate 6 is associated with a lateral wall 1a of the feed chute 1 while the lower end 6" of the plate 6 is associated with the lower end of the chute 1, immediately above the delivery rollers 3 and 4. At its lower end 6" the wall element 6 is at a distance from the lateral wall 1a and thus the wall element 6 extends obliquely downwardly towards the oppositely located chute side wall 1b from which the lower end 6" is spaced as well. The wall element 6 may be displaced from a relatively steep position (shown in solid lines in FIG. 1) to a less steep position (shown in broken lines in FIG. 1) so that the fiber lap 9 discharged by the feed chute 1 may be varied in width. The upper zone of the wall element 6 reaches into the upper zone of the feed chute 1. The fiber tufts 7 fly as individual tufts downwardly through the major part of the feed chute 1. The width of their path is gradually reduced by the wall element 6 to prevent the tufts 7 from a premature bunching. There occurs only in the lower part of the feed chute 1 a fiber tuft accumulation (filling) 8 of the superimposed fiber tufts which are, from above, pneumatically densified by an air stream. The tuft filling 8 covers the air outlet openings 5. The air stream exits from the feed chute 1 through the air outlet openings 5. The densified fiber tuft filling 8 is withdrawn as a fiber lap 9 from the lower end of the feed chute 1 by means of the delivery rollers 3 and 4.
Turning now to FIG. 2, between the conveyor duct 2 and the lower feed chute 1 there is arranged an upper chute 10, from which the fibers are advanced into the feed chute 1 by means of a feed roller 11 and an opening roller 12. At the upper end of the feed chute 1 a fan 13 is arranged which directs an air stream into the feed chute 1. In the front wall 1c and the rear wall 1d of the feed chute 1 respective air outlet openings 5a and 5b are provided. The wall element 6 has upper and lower edges 6' and 6" which extend from the front wall 1c to the rear wall 1d. Underneath the delivery rollers 3 and 4 there is arranged a guide tray 14 for the lap 9.
Turning to FIG. 3, the wall element 6a is, at its upper edges, articulated at 14 to a vertical support plate 15 which is vertically displaceably connected with the stationary lateral wall 1a of the feed chute with the intermediary of a mounting element 16.
According to FIG. 4, lateral edges of the wall element 6b are bent angularly at 6b' so that the wall element has an approximately U-shaped cross section. The lower terminal portion 6b" of the wall element 6b which is situated in the zone of the air outlet openings 5a, 5b of the feed chute 1 is oriented parallel to the lateral walls 1a and 1b of the feed chute 1. The wall element 6b may be, in case of a sufficient own weight, supported at its upper zone (edge 6b"') at the wall 1b. The lower part 6b" may be supported (by means not shown) at its side on the chute wall where the air outlet openings 5a, 5b are provided.
FIG. 5 illustrates a vertical fiber tuft divider 17 which is arranged in the feed chute for dividing it into two partial chutes. The upper, rounded part of the divider 17 may reach approximately to the mid height of the feed chute 1, while the lower zone of the divider 17 extends into the divided fiber tuft columns 8a, 8b which leave the fiber chute 1 as respective divided laps 9a, 9b. The lateral walls 1a and 1b of the feed chute 1 are each associated with a wall element 6c and 6d, respectively, whose upper respective ends 18 and 19 extend into respective support devices 20 and 21 through non-illustrated slots provided in the lateral walls 1a and 1b. The support devices 20 and 21 are situated at the outside of the lateral walls 1a and 1b. The upper ends 18 and 19 of the respective wall elements 6c and 6d are vertically displaceably arranged in the support elements 20 and 21 so that a varying slope of the wall elements 6c and 6d and thus a varying width and degree of fiber tuft filling 8a and 8b of the lap 9a and 9b may be set. The oblique positioning of the wall elements may be effected in a continuous (stepless) manner.
Turning now to FIG. 6, a displaceable wall element 6e is associated with the tuft divider 17. The upper end of the wall element 6e is vertically displaceably carried in a support element 22 mounted on the divider 17.
FIG. 7 illustrates a feed chute 1 in which two wall elements 6f and 6g are arranged which are each connected with an externally located eccentric setting device 24, 25 by means of respective coupling elements 22, 23. Dependent upon the setting of the wall elements 6f, 6g, the width of the lap 9 discharged by the feed chute 1 is varied. In this manner, a fiber lap of predetermined varying contour may be obtained.
Turning to FIG. 8, the wall element 6h is formed of three parts which are displaceable telescopically in their longitudinal direction, so that in this manner the entire length of the wall element 6h may be varied. The uppermost part of the wall element 6h is mounted by means of a rotary articulation 26 to the lateral wall 1b of the feed chute 1. By rotating the articulation 26 and varying the length of the wall element 6h the width of the feed chute 1 is varied.
It will be understood that the above description of the present invention is susceptible to various changes, modifications and adaptations, and the same are intended to be comprehended within the meaning and range of equivalents of the appended claims. | An apparatus for producing a fiber lap includes a generally vertically oriented feed chute in which fiber tufts are introduced at the top and from which a fiber lap is discharged at the bottom. There is provided a movable wall element for varying an effective width of the feed chute for altering the width of the fiber lap produced by the apparatus. | 3 |
BACKGROUND OF THE INVENTION
The invention relates to an apparatus for extending and setting rolled photosensitive materials, and more particularly to an apparatus for extending and setting large-sized rolled film, printing paper or the likes (hereinafter inclusively called "film") which are to be set on a large-sized projection photographing device for a process camera system.
The process camera system may have, in addition to the standard photographing device, a large-sized film holder for use in preparation of negatives for printing outdoor advertisements.
In manually setting a large-sized film on the vacuum film holder provided in the large-sized photographing device or a so-called projection-back device, at least two operators have had to carefully work in order to avoid any discrepancy, slackening, wrinkle or fold in the film. The Japanese Patent Laying-open Gazette No. Sho. 54-149621 in name of the Applicant of this application has disclosed an example of apparatuses for mechanically loading the film. In the proposed apparatus in said Gazette, film magazines for the large-sized rolled films are disposed above and below a vacuum film holder, each of them having a film take up roller or a film feeding roller both driven by a motor so that the rolled film discharged from one of the magazines that is provided with a cutter may advance via the vacuum holder toward the other magazine so as to be received therein while the photographed portion of said film being cut prior to said receipt. Since such usage of projection-back is not so frequent, the above known apparatus may be inconvenient from a practical viewpoint and so expensive because of considerable wide space occupied by it in a darkroom.
BRIEF SUMMARY OF THE INVENTION
It is an object of the invention is to provide an apparatus for extending and setting rolled films, the apparatus comprising a film feeder, a vacuum film holder and a mechanism adapted to move the film feeder in a direction parallel with the film holder so that the film can be loaded by one personnel alone with easiness without a necessity of wide space occupied by the apparatus.
It is a further object of the invention to provide such an apparatus that comprises, in its film feeder, a film reel for rolling up a film and a feeder roller or feeder rollers for supplying the film therethrough.
It is a still further object of the invention to provide an apparatus comprising, in its film feeder or elsewhere, a film cutter for cutting a film supplied from said feeder to advance along and extend over the vacuum film holder while being sucked thereto.
Other objects and merits will be made apparent in the course of following description with reference to the drawings showing an embodiment.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side elevational of an entire assembly of process camera apparatus additionally equipped with a projection-back having an embodied apparatus of the invention; and
FIG. 2 is a plan view of the primary portion of said embodiment.
DETAILED DESCRIPTION OF THE INVENTION
In the illustrated assembly, there are laid out a process camera (A), a lighting source (B 1 ) for transparently photographing, a lighting source (B 2 ) for reflectional photography, a holder (C) for original pictures, a usual plate (D) for sucking and holding thereon usual films, a large-sized photographing device (E) (projection-back) for projection photography, and a partition (F) of a darkroom. The members (A) to (C) are located in a "lightroom".
A vacuum film holder 2 for large-sized films is secured to a stand frame 1 in the projection-back (E) in such a state that the optical axis 4 of a lens 3 passes through the center of said holder 2 whose surface is meeting at right angles with the axis. The vacuum film holder 2 is communicated with a vacuum pump 5 by means of a duct 6. A large number of small apertures are opening on the surface of said holder 2 with a uniform distribution over a certain range thereof to thereby impart to it a sucking ability.
Guide rails 7, 8 are respectively fixed to the uppermost end and the lower portion of the stand frame 1 in a horizontal direction parallel to the film holder 2. A film feeder 13 comprises a film reel 10 having a film 9 rolled up thereon, a pair of feeder rollers 11 and a film cutter 12, all of these being built-in parts. The feeder 13 is also provided with supporting brackets 14, 15 one of which is secured to the upper end of said feeder while the other being secured to the lower end. The upper bracket 14 has paired guide rollers 16 as well as an unpaired guide rollers 17 so that the former may roll along the upper rail 7 placed therebetween while the latter rolling on the upper surface of said rail 7. The lower bracket 15 has one or more guides 18 which run on the side surface of the lower rail 8. Thus, the film feeder 13 securely engages with the vacuum film holder 2 in such a manner as to be movable along said plate in a horizontal direction and in parallel therewith.
Provided on a said feeder's 13 surface facing the film holder 2 is a sheet reel 20 adapted to wind up a sheet 19 for closing up the abovesaid small sucking apertures distributed over the surface of said film holder 2. The supporting shaft for said reel 20 is disposed parallel with that of film reel 10.
The sheet reel 20 is a hollow cylinder having bearing portions on its upper and lower ends, each of stubs supported by arms and constituting the supporting shaft for the reel 20 thereby being journaled by said bearing portions so as to render said reel rotatable. There is provided a coil spring within said cylinder and one end of this spring is secured to said supporting shaft while the other end being fixed on the inner surface of said cylinder. The coil spring thus gives to the reel 20 a torque urging the sheet 19 toward a winding direction. The free end of said sheet 19 is, in FIG. 2, engaging with the left-hand end of the film holder 2, seen from the arrowed direction.
In operation, the film feeder is at first caused to move along the film holder 2 rightwards seen from the arrowed direction in FIG. 2. During this motion of the feeder 13, the sheet 19 is pulled out from the sheet reel 20 against the abovesaid winding torque and at the same time the vacuum pump 5 is kept running for sucking air through the abovesaid sucking apertures of the plate 2. The feeder 13 will continue to move rightwards until its supporting bracket 14 abuts against a stopper 21 disposed at the right end of the film holder 2. The feeder is then caused to move in the reverse direction, i.e. leftwards, with a reduced speed also along the vacuum film holder 2.
At the beginning of this reverse motion, the rolled film 9 is pulled out by the feeder rollers 11 from the film reel 10, and then the free end of said film 9 is fixed on the right-hand end portion of the vacuum film holder 2 by means of the sucking action thereof wherein the predetermined position of said film's free end is indicated and adjusted on a scale provided adjacent the right-hand end of said holder 2.
Subsequently, the film feeder 13 will be caused again to move leftwards also along the film holder 2. The speed of thus reopened reverse motion of said feeder is controlled to coincide with the feeding speed of the feeder rollers 11. The sheet 19 will be, according to this movement of the feeder 13, retracted from the film holder 2 and wound on the sheet reel 20.
It will be appreciated now that the vacuum film holder 2, when in operation, is covered almost wholly with the film 9 and/or the sheet 19 so that most of the small apertures on said holder are thereby closed. Consequently, the unwound film 9 is gradually extended over the suction plate 2 and forcibly sucked thereto while being pulled out of the reel 10 wherein the strong suction effected by the sucking apertures overcomes the resilient force of said film, which force tends to bend the film itself, to thereby ensure a secure fixation thereof onto the surface of said holder 2. The discrepancy or misplacing, slackening, wrinkle or fold which are inevitable in the known methods are shut out in this manner. The film 9 will then be cut with the cutter 12 when a desired length of said film (it may be detected on a counter integratingly counting the revolution number of the feeding rollers 11) has been supplied. At last, the cut end is fixed to the vacuum film holder 2.
Summarizing the invention, the proposed apparatus for extending and setting rolled sensitive films is suited for use in the projection-back of process camera apparatus in setting thereon large-sized films because the film feeder moves along the vacuum film holder in said projection-back so that any desired length of film might be easily pulled out of the film reel and be set on said plate by one operator without producing any slackening, wrinkle or fold in said film. If there is added to the film feeder a sheet reel having a wound sheet adapted to close sucking apertures of the film holder, the sucking efficiency is improved by locally or selectively intensifying the sucking power of a restricted portion of said apertures distributed over said plate so that the vacuum pump is designed to have the lowest necessary capacity. Further, since said film is gradually sucked onto said film suction plate by moving the film feeder, it is possible to securely extend and set the film on said plate by effectively overcoming the film's resilient force thereby avoiding any discrepancy of film from the exact position. Still further, the proposed apparatus does not require a so wide space for equipment thereof. All the above merits will make the apparatus more suitable for practical use in the above-said projection-back device.
The invented apparatus can be attached also to the usual vacuum film holder (D), and a knife may be used as a substitute for the cutter. | A propsed apparatus comprising a film reel, a film feeder, a vacuum film holder and a mechanism adapted to move the feeder along the plate is adapted for use in the projection-back in process camera device. These members are arranged such that a film which is being unwound away from the reel is gradually sucked onto said film holder with the movement of said feeder guided by the mechanism. The apparatus may include a film cutter for cutting the film after each stroke of said feeder together with a sheet reel having a wound sheet and adapted to supply it for closing up sucking apertures of said holder portion not covered with the film. | 8 |
This application claims benefit of provisional application number 60/035,198 filed Jan. 14, 1997.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to a mathematical teaching or learning method in which numerical quantities can be represented directly on the number. By this means, many of the basic functions of mathematics such as learning ones, tens, hundreds, thousands columns, addition, multiplication, exponents, subtraction, division, fractions (addition, subtraction, multiplication, division of fractions), negative numbers (addition, subtraction, multiplication, division of negative numbers both fractional and whole), decimals, and the like are quantitatively represented, viewed, manipulated, and solved directly on the numbers themselves. The invention represents a method. The numbers may be represented on a mutable substrate, such as paper and a kit for practicing the method is part of the invention. The method of the invention may be adapted to other platforms such as computer programs and video games within the scope of this invention.
2. Description of the Prior Art
There is a diverse and eclectic body of prior art directed to mathematical learning and teaching. During a search directed to the subject matter of this invention, the following US patents were noted.
U.S. Design Pat. No. 163,085 (Bishop) and Utility Pat. Nos. 367,223 (Moody), U.S. Pat. No. 2,842,870 (Lilly), U.S. Pat. No. 3,357,116 (Bazacos), U.S. Pat. No. 4,808,111 (Pratt) and U.S. Pat. No. 5,040,987 (Frazier).
The Lilly patent discloses manipulatives for representing various numbers and numerical representations of numbers. Referring to FIGS. 5 and 6, there are illustrated ten disks (50) representing a one in the tens column. The disks, however, are received in a receptacle in which they can not be further manipulated.
The Bazacos patent discloses a device comprising a display board, supports for hanging numbers, i.e. one through nine, on the board and pegs or other indicia attached to the board, adjacent each support, and representing the number which is to be hung on each support.
The Pratt patent discloses a device comprising a number rack with variously shaped openings, number plates, with corresponding shapes, which can be inserted only in the appropriate recess, and indicia adjacent each opening corresponding in number to the number that is to be received in the recess. This appears to be an "improvement" on the device disclosed in the Bazacos patent.
The Moody patent discloses number cards including dots.
The other patents appear to have only marginal relevance to the present invention.
A series of workbooks published in 1991, entitled NO MEMORIZATION ADDITION AND SUBTRACTION, disclose several techniques for adding and subtracting numbers. One of the workbooks, entitled SUBTRACTION WORKBOOK 2, discloses printed digits, i.e., whole numbers from one to nine, with a corresponding number of dots on the printed digit. This workbook also discloses the use of toothpicks to represent the value of a digit in the one's place and of ten bundled toothpicks to represent the value of a digit in the ten's place.
There are many math resources that are available to assist teachers in teaching students. Math manipulatives are generally known and can comprise tiles, blocks, measuring devices and the like which give students hands-on learning opportunities. Some currently available math resources are discussed in a catalog called "Summit Learning" for Spring, 1996.
Despite the abundance of mathematics teaching and learning materials and methods, there remains a need for a simple, effective and versatile method for teaching and learning basic and advanced math skills.
SUMMARY OF THE INVENTION
The present invention involves the use of digits with markers (which may be printed on cards as in the accompanying kit) and attribute tags. These represent quantities and facilitate mathematical manipulation and problem solving. The given number of markers per digit corresponds to the value of the digit. For example, the digit three is enhanced with three markers. The attribute tags are also provided with a given number of markers, for example, ten markers per attribute tag for math problems in base ten mathematics. An example of an attribute's use would be digit three in the tens column which would have an attribute tag positioned on each of its three markers making a total of thirty markers (in base ten mathematics). The digits and the attributes are then used to represent and solve math problems, for example, subtraction of two digit numbers. If the solution of the problem does not require regrouping, for example twenty eight minus thirteen, digit two and digit eight are arranged to represent the number twenty eight and one attribute tag (consisting of ten markers for base ten mathematics) is positioned on each marker of digit two in the tens place of the number twenty eight. To solve the problem, three of the eight markers in the ones place digit eight are then at least partially obliterated or crossed out and ten of the twenty markers in the tens column digit two are at least partially obliterated or crossed out. The remaining number of markers represents the solution to the problem. If the solution of the problem requires regrouping (borrowing from the tens place to the ones place), for example, thirty two minus nineteen, the digits are arranged to represent the numbers thirty two and nineteen (nineteen being displayed in order to represent an optional subtraction technique). One attribute tag is positioned on each marker of the digit three in the tens place of the number thirty two and one attribute tag is positioned on the marker of the digit one in the tens place of the number nineteen (each two digit number will have a number of markers corresponding with the value of the number). Regrouping is effected by removing one of the attribute tags and the underlying marker from the digit three in the tens place of the number thirty two and positioning it in the ones place or column. As a result of this manipulation, the problem can be easily solved by obliterating as by an X, or by superimposing the negative markers and negative attribute tags over the positive markers and positive attribute tags, then obliterating. This can be expanded to three digit problems by using ten attribute tags with ten markers each and placing a bundle of such attribute tags on each marker on each digit in the hundreds place. It can further be expanded even to thousands place by using a hundred attribute tags with ten markers each and placing this bundle on each marker of each digit in the thousands place.
Addition problems which require regrouping are approached in a similar fashion in that groups of ten markers from the ones column can be collected as by circling or the like and tallied and also be physically moved to the tens column. This can be expanded to tens and hundreds columns by collecting and tallying attribute tags as opposed to collecting and tallying individual markers. Problems involving exponents can be represented and solved with digits which are preferably provided in large and small sizes. For example, three squared is represented by placing a small digit three (having three markers) on each of the three markers of a large digit three with the result that there will be a total of nine markers. Three cubed is represented by placing the preconstructed three squared digits on a preferably larger digit three, one preconstructed three squared digit at each point on the larger digit three where a marker would normally be represented. This can be continued to digit three to the fourth power.
Multiplication problems are also readily represented and solved according to the method of the present invention. For example, eleven times two can be represented by selecting two large digit ones and placing a large attribute tag on the marker of large digit one of the tens place. Eleven digit twos, preferably small twos (one digit two with its two accompanying markers) are then placed on each marker of the large attribute tag of large digit one of the tens column and the marker of large digit one of the ones column. This produces a number eleven with twenty two markers. The problem can also be shown with two smaller elevens (each having a smaller attribute tag) placed on each marker of a large digit two. Division problems are represented and solved according to the present invention by using digits, and attribute tags if necessary, to represent the dividend. Markers on the dividend are then grouped, as by circling or the like, in groups equal to the divisor. Alternatively, the dividend can be cut or separated into pieces, each containing a number of markers equal to the divisor. The quotient is arrived at by counting the groups or pieces, and the remainder, if any, corresponds with number of ungrouped or left over markers.
Negative numbers are represented by using markers and attribute tags which are visually distinguishable from markers and attribute tags used for positive numbers. For example, black markers can be used for positive numbers and red markers can be used for negative numbers.
Markers can also be subdivided, for example into fourths, to represent fractions or solve problems involving fractions. Portions of markers can be represented by some means such as superimposing, highlighting or the like. Addition of fractions can be accomplished by taking the superimposed or highlighted marker parts and grouping them together to form full markers or portions of full markers. Subtraction of fractions can be accomplished by highlighting the amount to be subtracted (or the negative portion of markers) by another means, such as highlighting in red. These negative marker parts can then obliterate positive portions of markers by some means such as overlapping and canceling. Portions not obliterated would represent the answer to the subtraction problem. Multiplication of a whole number by a fraction can be accomplished by superimposing or highlighting that fraction amount of whole markers within a whole number thereby leaving any remaining markers not highlighted, or by highlighting that fraction amount within each individual marker thereby leaving any remaining portion of each marker not highlighted. Optionally, highlighted portions of markers are then collected and added. Multiplication of fractions by another fraction is accomplished by taking the existing marker part which is the fraction, dividing it into equal portions, and superimposing or highlighting the representative parts to show the answer. Division of fractions is accomplished by rewriting the problem into a multiplication problem. Multiplication and division of negative fractions just like any other negative number are again accomplished by using markers distinguishable from positive markers such as highlighting in red. Decimals are represented in the same manner as fractions. For example, decimal numbers such as one tenth can be represented by markers in which one tenth of the marker is superimposed or highlighted by some means.
The present invention also contemplates attribute tags assuming various configurations i.e. rectangular strips, curved strips, spirals, zigzags, as well as clumps of sticky markers such as pieces of tape rolled up with the sticky side out. Sticky markers can be stuck on numbers or to each other, for example, in groups of ten, forming the sticky attribute tags.
Accordingly, it is an object of the present invention to provide a unique and simple method for representing numbers and quantities.
It is a further object of the invention to provide a method for manipulating numbers and numerical quantities to facilitate the solution of mathematical problems.
It is yet another object of the present invention to make mathematics easier to understand and to learn.
These and other objects will be apparent to those skilled in this art from the following detailed description and drawing figures.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows enhanced digits which are useful in practicing the method of the present invention.
FIG. 2 shows an attribute tag which is used in practicing the method of the present invention.
FIG. 3 depicts a step according to the method of the present invention for representing numerical quantities and solving a subtraction problem.
FIG. 4 depicts a further step according to the method of the present invention for representing and solving a subtraction problem.
FIG. 5 depicts a step according to the method of the present invention for representing numerical quantities and solving a subtraction problem involving borrowing.
FIG. 6 depicts a further step according to the method of the present invention for representing and solving a subtraction problem involving borrowing.
FIG. 7 depicts a step according to the method of the present invention that is an alternative subtraction technique using negative numbers.
FIG. 8 depicts a method of representing negative markers and negative attribute tags.
FIG. 9 depicts a further step according to the method of the present invention that is an alternative subtraction technique using negative numbers.
FIG. 10 illustrates a method of the present invention for representing numerical quantities and solving addition problems.
FIG. 11 shows a large enhanced digit three.
FIG. 12 illustrates a step in a method according to the present invention for representing and solving a multiplication problem.
FIG. 13 illustrates a portion of a large attribute tag.
FIG. 14 shows a large enhanced number eleven possessing a large attribute tag.
FIG. 15 illustrates a step in a method according to the present invention for representing and solving a multiplication problem where one factor possesses an attribute tag.
FIG. 16 shows a large enhanced digit two.
FIG. 17 illustrates a step in a method according to the present invention for representing and solving a multiplication problem where one factor possesses an attribute tag that is an alternative to FIG. 15.
FIG. 18 illustrates a step in a method according to the present invention for representing and solving an exponential problem whereby a number is squared.
FIG. 19 illustrates a step in a method according to the present invention for representing and solving an exponential problem whereby a number is cubed.
FIG. 20 illustrates the number seventeen.
FIG. 21 illustrates the steps involved in representing and solving a division problem according to the method of the present invention.
FIG. 22 shows a large enhanced digit four.
FIG. 23 illustrates a step in a method according to the present invention for representing a fractional part of a whole number.
FIG. 24 illustrates a fractional part of a whole number as it stands aside from the number.
FIG. 25 illustrates a step in a method according to the present invention for representing a fractional part of a whole number which is an alternative to FIG. 23.
FIG. 26 illustrates fractional parts of a whole number as it stands aside from the number and is combined to show addition of fractions.
FIG. 27 illustrates a step in a method according to the present invention for representing a fractional part of a whole number which possesses an attribute tag.
FIG. 28 illustrates fractional parts of a whole number (which formerly possessed an attribute tag) as it stands aside from the number and is combined to show addition of fractions.
FIG. 29 illustrates a step in a method according to the present invention for representing a fractional part of a fraction.
FIG. 30 illustrates a further step in a method according to the present invention for representing a fractional part of a fraction.
FIG. 31 illustrates fractional parts of a fraction as it stands aside from the number and is combined to show addition of fractions.
FIG. 32 illustrates a step in a method according to the present invention for representing positive and negative fractions.
FIG. 33 illustrates a step in a method according to the present invention for adding and subtracting fractions
FIG. 34 illustrates a large digit three enhanced with markers alternatively shaped.
FIG. 35 illustrates a sticky pick for use in practicing the methods of the present invention
FIG. 36 illustrates an extended attribute tag which is useful in practicing the methods of the present invention for numbers with digits in the hundreds column.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to FIG. 1, a set of prior art digits are illustrated. A digit one 10 includes a marker 12. A digit two 14 includes two markers 16. A digit three 18 includes three markers 20. A digit four 22 includes four markers 24. A digit five 26 includes five markers 28. A digit six 30 includes six markers 32. A digit seven 34 includes seven markers 36. A digit eight 38 includes eight markers 40. A digit nine 42 includes nine markers 44. A zero 46 has no markers. Each digit has a number of markers corresponding with the value of the digit. The position of the markers relative to the digits is not critical, although each marker is shown in a preferred position. Each of the markers 12, 16, 20, 24, 28, 32, 36, 40 and 44 are illustrated as black dots. It will be appreciated that other shapes may be used and some preferred shapes for specific applications are discussed below in more detail.
In FIG. 2, there is illustrated an attribute tag 50. The tag 50 has ten markers 52, again in the form of a black dot. The ten markers 52 on the attribute tag 50 makes it especially suited for use in base ten mathematics. The use of other attribute tags for differently based math is certainly within the scope of the present invention. An attribute tag (not shown) for base eight mathematics, for example, would have eight markers.
An example of a subtraction method according to the present invention will now be described with reference to FIG. 3 and FIG. 4. The example involves subtracting the number thirteen from the number twenty eight. According to the method, the digit two 14 and the digit eight 38 are arranged to represent the number twenty eight, indicated generally at 60 in FIG. 3. One attribute tag 50 is positioned on each one of the markers 16 (FIG. 1) on the digit two 14 in the tens place of the number twenty eight. The number twenty eight 60 is now represented so that there are a total of twenty eight markers, twenty markers 52 and eight markers 40. In the next step of the method, three of the eight markers of digit eight 38 in the ones place are then at least partially obliterated or crossed out by marking them with an X 62, or the like (FIG. 4). In the next step, ten of the twenty markers 52 of digit two 14 in the tens column are at least partially obliterated or crossed out by marking them with an X 64. The remaining number of markers 40 of digit eight 38 and 52 of digit two 14 which are not partially obliterated or crossed out represent the solution to the problem twenty eight minus thirteen.
An example of the steps involved in representing and solving a subtraction problem which requires regrouping (borrowing from the tens place to the ones place), are illustrated in FIG. 5 and FIG. 6. The example involves subtracting nineteen from thirty two. Referring now to FIG. 5, the digits three 18, two 14, one 10 and nine 42 are arranged to represent the numbers thirty two and nineteen (nineteen being displayed in order to represent an optional subtraction technique). One attribute tag 50 is then positioned on each of the markers 20 on the digit three 18 in the tens place of the number thirty two and one attribute tag 50 is positioned on the marker 12 on the digit one 10 in the tens place of the number nineteen. As shown in FIG. 5, as a result, each two digit number has a number of markers corresponding with the value of the number. Regrouping is effected by removing one of the attribute tags 50 and the underlying marker 20 from the digit three 18 in the tens place of the number thirty two and positioning the attribute tag 50 in the ones column, as shown in FIG. 6. The tag 50 can remain complete or it can be cut into pieces 50' or into individual markers. As a result of this manipulation, the problem can be easily solved.
Another technique of obliterating markers in a subtraction problem is by the use of negative numbers. In FIG. 7, markers 123 on digit nine 42 in the ones column and attribute tag 124 on digit one 10 in the tens column are highlighted as indicated generally by shading (or other visually perceptible way) in FIG. 8 to differentiate them as negative markers 123, negative attribute tags 124, and negative numbers. FIG. 9 illustrates the use of negative markers 123 from digit nine 42 in the ones column to obliterate markers 16 and 52 on digit two 14 in the ones column. Correspondingly in the tens column, negative attribute tag 124 is removed from digit one 10 of the tens column and is used to obliterate an attribute tag 50 on digit three 18 in the tens column. The remaining markers, i.e., the ones not obliterated by the negative markers and negative attribute tags, represent the answer to the subtraction problem.
An example of the steps involved in representing and solving an addition problem according to the method of the invention is illustrated in FIG. 10. The digits one 10, eight 38, nine 42 and seven 34 are arranged as shown to represent the problem eighteen plus nine plus seven. An attribute tag 50 is positioned on the marker 12 of the digit one 10. Circles 70 are drawn around groups of ten markers in the ones column. This leaves four uncircled markers and the digit number four 72 is written below the ones column. The two groups of circled markers are counted and the digit number two 74 is recorded. Grouped markers may also be removed from the ones column and physically placed at the top of the tens column (not shown). It is also recognized that attribute tags can be grouped and tallied in the tens column just as individual markers are grouped and tallied in the ones column (not shown).
An example of the steps involved in representing and solving a multiplication problem are illustrated in FIG. 11 and FIG. 12. The problem of this example is three times four. A large digit three 80 is illustrated in FIG. 11. The large digit three 80 has three large markers 82. In the next step, three small digits four 22, each having four small markers 24, are placed on each of the large markers 82 of the large digit three 80, as shown in FIG. 12. The total number of markers 24 equals twelve, the solution to the problem. It will be appreciated, of course, that the problem could have been set up with a large digit four (not shown) and four small digit threes 18.
In the case of a multiplication problem in which one of the factors has two digits, such as the number 11, it is represented according to the method by two large digits one 125 (FIG. 14) and a large attribute tag 120 (FIG. 13). The multiplication problem two times eleven is represented, as shown in FIG. 15 with a small digit two 14, on each marker 122 of the attribute tag 120 on the large digit one 125 in the tens column as well as on a marker 127 (FIG. 14) on the digit one 125 in the ones column (FIG. 15). The sum total of markers 16 on the digits two 14 in FIG. 15 is equal to the answer, twenty two.
FIG. 16 and FIG. 17 illustrate an alternative method for representing and solving the multiplication problem two times eleven, starting with the factor two represented by a large digit two 128 having large markers 129 (FIG. 16). FIG. 17 shows the markers 129 of the factor two 128 each covered or replaced with the co-factor eleven represented by a tens column digit one 10 with its attribute tag 50 along with ones column digit one 10. Again, the sum total of all of the markers 12 and 52 in FIG. 17 is equal to the answer, twenty two.
The steps involved in solving an exponential math problem are illustrated in FIG. 18. The problem in this example is three squared or three times three. The large digit three 80 in FIG. 11 has its three markers 82 (FIG. 11) covered or replaced with small digits three 18, each having three markers 20. The total number of markers 20 equals nine, the solution to this problem. With a third, extra large digit three 136 (FIG. 19), it is possible to represent the cubing of a number, as in three cubed, by placing three of the squared large digit threes (FIG. 18) on the marker points (not shown) of the extra large digit three 136. The total number of markers 20 now equals twenty seven, the solution to this problem. This technique can be extended to represent and solve the problem of the number three to the fourth power, although this is not illustrated.
An example of the steps involved in solving a division math problem are illustrated in FIG. 20 and FIG. 21. The problem in this example is seventeen divided by four. In FIG. 20, the number seventeen, the dividend, is represented by a digit one 10, an attribute tag 50 and a digit seven 34. There are ten attribute tag markers 52 and seven digit markers 36 for a total of seventeen markers. In FIG. 21, circles 90 have been drawn around groups of four markers. There are a total of four circles 90 and there is one uncircled marker 36. The solution to the problem is four, remainder one and this is graphically illustrated in FIG. 21.
Fractions can readily be represented and solved in accordance with this invention by rendering a portion of a marker visually distinct from the rest of the marker, as by some means such as covering, shading, outlining, or the like, a portion of the markers. FIG. 22 shows a large digit four 130 with markers 131. FIG. 23 shows one method of representing the fraction one fourth and the multiplication problem one fourth times four (as well as four divided by four) whereby one marker, designated 131', on the digit four 130, is rendered visually distinct from the other three markers 131. It will be appreciated that this can be accomplished in numerous ways, as by shading a marker 131, covering a marker 131 with a marker 131' or replacing a marker 131 with a marker 131'. FIG. 24 shows the one shaded marker that was formerly marker 131' of digit four 130.
FIG. 25 shows another method for representing the fraction one fourth and the multiplication problem one fourth times four (as well as four divided by four) whereby each of four markers 131" on digit four 130 are sectioned into four marker parts, three of which are relatively light and are designated 132 and one of which is dark and is designated 132'. Again, the marker parts 132 and 132' are visually distinct from each other. In FIG. 26, the dark marker parts 132' have been regrouped and organized into a complete marker. FIG. 26 also shows addition of the four shaded or darkened marker parts 132' in the problem one fourth plus one fourth plus one fourth plus one fourth.
Multiplication problems involving a fraction and a two, three or four digit number can also be readily represented and solved according to the method of the present invention. FIG. 27 shows a modified version of the number eleven shown in FIG. 14. Specifically, in FIG. 27, modified markers 122' and 127' have been substituted for the markers 122 of the attribute tag 120 and the marker 127 of FIG. 14. Each marker 122' and 127' has been divided into two visually distinct half markers, a darker half marker 133 and a lighter half marker 133'. This division can be carried out in numerous ways. For example, a darker half marker 133 can be applied or adhered to a marker 122 or 127. Alternatively, half of a marker 122 or 127 can be shaded. In any case, FIG. 27 is a representation of the multiplication problem eleven times one half In FIG. 28, the darker half markers 133 have been regrouped into five and one half whole markers, representing the solution to the multiplication problem eleven times one half as well as the solution to the division problem eleven divided by two. FIG. 28 shows addition of eleven of the one half markers 133.
Furthermore, fractions can be represented starting with a marker part. FIG. 29 shows digit one 125 with a modified marker 127". A half 133" of marker 127" is heavily outlined and a second half 133' is not outlined. This renders the marker halves 133" and 133' visually distinct. In FIG. 30, the one half marker part 133" is further subdivided into four marker parts, three of which, indicated at 134, are darker and one of which, indicated at 134', is lighter. In other words, three fourths of the half marker 133" has been rendered visually distinct from one fourth of the half marker 133". FIG. 31 shows the three marker parts 134 of the marker half 133" regrouped aside from digit one 125. FIG. 30 and FIG. 31 demonstrate the answer to the multiplication problem one half times three fourths. FIG. 30 and FIG. 31 also demonstrate the answer to the division problem one half divided by four thirds. FIG. 31 shows addition of one eighth, plus one eighth, plus one eighth.
Whole markers and marker parts can be used to demonstrate addition and subtraction of fractions. FIG. 32 shows two digits one 125, each having a modified marker (as in FIG. 27) which has been divided into two visually distinct half markers, a darker half marker 133 and a lighter half marker 133'. Each represents the fraction one half Also shown in FIG. 32 is a digit one 125 including a modified marker 127"' which has been divided into six parts, one of which is indicated at 135 and has been rendered visually distinct from the other parts, to indicate that it is a negative one sixth. In FIG. 33, the one half marker parts 133 have been grouped together and the marker part 135 has been positioned to obliterate a corresponding portion of one of the one half marker parts 133. That is to say, the marker part 135 (representing a negative one sixth) covers a corresponding portion of one of the marker halves 133, each canceling the other and this is further indicated in FIG. 33 by an "X" 138 or the like. FIG. 33 provides, therefore, a visual representation of the solution to the problem one half plus one half minus one sixth.
Addition, subtraction, multiplication, division, both of whole numbers and of fractions can be carried out with negative markers as well as with positive markers. The same rules that apply in mathematics with negative numbers such as the multiplication of two negative numbers to form a positive number also applies in this invention.
The present invention can be used to introduce and represent units of measure. For example, attribute tags and digits can include markers representing various units such as cups, pints, quarts and gallons. These markers may take the shape or imprint of the various units of measure such as the shape of a gallon 137 (FIG. 34) stamped on all the markers 82 of digit three 80 (FIG. 11). These tags and digits can be used, as described above, to represent and solve mathematical problems involving these units, taking into account the relationships between the units represented by the various markers. Another example of this would be markers in the form of segmented rectangles to demonstrate decimals/fractions. Units of time can also be represented by markers in attribute tags and digits according to the present invention. Again, these would be used as described above, taking into account the relationships between units of time such as seconds, minutes and hours.
In SUBTRACTION WORKBOOK 2, discussed above, there is disclosed the use of toothpicks as manipulatives in solving mathematical problems. The present invention contemplates the use of sticky picks made from pieces of tape which have been rolled so that the outside surface is sticky. A sticky pick 100 is illustrated in FIG. 35. The pick comprises a piece of tape 102 rolled up with a sticky side 104 exposed. Ten of these sticky picks 100 may be stuck together in a clump (not shown) to constitute a three dimensional attribute tag. It will be appreciated that attribute tags according to the present invention may take many forms. Essentially, an attribute tag will comprise a number of markers physically connected to each other (as in the case of the sticky picks) or connected to or represented on a common substrate, as in the case of the attribute tags shown in the various drawing Figures. For base ten mathematics, attribute tags having ten markers are used in the methods according to the invention. For other number based systems, for example, base eight, an attribute tag according to the instant invention would have eight markers. As discussed above, the markers may take many forms and may even represent fractions.
The foregoing examples involve the representation and mathematical manipulation of one and two digit numbers and, in the latter case, attribute tags having ten markers. Three and even four digit numbers can be represented with extended attribute tags. An extended attribute tag 110, for use with digits in the hundreds place, is illustrated in FIG. 36. The extended tag 110 comprises the equivalent of ten attribute tags 50 or ten connected attribute tags 50, each having ten markers 52. The attribute tags 50 have been overlapped and joined, as indicated at 112. In the substrate paper, the tags may be joined with an adhesive, staples, or the like. The extended tag in this instance has been rolled into a cylindrical configuration and may be conveniently retained in that configuration with a clip 114 or twisters. Adhesive may be used to attach the extended tag 110 to a marker on a digit, especially a digit in the hundreds place. Small attribute tags 50 are placed on small digits and large attribute tags 120 are used in the same manner on large digits.
The present invention is also concerned with a kit comprising worksheets, at least two sizes of pre-printed digits enhanced with markers, and two sizes of pre-printed attribute tags with markers comparable to the digit'smarkers. The two sizes of digits include a set of small digits like those illustrated in FIG. 1 and a set of large digits like the digit three 80 shown in FIG. 11. The height of the large digit three 80 is five or six times the height of the small digits shown in FIG. 1. It is preferred that the height of the large digits be at least about three times the size of the small digits, and, more preferably, four to eight times the height of the small digits. The two sizes of attribute tags include the small attribute tags 50 in FIG. 2 and the large attribute tags 120 in FIG. 13. It is also preferred that the overall size of the small digits be approximately equal to the size of the markers on the large digits. A small digit according to the invention is small enough, relative to a large digit, that the small digit can be placed on the large digit and the large digit can still be recognized.
The digits and attribute tags may be printed on cards which simply means printed on paper type stock, whether it is thick, thin, or in between, or any other suitable substrate.
It will be appreciated that it is desirable for the markers, the digits and the attribute tags to be mutable, i.e., changeable in a visually perceptible way. It will be further appreciated that the objects and advantages of the present invention can be readily achieved by applying the principles described above to images of digits with markers and attribute tags with markers generated by a microprocessor and displayed on a video display terminal, a television screen, a computer monitor or the like and by providing a means which renders them selectively mutable in a visually perceptible way. For example, a marker might appear on a computer monitor as a white circle and a computer program could provide a means by which the marker can be selected and visually altered, by changing color to black, for example, to represent the addition of a negative number as described above. The provision of such microprocessor generation and display of digits with markers and attribute tags with markers is well within the ability of one skilled in the art and will not be described further. In this application, the substrate for the digits, the markers and the attribute tags would be the computer monitor, video display terminal, television screen or the like and the digits and attribute tags would be mutable. As used herein, the term mutable means that a marker, a digit or an attribute tag can be highlighted, divided, covered, adhered to or repositioned to represent numbers and math processes such as the representation of ones, tens, hundreds and thousands columns, addition, multiplication, subtraction and division of whole numbers, fractions, negative whole numbers and negative fractions, as well as decimals, exponents and the like. Markers, digits and attribute tags which are printed on a substrate such as paper are mutable meaning that they can be highlighted, divided, covered, adhered to or repositioned to represent numbers and math processes such as the representation of ones, tens, hundreds and thousands columns, addition, multiplication, subtraction and division of whole numbers, fractions, negative whole numbers and negative fractions, as well as decimals, exponents and the like.
The foregoing description is intended to enable one skilled in the art to make and use the instant invention and not to limit it except by reference to the following claims. | The present invention involves the use of numerical digits with markers and attribute tags as a means to represent quantities, facilitate mathematical manipulation, and solve problems. The given number of markers on each digit corresponds to the value of the digit. For example, the digit three is enhanced with three markers. The attribute tags are also provided with a given number of markers, for example, ten, for math problems in base ten. The digits and the attribute tags are then used to represent and solve math problems including, but not limited to, learning ones, tens, hundreds, thousands columns, addition, multiplication, subtraction, and division, of whole numbers, of fractions, of negative whole numbers and of negative fractions, as well as decimals and exponents. The problems are quantitatively viewed, manipulated, and solved directly on the numerical digits incorporating the markers and attribute tags. A kit is disclosed for use in practicing the invention and the kit comprises digits represented on a mutable substrate and having a number of markers corresponding with the numerical value of the digit and attribute tags represented on a mutable substrate and having a number of mutable markers corresponding with the base number in a given base number systems. | 6 |
RELATED APPLICATION
This application claims priority from co-pending provisional application Ser. No. 60/949,945, which was filed on 16 Jul. 2007, and which is incorporated herein by reference in its entirety.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
The invention was made with government support under National Institutes of Health grant number K01CA101781. The government has certain rights in the invention.
FIELD OF THE INVENTION
The present invention relates to the field of biosensors and, more particularly to a method of making magnetic iron oxide nanoparticles coated with a polymer and functionalized with a ligand and the nanoparticles made accordingly.
BACKGROUND OF THE INVENTION
Iron oxide based magnetic nanocrystals have been widely used in a variety of biomedical applications such as diagnostic, magnetic resonance imaging (MRI) and in magnetically guided site specific drug delivery systems. Their use as MRI contrast agents and as an enhancer in hypothermia (heating of diseased tissue by application of an RF pulse) has been widely discussed in the literature. Recently, it has been found that dextran coated iron oxide nanoparticles, ranging in size from 1 to 100 nm, can be used as magnetic relaxation switches (MRS) or magnetic relaxation nanosensors (MRnS). When these nanosensors self assemble in the presence of a molecular target, there is a significant change in the spin spin relaxation time (T 2 ) of neighboring water molecules. This parameter (T 2 ) is a component of the MR signal. The observed target-induced self assembly of iron oxide based nanoparticles has been used as a sensitive detection method for various targets and reported in the literature.
SUMMARY OF THE INVENTION
With the foregoing in mind, the present invention advantageously provides iron oxide nanoparticles that have been specifically prepared for in vivo studies and for clinical applications, as injectable MRI contrast agents.
Monodisperse, water-soluble dextran-coated iron oxide nanorods were synthesized using a facile and scalable method. Our room temperature method involves the mixing of an acidic solution of iron salts with a basic solution of ammonium hydroxide to facilitate initial formation of iron oxide crystals. The stability, cystallinity and shape of these nanorods depends on the time of addition of the dextran as well its degree of purity. The as-synthesized nanorods exhibit unique magnetic properties, including superparamagnetic behavior and high spin-spin water relaxivity (R 2 ). Additionally, they posses enhanced peroxidase activity when compared to those reported in the literature for spherical iron oxide nanoparticles. Thus, this high yield synthetic method for polymer-coated iron oxide nanorod will expedite their use in applications from magnetic sensors, devices and nanocomposites with magnetic and catalytic properties.
Iron oxide based magnetic nanoparticles have been widely used in a variety of biomedical applications such as magnetic separation, magnetic resonance imaging, hyperthermia, magnetically-guided drug delivery, tissue repair, and molecular diagnostics. For most applications, a polymeric coating is needed to improve the nanoparticles' aqueous stability, biocompatibility and conjugation properties. Typically, dextran-coated iron oxide nanoparticles have been successfully used as magnetic resonance imaging (MRI) contrast agent, due to their strong ability to dephase water protons in surrounding tissue, which results in a decrease in the MRI signal. In addition, the dextran coating can be crosslinked and functionalized with amino groups to facilitate the conjugation of targeting ligands for MRI and in vitro diagnostics applications. Current synthetic procedures for dextran-coated iron oxide nanoparticles involve the formation of the iron oxide core in the presence of dextran, as stabilizer and capping agent, in an alkaline solution. Under these in situ conditions, the nature, quality and amount of the polymer modulate the nucleation, growth and size of the newly formed iron oxide nanocrystal. A common characteristic of most reported in situ dextran-coated iron oxide nanoparticles synthetic procedures is the formation of nanoparticles with a spherical iron oxide core. Research efforts have been geared towards the production of small, uniform and highly dispersed spherical nanocrystals. Only recently, has the importance of the nanoparticles' shape been recognized, in particular one dimensional (1-D) structures such as nanorods and nanotubes, because they exhibit unique properties that are different from their corresponding zero dimensional counterparts (0-D or spherical nanocrystals). Particularly in the case of iron oxide, 1-D nanorods have been found to exhibit interesting magnetic properties due to their shape anisotropy, such as higher blocking temperatures and larger magnetization coercivity, compared to their 0-D counterparts. However, their wide application in biomedical research has been hampered by difficult and non-reproducible synthetic procedures, use of toxic reagents and poor yields. For instance, current methods for making iron oxide nanorods involve hydrothermal, sol-gel and high temperature procedures, among others. Therefore, a water-based synthetic procedure for iron oxide nanorods that is simple, economical, low temperature and high yield would be in high demand. In particular, synthetic methods that yield water soluble and stable polymer-coated nanorods would be ideal for studies geared towards the development of magnetic biosensors and magnetic devices.
For these reasons, we surmised it would also be advantageous to develop a new, facile, reproducible and low cost method to synthesize iron oxide nanoparticles for in vitro applications. In particular, a simple synthetic method that yields larger nanoparticles (100-500 nm) with a unique crystal shape and enhanced magnetic relaxation (high R 2 and R 1 ) would be helpful in studying the effect of shape and size on the sensitivity of the MRS assay.
To our understanding, it has not yet been reported what effect larger nanoparticles (100 to 500 nm) would have on the sensitivity of the magnetic relaxation assay. It has been hypothesized that the target induced self assembly of large nanoparticles would result in nanoparticles clusters so large that they would precipitate and thereby render the system useless. However, if these nanoparticles contain a large iron oxide crystal with a high magnetic relaxation (high R 2 ), a lower amount of nanoparticles would be required to achieve a detectable T 2 signal (MRI signal). In such case. the amount of nanoparticles that participate in cluster formation would be small, resulting in smaller clusters of magnetic nanoparticles that remain suspended in solution and do not precipitate out. We hypothesized that having a lower number of nanoparticles participating in target-induced cluster formation would result in a more sensitive assay, having a lower detection limit.
Accordingly, here we disclose a facile, high-yield, room-temperature, and water-based synthetic protocol that yields disperse dextran-coated iron oxide nanorods (DIONrods). Our synthetic procedure differs from previously reported methods for dextran-coated iron oxide nanoparticles in that the dextran is not present during the initial nucleation process. Instead, the dextran is added at a later stage. This “stepwise” process, as opposed to the in situ process, allows for the formation of stable, disperse and highly crystalline superparamagnetic iron oxide nanorods with unique magnetic properties, such as high blocking temperature and improved high water relaxivity.
BRIEF DESCRIPTION OF THE DRAWINGS
Some of the features, advantages, and benefits of the present invention having been stated, others will become apparent as the description proceeds when taken in conjunction with the accompanying drawings, presented for solely for exemplary purposes and not with intent to limit the invention thereto, and in which:
FIG. 1 , according to an embodiment of the present invention, is a TEM image of aminated (a) dextran and (b) silica coated iron oxide nanoparticles; the TEM images show that the dextran coated nanoparticles are rod shaped whereas the silica ones are spherical in nature (Bar=500 nm);
FIG. 2 is a selected area electron diffraction (SAED) image of aminated (a) dextran and (b) silica coated iron oxide nanoparticles (Bar=5 1/nm); the images show that the dextran coated particles are more crystalline than silica ones and consequently showing better magnetic relaxivity;
FIG. 3 shows an XRD pattern of TO nanocrystals wherein the XRD shows that the peaks matches well with that of Fe 3 0 4 as reported in literature; both dextran and silica coated particles show same XRD pattern;
FIG. 4 provides an XPS spectrum of Fe 3 0 4 nanocrystals where (a) shows the peaks due to Fe2p electrons and (b) shows that due to O1s electron; both dextran and silica coated particles show same XPS pattern; thus, XPS confirms the formation of Fe 3 0 4 nanocrystals in solution;
FIG. 5( a ) shows a time dependent study, where after addition of 5 μg avidin in 0.5 μg IO-dextran biotin conjugate; the control contains 5 μg 0.1 M phosphate buffer, pH 7.4; 5(b) shows a time dependent study after addition of 5 μg avidin in 0.7 μg IO-silica biotin conjugate; the control contains 5 μg 0.1 M phosphate buffer at pH 7.4; 5(c) is a plot of T 2 (ms) vs. Time (min) after addition of 5 μg avidin in 0.5 μg of both silica and dextran coated biotinylated IO particles; 5 ( d ) depicts a dose dependent study where T 2 was measured after 1 hr incubation of the 0.5 μg IO-dextran-biotinylated particles with avidin at different concentrations; detection limit of avidin=0.091 μg; 5 ( e ) shows a dose dependent study where T 2 was measured after 1 hr incubation of the 0.5 μg I0-silica-biotinylated particles with avidin at different concentrations; detection limit of avidin=0.071 μg;
FIG. 6 ( a ) is a time dependent study after addition of 1 μg of Antibody against Protein G in 0.42 μg IO-dextran-protein G particles; 6 ( b ) depicts another time dependent study where after addition of 1 μg of Antibody against Protein G in 0.66 μg IO-silica-protein G particles; 7 ( a ) is a time dependent study; after addition of 51.25 CFU MAP in 0.54 μg IO-dextran-protein G particles; control=1 μl phosphate buffer, pH 7.4; and 7(b) is a time dependent study; after addition of 51.25 CFU MAP in 0.82 μg IO-silica-protein G particles; control=1 μl phosphate buffer, pH 7.4. IO-silica-protein G was conjugated with antibody specific to MAP and then MAP was added;
FIG. 8( a ) hysteresis loops obtained at temperatures 5K, 100 K and 200 K; (b) zero field cooled and field cooled magnetic susceptibilities in an external magnetic field H=200G; (c) real and (d) imaginary components of ac susceptibility at different frequencies, the inset of (d) shows the Arrhenius plot obtained from the imaginary component of susceptibility measurements; and
FIG. 9 ( a ) dynamic light scattering study of DIONrods with ConA; (b) time dependent response in T 2 of DIONrods (200 μl, 0.002 mg Fe per ml) when treated with 10 μl ConA (1 mg in 1 ml PBS); (c) FTIR spectra of free dextran and DIONrods.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The present invention will now be described more fully hereinafter with reference to the accompanying drawings, in which preferred embodiments of the invention are shown. Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains. Although methods and materials similar or equivalent to those described herein can be used in the practice or testing of the present invention, suitable methods and materials are described below. Any publications, patent applications, patents, or other references mentioned herein are incorporated by reference in their entirety. In case of conflict, the present specification, including any definitions, will control. In addition, the materials, methods and examples given are illustrative in nature only and not intended to be limiting. Accordingly, this invention may be embodied in many different forms and should not be construed as limited to the illustrated embodiments set forth herein. Rather, these illustrated embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art. Other features and advantages of the invention will be apparent from the following detailed description, and from the claims.
FIGS. 1 , through 7 ( b ) illustrate various aspects of the present invention. Herein, we disclose a simple water based technique for the synthesis of high quality Fe 3 0 4 nanocrystals having high magnetic relaxivities. The method is based on the co-precipitation of ferric and ferrous chloride salts in an acidic environment, with the subsequent growth and morphology of the iron oxide crystal being controlled by addition of a polymeric capping agent at a specific time. Two different kinds of capping agents (dextran and silica) have been used in our experiments, showing that besides stabilization, the capping agents control the morphology and consequently magnetic property of the evolved particles. In our experiments, we found that rod-shaped particles of approximately 300 nm in length by about 100 nm in diameter with R 2 relaxation of 300 mMs-1 were obtained when dextran was used as a capping agent. On the other hand, spherical nanoparticles of approximately 150 nm diameter with R 2 relaxation of 150 mMs-l were obtained when a coating of aminated silica was used.
The proper functionalization and bioconjugation of the nanoparticles with various targeting ligands resulted in robust nanosensors able to detect a molecular target by magnetic relaxation with high sensitivity. The high relaxivity of these particles allow us to do sensing experiments at a very low concentrations of nanoparticles, with improved sensitivity and without precipitation of the particles because of their size. Furthermore, the fact that our facile synthetic method yields different sized particles depending on the polymer used is novel and can be used to generate multiple sizes and shapes of particles for further studies.
In our first set of experiments, we optimized the synthetic protocol, including the order of addition (in situ vs. step-wise), and the time of addition of the dextran polymer. Our water-based synthetic protocol involves an acid-base reaction between an acidic solution of iron salts and a basic solution of ammonium hydroxide. Upon mixing, the resulting solution becomes alkaline (pH=9.0), facilitating the formation of iron oxide nanocrystals. This initial formation of nanocrystals can occur either in the presence (in situ) or absence (step-wise) of dextran.
Since most synthetic procedures that afford stable and monodisperse nanoparticles use an in situ approach, we opted to try this approach first. In these experiments, a mixture of iron salts (FeCl 3 .6H 2 O and FeCl 2 .4H 2 O) was dissolved in an aqueous solution of HCl. A dextran solution was prepared in aqueous ammonia solution and placed on a digital vortex mixer. Finally the resulting iron salt solution was poured at one time into the ammonia solution of dextran under vigorous stirring. Following this protocol, we obtained poorly crystalline, spherical nanocrystals of 20±5 nm in diameter and poor R 2 relaxivity (<1 mMs-1). This poor relaxivity contrasts with the relaxivity obtained with other published in situ procedures where relaxivity values between 60-100 mMs-1 are obtained.
We then investigated if a step-wise approach might result in larger iron oxide nanocrystals and in improved R 2 relaxivity. In this approach, a dextran solution was added at a particular time after initiating the nucleation of the iron oxide crystals. In initial optimization experiments, we measured T 2 relaxivity (R 2 ) and obtained TEM images of a series of dextran iron oxide nanoparticles prepared after adding dextran at different times (1, 10, 30 and 60 sec). Following this approach, we obtained nanorods where their size, crystallinity and R 2 relaxivity improved with time of addition (Table 1). No significant difference was observed between 30 and 60 seconds. Interestingly, the yield was reduced at 60 sec, based on measurements of the concentration of iron in the solution, which were performed as described [ref]. The most optimal preparation was obtained when dextran was added 30 seconds after initiating the iron oxide nucleation, resulting in dextran iron oxide nanorods (DIONrods) with an R 2 of 300 mMs-1.
TABLE 1 Effect on T2 relaxivity compared to time of addition of dextran (θ) to the reaction mixture. Time of addition of Dextran (θ) R2 (mM −1 s −1 ) Before adding ammonia <1 1 sec 50 10 sec 150 30 sec 300 60 sec 300
I. Synthetic Procedure
Synthesis of Aminated Dextran Coated 10 Nanoparticles
A mixture of iron salts containing 0.203 g FeCl 2 4H 2 O and 0.488 g FeCl 3 6H 2 O in HCl solution (88.7 12 N HCl in 2 ml water) was added to NH 4 OH (830 μl in 15 ml N 2 purged DI water) and stirred on a digital vortex mixer for 10 sec. Then, an aqueous solution of dextran (5 g in 10 ml water) was added to the mixture and stirred for 1 hr. Finally, the entire mixture was centrifuged for 30 minutes, to pellet large particles, and the supernatant was collected, filtered and washed several times with distilled water through an Amicon cell (Millipore ultrafiltration membrane YM—30 k). This process helps to get rid of the unbound dextran molecules. The dextran coated nanoparticle (3 mg, i.e. 3 ml 10 solution containing—1 mg Fe per ml) was then crosslinked by treating with 200 p1 epichlorohydrin and 5 ml 0.5 M NaOH and the mixture was stirred vigorously at room temperature for 8 hrs. Afterwards, the particles were aminated by mixing 850 W, 30% ammonia and stirred overnight at RT to get aminated dextran coated 10 particles. The free epichlorohydrin was removed by washing the solution repeatedly with distilled water using an Amicon cell.
Synthesis of Aminated Silica Coated 10 Nanoparticles:
A mixture of 0.203 g FeCl 2 .4H 2 0 and 0.488 g FeCl 3 .6H 2 0 in HCl solution (88.7 μl 12 N HCl in 2 ml water) was poured into a solution of NH 4 0H (830 μl in 15 ml N 2 purged DI water) and stirred on a digital vortex mixer. After 10 sec of stirring 2680 μl tetraethylorthosilicate, 670 μl 3-(aminopropyl)triethoxysilane and 6180 μl 3-(trihydroxysilyl)propylmethylphosphonate were added to the iron oxide nanoparticle solution and stirred for 1 hr at 3000 rpm. Then, the solution was centrifuged to remove large particles and washed finally with distilled water through Amicon cell (Millipore ultrafiltration membrane YM—30 k).
II. Advantages of the Present Method:
1) Facile, cost effective, and green chemistry synthesis that does not require vigorous experimental conditions.
2) Synthesis does not require the use of toxic reagents and therefore they are highly biocompatible.
3) Good solubility and stability of resulting particles in water, phosphate buffer saline and citrate buffer for a long time period makes them suitable for biomedical applications.
4) The resulting IO particles can be concentrated using ultrafiltration devices without inducing agglomeration of the nanoparticles.
5) The evolved particles are highly magnetic. Therefore they can be used at a very low concentration for biological applications.
6) The aminated particles can be conjugated with proteins and other biomolecules for sensing application.
7) Stable nanoparticles suspension of size range 100-500 nm (depending on experimental conditions) can be obtained.
8) Using this protocol, we can obtain iron oxide crystals of defined size and shape by simply changing the polymer used as stabilizer/coating. For example, using dextran we favor formation of rods, while using silica we favor formation of spheres, under the same general experimental conditions.
9) Other polymers can be used, potentially obtaining other shapes and sizes of nanoparticles. In particular, biodegradable or biocompatible polymers viz. polyvinyl alcohol, polyacrylic acid. among others can be used in the present method.
10) Resulting nanoparticles can be used for both in vitro and in vivo applications since synthetic procedure involves non-toxic materials.
11) Both the silica coating and dextran coating nanoparticles can achieve a strong water relaxation effect. Larger R 1 and R 2 are obtained.
12) Because of the larger R 2 and RI. we can achieve a detectable MRI signal at low concentration of particles.
III. Characterization
A. Transmission Electron Microscopy (TEM)
The results of examination of the evolved particles by TEM is shown in FIG. 1 . Shown is the TEM image of aminated (a) dextran and (b) silica coated iron oxide nanoparticles. The TEM images show that the dextran coated nanoparticles are rod shaped whereas the silica coated nanoparticles are approximately spherical in nature. (Bar=500 nm).
FIG. 2 depicts selected area electron diffraction (SAED) images of aminated (a) dextran and (b) silica coated iron oxide nanoparticles (Bar=5 1/nm). The images show that the dextran coated particles are more crystalline than silica ones and consequently showing better magnetic relaxivity.
B. X-Ray Diffraction Study (XRD)
FIG. 3 shows the XRD pattern of 10 nanocrystals. The XRD shows that the peaks match well with those of Fe 3 O 4 , as reported in literature. Both dextran and silica coated particles show same XRD pattern.
C. X-Ray Photoelectron Spectroscopy (XPS)
FIG. 4 provides an XPS spectrum of Fe 3 O 4 nanocrystals where (a) shows the peaks due to Fe2p electrons and (b) shows that due to O1s electron. Both dextran and silica coated particles show same XPS pattern. XPS confirms the formation of Fe 3 O 4 nanocrystals in solution.
D. Quantification of Amines
After amination of the resulting nanoparticles, it is important to determine the amount of amine groups present per gram of iron oxide particles. The quantification of amine group on the surface of IO particles is important, as they can be used to conjugate to a series of targets according to the amount of amines. The amine groups present per gram of iron was determined through conjugation of the aminated particles with N-succinimidyl-3-(2-pyridyldithio) propionate (SPDP). Briefly, 500 μl aminated 10 (˜1 mg Fe per ml) was mixed with 100 μl 0.1 M sodium phosphate buffer (pH 7.4) and 60 μl 75 mM SPDP in DMSO and kept for 2 hrs. The unbound nanoparticles and SPDP were removed by passing the solutions through a Sephadex PD-10 column. Afterwards, a portion of the IO-SPDP conjugate was treated with 75 μl 20 mM 1,4-dithio-DL-threitol (DTT) and stirred for 2 hrs. The reaction mixture was then passed through Microcon centrifugal filter devices (YM 30) and absorbance of the filtrate was measured as previously described [Bioconjugate Chem. 1999, 10 186].
NOTE: It has been observed that the aminated IO-silica and aminated dextran particles have about 0.152 and 0.106 mmoles of amines present per gram of iron respectively. The silica coated particles are more easily aminated as the synthesis involves coating materials containing aminating agents, such as 3-(aminopropyl)triethoxysilane (APTS). On the other hand, aminated dextran coated particles are synthesized by first crosslinking the dextran coating and then aminating the crosslinked nanoparticle with ammonia. The later procedure might introduce a limited number of amino groups to the nanoparticle, as opposed to the silica/APTS protocol.
E. Characteristic Properties of Aminated Dextran and Silica Coated Iron Oxide Nanoparticles
The characteristics of the aminated dextran and silica coated iron oxide particles are shown in Table 2, below.
TABLE 2
mmoles of
amino
group per
r 1
r 2
gram of
Sample
Size (nm)
(mM −1 s 1 )
(m1v1 −1 s −1 )
r2/r1
iron
10-dextran-
L—330
16.80
296
17.61
0.106
NH 2
B—100
IO-silica-
—150
12.43
145
11.66
0.152
NH 2
F. Additional Characterization Studies
Subsequently, we studied the magnetic properties of the DIONrods. First, hysteresis loops, measured at three different temperatures ( FIG. 2 a ), demonstrated a coercivity of 500±10G at 5K that disappeared at 100 K and 200 K, which is typical of superparamagnetic behavior. Zero-field cooled (ZFC) and Field cooled (FC)—dc susceptibility studies ( FIG. 2 b ) show that the ZFC magnetic moment increased as the temperature increased, reaching a maximum at 28 K (the blocking temperature, T B ) and then it decreased with further increase in temperature. In the FC process, above the blocking temperature (T B ), the data followed the ZFC curve, but it deviated from ZFC curve below T B showing a slow increase in the moment with decreasing temperature. The maximum found in the ZFC curve (at T B ) is where a maximum number of particles exhibit superparamagnetic behavior. Below T B , the relaxation times of the particles are longer than the experimental measurement time; hence the particles acquire a blocked state. In the ac susceptibility, both real and imaginary components χ′(T) and χ″(T), at different frequencies ranging from 1 Hz to 1 kHz exhibited a frequency dependent maximum ( FIG. 2 c and d ), which shifted to higher temperatures with increasing frequency. This may be due to either spin glass or superparamagnetic behavior. To clearly distinguish between these two behaviors, the Mydosh parameter (φ) was calculated from the real part of the ac susceptibility according to the equation:
Φ = Δ T m T m [ Δ log 10 ( v ) ]
We used the χ′(1 Hz) and χ′(1 kHz) data to calculate φ, obtaining a value of 0.072. T m is the temperature corresponding to the observed maximum in χ′(1 Hz) and ΔT m is the expected for superparamagnetic systems is ˜0.10, which further corroborates that our DIONrods are superparamagnetic. The particle relaxation time follows the Arrhenius law, given by:
v = v 0 exp ( - Δ E k a T )
where ΔE/k B is the energy barrier and u is the experimental frequency. The data fitted well to a linear relation (inset of FIG. 2 d ) yielding ΔE/k B ˜800±10K and τ 0 ˜2×10 −14 s , whereas 10 −11 <τ 0 <10 −9 s is expected for superparamagnetic systems. The lower value of τ 0 is an indication of interparticle interactions present in the sample. Taken together, these results show that out DIONrods exhibit superparamagnetic behavior.
Regarding FIG. 2 , panel (a) shows hysteresis loops obtained at temperatures 5K, 100K and 200K, panel (b) depicts zero field cooled and field cooled magnetic susceptibilities in an external magnetic field H=200G, panel (c) shows real and (d) imaginary components of ac susceptibility at different frequencies. The inset of FIG. (d) shows the Arrhenius plot obtained from the imaginary component of susceptibility measurements.
Furthermore, we performed experiments to assess the quality and stability of our nanorods. First, the presence of dextran on nanorod surfaces was confirmed by performing clustering experiments with Concanavalin-A (ConA). Specifically, the presence of dextran on nanoparticles can be identified via ConA-induced nanoparticle clustering, due to the strong affinity and multivalency of ConA towards carbohydrates, such as dextran. DLS experiments ( FIG. 3 a ) show a time-dependent increase in particle size distribution upon ConA administration, due to formation of nanoparticle assemblies. Most importantly, a fast and reproducible change in T 2 relaxation time was observed ( FIG. 3 b ), not only indicating the association of dextran with the nanoparticle, but indicating the feasibility of our DIONrods as magnetic relaxation sensors.
With reference to FIG. 3( a ), shown is a dynamic light scattering study of DIONrods with ConA; FIG. 3( b ) shows the time dependent response in T 2 of DIONrods (200 μl, 0.002 mg Fe per ml) when treated with 10 μl ConA (1 mg in 1 ml PBS); FIG. 3( c ) shows FTIR spectra of free dextran and DIONrods. The FT-IR experiments further confirmed the presence of characteristic dextran peaks on the DION rods preparations. Most importantly, the prepared DIONrods can be concentrated in PBS by ultrafiltration, obtaining highly concentrated preparations without nanoparticle precipitation even upon storage at 4° C. for over twelve months. Taken together, these results demonstrate the robustness of the dextran coating on the nanorods, making them suitable for biomedical applications.
IV. Applications
A. Conjugation with Biotin:
To conjugate biotin onto the aminated IO nanoparticles, the nanoparticle solution (1 ml) was incubated with Sulfo-N-hydroxysuccinimide-LC-Biotin (Pierce, 1 mg) for 2 hrs. The solution was then centrifuged at 13.2 k rpm for 30 min and the supernatant was discarded. The pellet was then redispersed in phosphate buffer (pH 7.4) to obtain biotinylated nanoparticles. The centrifugation and redispersion were repeated three times to get rid of unbound biotin molecules. The presence of biotin on the surface of nanoparticles was assessed via biotin-avidin interaction through magnetic relaxation. The biotin-avidin interaction is used as a model system to prove the utility of our nanoparticles as magnetic relaxation switches. The binding of avidin to the biotin of the nanoparticles causes clustering of the nanoparticles with a concomitant decrease in T 2 relaxation time. The biotinylated particles were targeted with avidin and the changes in T 2 was measured in a relaxometer at 0.47 T. It has been observed that even a very low concentration of the biotinylated particles can sense avidin through magnetic relaxometer.
In that regard, FIG. 5 ( a ) shows a time dependent study. After addition of 5 μg avidin in 0.5 μg IO-dextran biotin conjugate. The control contains 5 μl 0.1 M phosphate buffer at pH 7.4. FIG. 5 ( b ) shows another time dependent study, this after addition of 5 μg avidin in 0.7 μg IO-silica-biotin conjugate. The control contains 5 μl 0.1 M phosphate buffer, pH 7.4. FIG. 5 ( c ) shows a plot of T 2 (ms) vs. Time (min) after addition of 5 μg avidin in 0.5 μg of both silica and dextran coated biotinylated 10 particles. NOTE: At this concentration of iron, aminated silica coated particles show greater sensitivity than the dextran coated ones, as silica coated particles have more amine groups on their surface. Therefore. they are more biotinylated and can conjugate with avidin to a greater extent.
FIG. 5( d ) presents a dose dependent study where T 2 was measured after 1 hr incubation of the 0.5 μg IO-dextran-biotinylated particles with avidin at different concentrations. The detection limit of avidin=0.091 μg.
FIG. 5( e ) shows another dose dependent study where T 2 was measured after 1 hr incubation of the 0.5 μg IO-silica-biotinylated particles with avidin at different concentrations. Detection limit of avidin=0.071 μg. NOTE: Here also, the silica coated biotinylated 10 particles show better sensitivity with respect to dextran coated ones for avidin and can detect the presence of avidin to a lower concentration.
B. Conjugation of Protein G with Aminated Nanoparticles
To conjugate 10 nanoparticles with protein G at first the particles are to be dissolved in DMSO to conjugate with disuccinimidyl suberate (DSS). The DMSO suspension of the 10 nanoparticles was obtained by combining 1 ml of aminated nanoparticles with 1 ml isopropanol, mixing well and spinning down at 13.2 k rpm for 1 hr. The supernatant was decanted and the pellet was dissolved completely in 500 μl DMSO. The suspension was again treated with isopropanol and spinned down. The centrifugation and redispersion were repeated three times to get rid of trace amounts of water. Afterwards the nanoparticle pellets were again redispersed in 500 μl DMSO and to that suspension 5 μl of disuccinimidyl suberate (DSS, 5.88 mg in 128 μl DMSO) was added. The mixture was stirred well and allowed to react for 30 mins to link DSS on the surface of the particles. Then the DSS linked particles were treated with 1.5 ml isopropanol and mixed properly. The reaction mixture was centrifuged and pellets were again dispersed in DMSO. The centrifugation and redispersion was repeated for 3 times to eliminate excess DSS. Finally, the pellets were redispersed in protein G (Sigma) solution (1 mg protein G in 1 ml, 200 mM phosphate buffer, pH 8.0). The mixture was kept for 1 hr at room temperature and then overnight at 4° C. to obtain the protein G functionalized particles.
The synthesized protein G functionalized nanoparticles were targeted with an antibody against protein G and the changes in T 2 were measured ( FIGS. 6 a and 6 b ). FIG. 6( a ) shows a time dependent study: after addition of 1 μl of antibody against protein G in 0.42 μg IO-dextran-protein G particles. FIG. 6( b ) is a time dependent study, where after addition of 1 μl of antibody against protein G in 0.66 μg IO-silica-protein G particles. NOTE: When an antibody specific to protein G was added to protein G functionalized nanoparticles, a concomitant decrease was observed due to clustering of the particles. The antibody binds to the proteins and causes clustering with other antibody conjugated particles. Consequently an instantaneous decrease in T 2 was observed. The silica coated protein G functionalized particles show a greater decrease as compared to dextran coated ones. The presence of more amines on their surface of silica coated particles made them more easily bounded to protein G and causes a greater change in T 2 relaxation time when treated with antibody.
C. Detection of Mycobacterium avium Paratuberculosis (MAP)
To test the capability of our particles in sensing a “real” target we planned to use the newly synthesized protein G conjugated particles to sense the presence of bacteria in fluid media. As a model system, we used Mycobacterium avium paratuberculosis (MAP). A MAP specific magnetic nanosensor was prepared by conjugating an anti-MAP antibody to protein G-IO nanoparticles.
Upon addition of the bacteria to a solution containing the bacteria-specific nanosensors, a rapid and sensitive detection of the bacterial target was achieved via changes in T 2 . This observation proves that our relatively large iron oxide nanoparticles can be used to detect a molecular target in solution, similar to previously reported studies that use smaller nanoparticles in the range of 30-50 nm [Perez, J. M.; Josephson, L.; O'Lou•hlin, T.; Hogemann, D.; Weissleder, R. Nat Biotechnol. 2002, 20(8): p. 816-20.
FIG. 7 ( a ) presents the results of yet another time dependent study, after addition of 51.25 CFU MAP in 0.54 μg IO-dextran-protein G particles. The control=1 p. 1 phosphate buffer, pH 7.4. IO-dextran-Protein G was conjugated with an antibody specific to MAP and then MAP was added. FIG. 7( b ) is a time dependent study, showing after addition of 51.25 CFU MAP in 0.82 μg IO-silica-protein G particles. The control=1 μl phosphate buffer, pH 7.4. IO-silica-protein G was conjugated with antibody specific to MAP and then MAP was added.
Accordingly, in the drawings and specification there have been disclosed typical preferred embodiments of the invention and although specific terms may have been employed, the terms are used in a descriptive sense only and not for purposes of limitation. The invention has been described in considerable detail with specific reference to these illustrated embodiments. It will be apparent, however, that various modifications and changes can be made within the spirit and scope of the invention as described in the foregoing specification and as defined in the appended claims. | The invention discloses an aqueous method of making polymer coated superparamagnetic nanoparticles. The method comprises providing a mixture of iron salts in an aqueous solution of hydrochloric acid. A solution of ammonium hydroxide is added to the mixture and stirred. Stirring continues with an aqueous solution of one or more biocompatible polymers so as to promote formation of polymer coated iron nanoparticles in suspension, wherein optionally at least one of the polymers in the coating may be aminated. Centrifuging the suspension leaves a supernatant without large particles. Filtering the supernatant through an ultrafiltration membrane and collecting the filtrate recovers polymer coated nanoparticles. Crosslinking the polymer is effected by treatment with a solution of epichlorohydrin and sodium hydroxide while stirring vigorously for up to about eight hours. Optionally aminating the polymer may be accomplished by treatment with ammonia after crosslinking and then removing remaining free epichlorohydrin. Nanoparticles made by the method are included in the invention. | 1 |
FIELD OF INVENTION
[0001] The present invention relates to respiratory filtration nose mask with electronic air filtration system for human breath, and more particularly, a filtration device for both inhalation and exhalation breath.
BACKGROUND OF THE INVENTION
[0002] Nose mask has been widely used in all kinds of industries from medical to industrial; from field works to home cleaning; and also in many different occasions whenever filtration of inhaling air is necessary. Usually the filter materials are of paper or fiber properties. The basic mechanism is using the human inhalation action as air suction driving force to suck the air through the filter media and stop all particles which is larger than the pores of the filtration media. It becomes very uncomfortable when someone has to wear the nose mask for an extended period of time and it is even worse if the user is kind of weak or having asthma or breathing difficulties.
[0003] Secondly, the filtration function is usually less efficient during the exhalation because the exhaust air tends to leak through the edges along the users' face rather than through the filter media.
[0004] Thirdly, the air passage resistance of the better filtration media is always higher and tougher to inhale through it.
[0005] Thus there is a need for a good inhalation and exhalation filtration system that does not exert breathing resistance to users during the normal breathing process. This filtration system shall be able to remove most of the contaminant in the air including airborne particles, bacteria and virus. The whole system shall be light enough for users to feel comfortable if wearing for extended time. It has to be very efficient in power consumption such that small consumer electronic type battery pack can support operation of the system for over a period of at least 8 hours. Easiness to clean and cost effective are also critical.
[0006] Furthermore, the filtration process shall be as efficient during both inhalation and exhalation such that if a patient is the user; the bacteria or viruses from the user breath will not get to outside ambient environment.
[0007] The present invention provides such an inhalation and exhalation filtration system nose mask.
CROSS REFERENCE TO RELATED APPLICATIONS
[0008] Field of Search
[0009] International Class: A62B 23/00, 7/10
[0010] US Class 128/200.24; 96/29, 54, 69, 71, 72, 75, 78, 97, 98, 100
U.S. Patent Documents
[0011] U.S. Pat. No. 4,549,887 Oct. 29, 1985 Joannou 96/58
[0012] This is not a human breathe cleaning device.
[0013] U.S. Pat. No. 5,042,997 Aug. 27, 1991 Rhodes 96/18
[0014] This is not a human body carrying electronic breath filtering mask.
[0015] U.S. Pat. No. 5,232,478 Aug. 3, 1993 Farris 96/26
[0016] This is not a human body carrying electronic breath filtering mask.
[0017] U.S. Pat. No. 5,573,577 Nov. 12, 1996 Joannou 96/66
[0018] This is not a human body carrying electronic breath filtering mask.
[0019] U.S. Pat. No. 5,690,720 Nov. 25, 1995 Spero 96/26
[0020] This is not a human body carrying electronic breath filtering mask.
[0021] U.S. Pat. No. 5,846,302 Dec. 8, 1998 Putro 96/66
[0022] This is not a human body carrying electronic breath filtering mask.
[0023] U.S. Pat. No. 6,245,132 Jun. 12, 2001 Feldman 96/28
[0024] This is not a human body carrying electronic breath filtering mask.
[0025] U.S. Pat. No. 6,497,754 Dec. 24, 2002 Joannou 96/67
[0026] This is not a human body carrying electronic breath filtering mask.
SUMMARY OF THE INVENTION
[0027] An electronic human breath filtration device is a human wearable light weight nose mask equipped with an absolute miniature electronic filtration system.
[0028] The unique feature of this invention is to provide a highly efficient filtration device to the user such that the air inhaled is purely clean and the exhaled air is also bacteria and virus free. The user can breathe through this filtration device without requiring extra effort as compare to sucking/breathing heavily through convention paper filter mask.
[0029] It is an object of this present invention to provide a very compact dual stages element filtration system mounted on a nose mask and utilizing small consumer electronic size battery as power source to operate this ultra high voltage ionic filtration system as well as electrostatic filtration system. It relies on the human breath as the air flow source to move the air stream through the dual stages filtration system during the inhalation and exhalation processes.
[0030] Other features and advantages of the invention will appear from the following description in which the preferred embodiments have been set forth in detail, in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0031] [0031]FIG. 1 is the overall diagram of the electronic inhalation and exhalation filtration device. It depicts a portion of the sectioned nose mask, a portion of the sectioned dual stages electronic filter, a portion of the sectioned front louver system, the electronic control box, the connecting cable with strain relief, a service loop clip and a user wearing the device to demonstrate the relative usage of the system according to present invention.
[0032] [0032]FIG. 2 illustrates the isometric front view of the filtration system with the contoured mask mounting system. It depicts the mask housing, the overall external view of the filtration system, the front louver cover, the contoured mask mounting system with the elastic face-contoured seal, the mounting strap and the under ear straps.
[0033] [0033]FIG. 3 is the sectioned illustration of the dual stages electronic filtration system, which depicts a portion of the front louver cover, a portion of the mask, a portion of the filter housing, a portion of the ionic stage filter, a portion of the electrostatic stage filter, a portion of the rear louver system, a portion of the electrical connection from the cable to the ionizing pins subassembly, a portion of the electrical connection from the cable to the electrostatic filter subassembly according to present invention.
[0034] [0034]FIG. 4 is the illustration showing the sectioned view as per FIG. 3 with negative ions released by the pins forming the ionic filtration chamber and the electrostatic charges established in the electrostatic filtration chamber.
[0035] [0035]FIG. 5 illustrates the electronic dual filtration mechanism system during inhalation of the user.
[0036] [0036]FIG. 6 illustrates the electronic dual filtration mechanism system during exhalation of the user.
[0037] [0037]FIG. 7 illustrates the application of the present invention into face mask with eye protection incorporated with the above mentioned nose mask electronic filtration system.
[0038] [0038]FIG. 8 illustrates the application of the present invention into a hood with eye and head protection incorporated with the above mentioned nose mask electronic filtration system.
[0039] [0039]FIG. 9 illustrates the modular concept of the filtration system assembly with the voltage multiplier PCBA integrated into the mask housing.
[0040] [0040]FIG. 10 illustrates the modular concept of the filtration system assembly with the voltage multiplier PCBA integrated into the electronic filter element subassembly.
[0041] [0041]FIG. 11 is the electronic circuit of generating a high voltage output to operate a dual stages electronic filtration device with a low voltage battery source.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0042] [0042]FIG. 1 is the overall electronic inhalation and exhalation breath filtration device system 2 . The overall system 2 is comprised of 3 subsystems namely the filtration system 11 , the control system 12 , and the contoured mask mounting system 6 .
[0043] The filtration system 11 includes the mask housing 26 , a dual stages filter element module 3 , a front louver cover 4 and a rear louver cover 55 . This filtration system 11 is shown in cross section view and is further detailed in FIG. 3. The front louver cover 4 is mounted to the outside of the mask housing 26 . The assembly can be by snap on, press-fitting, or by fastener which can facilitate the assembly means. The front louver cover 4 provides protective cover with a sufficient air passage for the air to pass from the ambient 22 to the dual stages filter element module 3 without resistance at low flow rate as human inhaling breath. It also provides a sufficient air passage for the air to pass to the ambient 22 from the dual stages filter element module 3 without resistance at low flow rate as human exhaling breath. The dual stages filter element module 3 is mounted inside the center opening of the mask housing 26 . The assembly can be by snap on, press-fitting, or by fastener which can facilitate the assembly means. This dual stages filter element module 3 will filter/capture all the particles entering inside the module carried by air stream induced by breath of the user 1 . The front louver cover 4 also blocks off some larger particles and rain drops from entering into the filter element module 3 as well. The rear louver cover 55 is mounted to the rear side of the mask housing 26 next to the filter element module 3 . The assembly can be by snap on, press-fitting, or by fastener which can facilitate the assembly means. The rear louver cover 55 provides protective cover with a sufficient air passage for the air to pass from the mask chamber 23 to the dual stages filter element module 3 without resistance at low flow rate as human exhaling breath. It also provides a sufficient air passage for the air to pass to the mask chamber 23 from the dual stage filter element module 3 without resistance at low flow rate as human inhaling breath. The rear louver cover 55 also blocks off contaminants from sneeze and saliva of the user 1 from entering into the filter element module 3 .
[0044] The mask housing 26 provides a rigid contoured shape cover the nose 10 and mouth 20 of the user 1 ; and a chamber to accommodate the front louver cover 4 , the dual stages filter element module 3 and the rear louver cover 55 . The mask housing 26 , front louver cover 4 and the rear louver cover 55 can be made of metal, plastic, paper product, fiberglass or carbon fiber material. The best choice and most cost effective method of producing this mask housing 26 is by plastic molding to achieve the shape and rigidity supporting the function of the mask housing 26 .
[0045] The contoured mask mounting system 6 is consisted of an elastic face-contoured seal 5 , a mounting strap 7 , a under ear strap 21 on each ear of the user 1 . The elastic face-contoured seal 5 is assembled to the mask housing 26 by snap on, press-fitting, or by fastener which can facilitate the assembly means. It is made of elastic material such as rubber, silicon rubber, foam pad, nylon or any other material which can facilitate a soft, flexible and sealing function of the contoured seal 5 . It can be made of one single piece part or an assembled piece part to facilitate the functions of the contoured seal 5 . The mounting strap 7 is with both ends assembled to the contoured seal 5 or the mask housing 26 . The mounting strap 7 is to be worn the way that it rests on the ears 9 of the user 1 and wraps around the back of the head of user 1 . The under ear strap 21 is with one end assembled to the contoured seal 5 or the mask housing 26 , and the other end assembled to the mounting strap 7 surrounding the ear of the user 1 . In result, the filtration system 11 is firmly mounted to cover the mouth and nose of the user 1 with the contoured seal 5 resting on the nose and cheek of the user 1 . The elastic contoured seal 5 separates the mask chamber 23 from the ambient 22 by forming a seal along the contour of the face and chin of the user 1 . The dual stages element filter module 3 becomes the only air passage between the air in the mask chamber 23 and the ambient 22 . The driving mechanism for the air exchange is the breathing process of user 1 with air movement from ambient 22 to mask chamber 23 caused by inhalation and air movement from mask chamber 23 to ambient 22 caused by exhalation of user 1 .
[0046] The control system 12 consists of a control unit 31 which is equipped with the main PCBA 35 with connection to the battery 33 and a multi-level power selector on/off switch 34 . The main PCBA 35 is equipped with electronic components and with the multi-level power selector on/off switch 34 set at “ON” position; the main PCBA 35 will generate high negative voltage functions to activate the dual stages element filter module 3 via the connector cable 28 . The connector cable 28 has a cable strain relief 24 at the connecting joint with the mask housing 26 and a cable strain relief 29 at the connecting joint with the control unit 31 . The control unit 31 is also equipped with a status indicator 36 showing the status of the battery 33 supply and the level of the power setting of the switch 34 . The control unit 31 is also equipped with a power adaptor input connector 32 allowing external power supply to be used or to recharge the battery 33 if rechargeable battery is being used.
[0047] An utility clip 25 is attached to the connector cable 28 and is to be used to clip onto the collar 30 or shirt of the user 1 . This feature provides a section of the connector cable 28 as the service loop 27 such that only the service loop 27 portion of the connector cable 28 will move with the user 1 as the user 1 rotates or tilts his/her head while the remaining portion of the connector cable 28 will stay still. The control unit 31 is also equipped with a belt mounting clip 13 to allow the user 1 to carry the control unit 31 with a belt.
[0048] [0048]FIG. 2 is the front isometric view of the filtration system 11 with the contoured mask mounting system 6 . The front louver cover 4 is assembled to mask housing 26 covering the front air entrance of the filtration system 11 . The mounting strap 7 is supported by the elastic face-contoured seal 5 and/or the mask housing 26 at both ends. The under ear strap 21 is supported by the elastic face-contoured seal 5 and/or the mask housing 26 at one end and attached to the mounting strap 7 at the upper end. The connection cable 28 is connected to the mask housing 26 with a strain relief feature 24 right at the connection joint. The mounting strap 7 may be made of rubber, silicon rubber, nylon, nylon base cloth like material, cotton base cloth like material; and may be made up of more than one piece part for easier mounting and dismounting onto the face of the user 1 .
[0049] [0049]FIG. 3 is the section view of the filtration system 11 with the basic structural support of the mask housing 26 . The mask housing 26 is designed to contour around the mouth 20 and nose 10 of general user 1 's face profile. The inner mask chamber 23 provides room for the user 1 to speak and move the lips freely without obstacle. The rear louver cover 55 is placed at the inside entrance of the dual stages element filter module 3 . The louvers 57 is set at an angle such that it will block off direct blow of contaminants generated by the user 1 during sneezing, coughing, and saliva from speaking from entering into the filter module 3 while leaving generous air passages 56 for the user to breathe through without restriction or resistance. This rear louver cover 55 can be made of plastic or metallic material. It is assembled to the mask housing 26 . The assembly can be by snap on, press-fitting, or by fastener which can facilitate the assembly means.
[0050] The dual stages element filter module 3 is in the middle of the mask housing 26 behind the rear louver cover 55 . It is assembled to the mask housing 26 . The assembly can be by snap on, press-fitting, or by fastener which can facilitate the assembly means. The dual stages element filter module 3 is comprised of two filtration system namely the ionic filtration system 93 and the electrostatic filtration system 94 enclosed in the filter housing 44 . The ionic filtration system 93 consists of a highly charged negative (−) electrode 42 with sharp metallic needles 50 connected to it and the needle points of the needle 50 locating in the center portion of the ionic filtration system 93 . The positively charged (+) conductive collector electrode 45 surrounds the negative electrode 42 and lines along the internal wall of the filter housing 44 . The negative electrode 42 is insulated from the positive electrode conductive collector 45 by the insulator 41 . The positive electrode conductive grill 49 is located at the front of the opening of the ionic filtration system 93 . It is connected to the positive electrode conductive collector 45 with perforated holes over the whole surface to allow generous air passages for the user 1 to breathe through without restriction or resistance. It also serves as the positive electrode collective conductor for the negatively charged particles to adhere to. The negatively (−) charged electrode 42 is assembled to the filter housing 44 by fastener 43 , which can be screw, rivet or any other mechanical fastener which can facilitate the assembly function.
[0051] The electrostatic filtration system 94 consists of parallel sets of negatively charged electrode fins 53 sandwiching with positively charged electrode fins 67 . An electrostatic field is formed between a negatively charged electrode fin 53 and positively charged electrode fin 67 . The strength of the electrostatic field is determined by the gap width 54 between the two oppositely charged electrodes and the potential difference between them. Further detail explanation of the filtration processes are illustrated in FIG. 4. The negatively charged electrode fins 53 are mounted inside the filter housing 44 with the insulator 41 . The positively charged electrode fins 67 are supported by the positive conductive collector 45 and are also electrically connected to the positive conductive collector 45 .
[0052] The negative (−) electrode 42 of the ionic filtration system 93 is connected to the control system 12 through the cable 28 via the conductor lead 60 and the wire conductor 62 of the cable 28 . The negatively charged electrode fins 53 of the electrostatic filtration system 94 are connected to the control system 12 through the cable 28 via the conductor lead 59 and the wire conductor 62 of the cable 28 . The positively charged electrode fins 67 of the electrostatic filtration system 94 are connected to the control system 12 through the cable 28 via the conductor lead 58 and the wire conductor 62 of the cable 28 . The electrical connection joint between the conductor lead 59 , 58 , 60 and the wire conductors 62 can be by contact, soldering or fastener whichever can facilitate the electrical conduction.
[0053] The cable strain relief 24 is present at the joint between the cable 28 and the mask housing 26 providing support to the cable 28 and the conductor wires 62 inside from breaking due to extensive bending and flexing action under normal usage of the breath filtration device 2 .
[0054] The front louver cover 4 is placed at the outside entrance of the dual stages element filter module 3 . The louvers 47 is set at an angle such that it will block off direct blow of large objects and rain from entering into the dual stages element filter module 3 while leaving generous air passages 51 for the user to breathe through without restriction or resistance. This front louver cover 4 can be made of plastic or metallic material. It is assembled to the mask housing 26 . The assembly can be done by snap on, press-fitting, or by fastener which can facilitate the assembly means.
[0055] [0055]FIG. 4 is the section view of the filtration system 11 illustrating the ionization status of the ionic filtration system 93 and the electrostatic charged status of the electrostatic filtration system 94 . Within the ionic filtration system 93 , needlepoint 50 produces high levels of negative ions 63 when high negative DC voltage is applied to it. This is the by far most effective way of ions 63 generation and will help to clean the air inside the ionic chamber 64 . The negative ion generators cause an electron to be added to molecules of Oxygen, Nitrogen and other trace gases in the inhaling or exhaling air from the user 1 's breath. This process creates ions with a negative charge 63 . When the ions become negatively charged, they collide with airborne pollutants such as pollen, mold spores, dust, bacteria, tobacco smoke, saliva moisture, sneeze moisture and many other airborne particles. The negative charge of ion is then transferred to the airborne particles. Surrounding this newly negatively charged particle are many other particles that are positively charged. These positively charged particles are drawn to the negatively charged particle and begin to build-up, eventually these particles become too heavy and fall harmlessly to the bottom positively charged conductor collector 45 . The other negatively charged airborne particles will then be attracted to the positively charged collector conductors, which include the positive conductor 45 , the anode conductive grill 49 and the positively charged fin 67 , when traveling along the air stream.
[0056] Small amount of ozone molecules and hydroxide molecules may also be generated in the ionic chamber 64 under very high voltage input potential. These ozone molecules and hydroxide molecules can help to fight bacteria in the air stream. The excessive ozone molecules and hydroxide molecules will be neutralized by the electrostatic filtration system 94 and will not harm the user 1 .
[0057] In the electrostatic filtration system 94 , a high negative voltage is induced to the negative fin 53 and the positive fin 67 is connected to the electrically positive. It results that the surface of the negative fin 53 will be highly negatively charged 66 and the causing an electrostatic field to form between the negative fin 53 and the positive fin 67 , which becomes equally highly positively charged 65 . This electrostatic field is an uniform electric field of force and causes an uniform distribution of electrons (negative charge 66 ) on the surface of negative fin 53 , and an equal and uniformly distributed deficiency of electrons (positive charge 65 ) on the positive fin 67 . The voltage graduation is uniform throughout this field, except at its edges and near sharp corners of the plates/fins.
[0058] A single positively-charged particle entering this electrostatic field is acted upon by a force equaling the sum of all attracting and repelling forces. These forces are due to the charge on the particle interacting with the field produced by the negative fin 53 and the positive fin 67 . These forces accelerate the positively-charged particles towards the negatively-charged fin 53 . In the same manner, a negatively charged particle is forced towards the positive fin 67 . The amount of force acting on the particle depends on the particle's charge, the voltage applied to the collecting fins and the space between the fins.
[0059] The uniformity of the field causes a particle to be acted upon by an equal force regardless of whether the particle is close to a negative fin 53 , to a positive fin 67 , or somewhere between. If no other force is acting on the particle, it moves with a constant acceleration toward the negative fin 53 .
[0060] The particles that are collected and are in physical contact with the charged collector fins lose their “opposite charge” and take on the charge of the respective collector fins. They remain attached to the collector fins because of molecular adhesion and due to cohesion to other particles already collected. As a result, contaminants are removed form the air stream of breath induced by the user 1 's inhalation and exhalation efforts. In practice, the filtration system 11 will charge floating particles as small as 0.01 micron and drive them to adhere to the collector plates where they will stay for good.
[0061] [0061]FIG. 5 is the section view of the filtration system 11 with the user 1 inhaling through the filtration system 11 . The inhaling breath becomes the engine to draw the air stream 92 from the mask chamber 23 into the user 1 's nose 10 and mouth 20 . As results, the air pressure in the mask chamber 23 will be lower than the air pressure in the electrostatic filtration system 94 and cause the air stream 95 in the electrostatic filtration system 94 to flow through the rear louver cover 55 into the mask chamber 23 . In the same token the air in the ionic filtration system 93 will flow to electrostatic filtration system 94 ; and the air stream 91 in the ambient 22 will flow through the front louver cover 4 to the ionic filtration system 93 . Eventually, during the inhalation process, the air flow from the ambient 22 through front louver cover 4 , the ionic filtration system 93 , the electrostatic filtration system 94 and the rear louver cover 55 into user 1 's nose 10 and mouth 20 . When the desirable voltage potential is applied to the filtration system 11 , the ionic filtration system 93 and the electrostatic filtration system 94 will remove most of the air borne particles, contaminants and bacteria from the inhaling air stream and supplying only very clean air to the user 1 . During the filtration processes, the air stream is free to move from one stage to the other and there will be no resistance induced to the inhalation effort. This is an advantage of this invention over the conventional filtration by filter material type nose mask. Weaker users 1 especially those with breathing difficulty like Asthma will find this electronic inhalation and exhalation breath filtration device system 2 very comfortable to use.
[0062] [0062]FIG. 6 is the section view of the filtration system 11 with the user 1 exhaling through the filtration system 11 . The exhaling breathe becomes the engine to drive the air stream 98 from the user 1 's nose 10 and mouth 20 to the mask chamber 23 . As results, the air pressure in the mask chamber 23 will be higher than the air pressure in the electrostatic filtration system 94 and cause the air stream 96 in the mask chamber 23 to flow through the rear louver cover 55 into the electrostatic filtration system 94 . In the same token the air in the electrostatic filtration system 94 will flow to the ionic filtration system 93 ; and the air stream 97 in the ionic filtration system 93 will flow through the front louver cover 4 to the ambient 22 . Eventually, during the exhalation process, the air flow from the user 1 's nose 10 and mouth 20 through rear louver cover 55 , the electrostatic filtration system 94 , the ionic filtration system 93 and the front louver cover 4 into ambient 22 . When the desirable voltage potential is applied to the filtration system 11 , the ionic filtration system 93 and the electrostatic filtration system 94 will remove most of the air borne particles, contaminants and bacteria from the exhaling air stream and supplying only very clean air to the ambient 22 . During the filtration processes, the air stream is free to move from one stage to the other and there will be no resistance induced to the exhalation effort. This is an advantage of this invention over the conventional filtration by filter material type nose mask. The exhaling air will pass through the filtration system 11 and be filtered rather than leaking through the edges as of using paper filter nose mask where the exhaling air finds easier way out.
[0063] [0063]FIG. 7 is the front view illustrating the application of the electronic inhalation and exhalation breath filtration device system 2 being applied as a face mask with built in goggle 99 to cover and protect the eyes of the user 1 . The seal 98 seals along the forehead of the user 1 . The air inside the mask chamber 23 is free to flow to the chamber covered by the eye goggle 99 resulting that the air surrounds the user 1 's eye is also cleaned by the dual stages element filter module 3 of the filtration system 11 .
[0064] An alternative method of providing the service loop 27 is also illustrated. A mechanical clip 100 is attached to the connecting cable 28 . This mechanical clip 100 is also attached to a string 102 , which loops around the user 1 's neck. This string 102 can be made of fabric, cloth, nylon, leather or any other material that can facilitate the function of hanging around the neck of the user 1 . The mechanical clip 100 can be made of metal, plastic or any other material that can facilitate the function of mounting the control cable 28 to the string 102 . The string 102 may also be used to tight directly to the connector cable 28 in the absence of the mechanical clip 100 to facilitate the mounting function of the control cable 28 and hanging around the neck of the user 1 .
[0065] [0065]FIG. 8 is the front view illustrating the application of the electronic inhalation and exhalation breath filtration device system 2 being applied as a hood 103 with built in lens 104 to cover and protect the eyes and the head of the user 1 . The air inside the mask chamber 23 is free to flow to the chamber covered by the lens 104 and the hood 103 , resulting that the air surrounds the user 1 's eye and head is also cleaned by the dual stages element filter module 3 of the filtration system 11 . The bottom edge 108 of the hood 103 can be sealed along the neck of the user 1 or connected to other garment worn by the user 1 .
[0066] [0066]FIG. 9 is the section view of the filtration system 11 showing the assembly of the front louver cover 4 , dual stages element filter module 3 and the rear louver cover 55 with respect to the mask housing 26 . An alternative to the former discussed arrangement in FIG. 3 is the addition of a PCBA 110 with electronic components. This PCBA 110 is installed between the cable 28 and the connector wires 62 inside the PCB compartment 109 . In the previous arrangement of FIG. 3, the cable 28 will carry the high voltage from the control system 13 all the way to the connector wires 62 and eventually to the dual stages element filter element 3 . In this alternative arrangement, the PCBA 110 is a voltage multiplier which works on the input voltage to produce a very high output voltage such that the cable 28 will only requires to carry a much lower voltage than the original arrangement. The PCBA 110 receives its input voltage source from the cable 28 and sends its high voltage potential output to the connector wires 62 . The connector wires 62 are connected to the connector 37 . Since the system requires very low current (less than 100 mA), there are a lot of choices of small components including surface mounting components to fit into a very small form factor and not causing the mask housing 26 to be too bulky to handle by the user 1 .
[0067] In the assembly the dual stages filter element module 3 will be assembled into the center cavity 106 . The assembly can be performed by fastener, snap on, press-fitting or any other means that can facilitate the assembly function. In the assembly the conductor leads 58 , 59 and 60 will be connected to connector 37 and receive the electrical power to operate the dual stages filter element module 3 . The front louver cover 4 is to be assembled into the front cover well 105 and the rear louver cover 55 is to be assembled into the rear cover well 107 respectively.
[0068] [0068]FIG. 10 is the section view of the filtration system 11 showing the assembly of the front louver cover 4 , dual stages element filter module 3 and the rear louver cover 55 with respect to the mask housing 26 . An alternative to the former discussed arrangement in FIG. 3 and FIG. 9 is the integration of the PCBA 110 with electronic components to be part of the electronic dual stages element filter module 3 . All the electronic components on the PCBA 110 are encapsulated 81 with encapsulation resin to protect the PCBA 110 from electrical shorting. The lead conductors 82 and 83 are connected to connector 37 , which is connected to the main PCBA 35 of the control system 12 through the connector wires 62 of cable 28 . The PCBA 110 receives the input power from main PCBA 35 through the lead conductors 82 and 83 with conductor 82 connected to the positive charge and the conductor 83 connected to the negative charge of main PCBA 35 . It performs the voltage multiplier function and sends the high voltage output to the electronic dual stages element filter element module 3 through the lead conductor 58 , 59 and 60 respectively.
[0069] In this alternative arrangement, the PCBA 110 is a voltage multiplier which works on the input voltage to produce a very high output voltage directly to the electronic dual stages element filter module 3 and minimizes the potential drop; resulting that the cable 28 is only required to carry much lower voltage than original arrangement as in FIG. 3. Since the system requires very low current (less than 100 mA), there are a lot of choices of small components including surface mounting components to fit into a very small form factor and not causing the mask housing 26 to be too bulky to handle by the user 1 .
[0070] In the assembly the dual stages filter element module 3 will be assembled into the center cavity 106 . The assembly can be performed by fastener, snap on, press-fitting or any other means that can facilitate the assembly function. In the assembly the conductor leads 82 and 83 will be connected to connector 37 and receive the input electrical power for the voltage multiplier PCBA 110 to generate high voltage to operate the dual stages filter element module 3 . The front louver cover 4 is to be assembled into the front cover well 105 and the rear louver cover 55 is to be assembled into the rear cover well 107 respectively.
[0071] [0071]FIG. 11 is the circuit diagram illustrating the high voltage power supply source that drives the dual stages element filtration system 3 . A low voltage battery 33 supplies power through a power level selector circuit 70 to an oscillator stage circuit 72 . The output is then stepped-up by transformer (TI) 74 , which in turn feeds the input of voltage to the voltage multiplier 71 . The high voltage output 68 from the voltage multiplier 71 is then sent to the needle points 50 where ionization occurs in the ionic filtration system 93 . The high voltage output 68 is also sent to the negatively charged fins 53 of the electrostatic filtration system 94 . The power selector circuit 70 allows the user 1 to select one of the preset voltage levels at the high voltage output 68 , which also represents the rate of ionic activities with respect to the ambient surroundings. User 1 can use a power saving mode or a high reaction rate filtration mode if the surrounding is dusty. Experiment shows the power consumption rate is less than 40 mA at 12 VDC power supply. As a result, a 1200 mAH battery pack of 12 VDC may support the breath filtration system 2 to operate for over 24 hours.
[0072] It will be appreciated that the sizes, quantities, shapes and dispositions of various components like needlepoint ionization pins, electrode fins, electro-collectors, louver covers, conductor leads, wires, cable length, material use, filter size, filter gap clearance, size of the mask and size of the seal can be varied, without departing from the spirit and scope of the invention. Similarly, the sizes and contour of the nose mask, face mask and hood with reference to adult, children, male and female, and the like may be varied. While the methods of connecting the service loop of the cable are illustrated, other methods may instead be used to facilitate the concept of service loop. While the methods of mounting the mask-filter system with straps concept is illustrated, other methods may instead be used to facilitate the concept of mounting to the user's face. While this electronic inhalation and exhalation breath filtration device system has been described with respect to application to nose mask, face mask and hood, the described system may also apply to other human wearing electronic filtration systems and may have more than one air inlet or air outlet.
[0073] Modifications and variations may be made to the disclosed embodiments without departing from the subject and spirit of the invention as defined by the following claims. | A battery powered portable human body carrying electronic human breath filtration device is an electronic nose mask and is the most ideal alternative to conventional filter paper type nose mask. It utilizes electronic ionization technique and electrostatic field to remove air borne particles, dust, pollens, contaminants, bacteria, viruses, toxic chemical, fume and tobacco smoke from human inhalation and exhalation breath. It interacts with human breathing action as the air flow driving system to move the inhalation and exhalation breaths through the electronic filter elements, in addition to a front louver cover and a rear louver cover's protection as pre-filters. The system requires very low running current and uses small batteries usually found in household electronics. This filtration system is light weight with negligible air flow resistance and is integrated into the nose mask which is connected to a pocket size control system via a connection cable. | 0 |
REFERENCE TO PRIOR APPLICATIONS
This application is a divisional of Ser. No. 08/295,563 filed Aug. 25, 1994 now U.S. Pat. No. 5,516,591 which is continuation in part of application Ser. No. 08/236,005 filed May 2, 1994 now abandoned which is a continuation to application Ser. No. 08/976,387 filed Nov. 13, 1992 now abandoned.
BACKGROUND OF THE INVENTION
The textile industry utilizes at high speed various kinds of machinery parts for processing textile fibers. Examples of other industries using machinery parts at high speed are the paper industry, the tobacco industry, molding of parts and others. The speed at which the fibers (or other materials) move through the parts results in abrasion to the machinery parts; the parts suffer wear and degradation and must eventually be discarded. It is well known in the art that sharp-toothed wire, or the like, is used in many areas of carding, spinning, and related textile operations. In open-end spinning, for example, a sliver of separate fibers is fed into a combing roller which has metallic wires wound around the periphery of the roller, which wires are of a saw-toothed structure. The wires contact the fibers and comb them. The fibers are then transferred from the combing roller to a rotor where the combed fibers are twisted to form a yarn which is then transferred to a take-up spool. Examples of combing rollers with various toothed combing wires thereon can be found in U.S. Pat. Nos. 2,937,413; 4,233,711; 2,731,676; 4,435,952; 4,358,923; 4,859,494 and 3,833,968 which patents are incorporated herein by reference. A more recent version of the wire combing roller is a homogeneous substrate of the teeth and sleeve machined from a single metal stock. An alternative device to the combing roller is a pin-ring which functions in the same way as the combing roller, but employs a multiplicity of pins extending from the roller (sleeve) rather than the toothed surface. For the purpose of this invention, the terms "combing rolls", "carding rolls", "pin-rings", and "beater rolls" (or "rollers") are used interchangeably.
These rollers are currently driven at speeds of 5,000-10,000 RPM (as described in U.S. Pat. No. 4,435,953), which cause tooth wear with time, with higher speeds expected in the future. Thus, the efficiency of the entire operation is adversely affected. Tooth wear lower the quality of the product produced over time, causing knots and neps in the yarn produced; it also causes yarn breaks, which in turn cause an individual spinning position either to shut down or to produce defective yarn.
The wire (or pins, in the case of pin-ring beater rolls) containing the teeth that do the fiber combing is generally made from steel. The wire is essentially comprised of two different parts: (1) the base of the wire, and (2) the toothed portion of the wire. Although the methods of manufacture and the specifications for the final wire or teeth vary from one manufacturer to another, it is a common practice to start with a wire initially haing a round section configuration. The section configuration is modified by a process of rolling to provide a wire which is finally strip-like, with a rib running along one side to constitute a base or foundation for the finished strip (as described in U.S. Pat. No. 2,731,676). After suitable treatment which makes the wire metallurgically suitable in terms of hardness, ductility, and, hopefully, wear resistance, this base portion is then embedded in the combing roller, be it a solid piece or a sleeve.
One commonly used method for the formation of the toothed portion itself is a punching operation which imparts the shape of the tooth while also producing the proper angles for the most efficient carding and combing of a specific type of fiber.
Following the punching operation, another mechanical process used (described in U.S. Pat. No. 4,233,711) is a grinding operation. The primary function of the grinding operation is to impart an evenness to the teeth, making them all exactly uniform, as well to remove any unwanted residual defects resulting from the punching operation. As a final step, some manufacturers post treat the wire using "needle finishing" which imparts a smoothness to the sides of the teeth, along with a very light, or minimal, amount of directional lines in the steel teeth, which lines run approximately parallel to the base portion of the wire. The grinding operation also helps the efficiency of the combing operation by reducing undesired "loading" of the teeth.
Degradation of the tooth geometry occurs with use, i.e., dulling of the sharpness of the tip of the tooth and the dulling of the tooth edges which eventually leads to the general wear of the entire tooth portion of the wire. Various coatings or wire treatments, applied by the diffusion treatment process, have been devised and attempted to prevent excessive wear, or to slow down the wearing process. Examples of such coatings and wire treatment are heat treatment of carbon nitriding; surface hardening by carbon nitriding; electrospark coating (including vanadium carbide, chromium carbide, tungsten carbide, titanium carbide, zirconium carbide, hafnium carbide, and iron boride).
In still another process, a chromium layer is electrodeposited onto the teeth of the combing roll, imparting a hard chromium wear resistant layer over the steel teeth (as described in U.S. Pat. No. 4,169,019).
A more popular, and seemingly more wide-spread, method of protecting the combing teeth is by the electroless deposition of a "composite" coating. These composite coatings are usually comprised of small particles which are codeposited along with an electroless metal matrix (usually, but not limited to, a nickel-phosphorous type matrix). The wear resistant particles can range from aluminum oxides and silicon carbides, to natural and synthetic diamonds (both polycrystalline and/or monocrystalline in nature). Lubricating particles (e.g., fluorocarbon polymers, graphite flouride and others) may also be used in composite deposition. These coatings, and their like, may be applied according to the technology taught in U.S. Pat. Nos. 3,617,636; 3,940,512; 4,358,923; 4,547,407; 4,666,786; 4,419,390; Re. 29,285; 4,358,923; 4,859,494, 4,997,686; 5,195,517; 5,300,330; 4,830,889 which patents are incorporated herein by reference. A review of this composite electroless technology can be found in Chapter 11 in the text "Electroless Plating Fundamentals and Applications", G. O. Mallory and J. B. Hajdu, editors, published by the American Electroplaters and Surface Finishers Society, 1990.
In the prior art of composite plating and particularly composite electroless plating, particulate matter having the generic properties of wear resistance, lubricity, and/or corrosion resistance were advocated and used.
After the wear resistant coating is depleted, the underlying surfaces of the combing teeth degrade, and wear away with relative rapidity. Once this degradation occurs, either the combing apparatus is discarded, or the old teeth are removed and are replaced by the insertion of new teeth. These procedures are both expensive and not very cost effective. It would therefore be desirable to enable the attainment of maximum use from the protectively coated combing apparatus (or other apparatus or machinery parts) without degradation of the teeth so that the usage can be extended to multiple generations.
In commercial usage of plated molds, when deterioration of the plated articles occurs, grinding and polishing of the worn mold must sometime be effected before a new generation of plating can be undertaken. These additional mechanical operations are time consuming and costly, and hence undesirable.
SUMMARY OF THE INVENTION
Broadly, the invention comprises an apparatus useful in textile manufacturing machinery, though it is not limited to textile machinery. The apparatus (machinery part) comprises a base metal and functional coating for either wear resistance, lubricity, or corrosion resistance thereof, and is characterized by the presence of an indicator layer interposed between the base metal and the functional coating. The interposed indicator layer, directly or indirectly, signals to an operator or a supervisor of the machine that the functional coating has been consumed, thereby enabling removal of the part from the machinery before further use causes irreparable degradation of the base metal. A preferred indicator layer would be comprised of fine particulate matter dispersed in a metallic matrix that has light emitting properties. The invention further comprises methods for producing such an apparatus.
It should be understood that the invention is not intended to be limited to any particular base metal, indicator layer, or functional coated layer, and that the apparatus may also include other layers either under or over the wear resistant layer such as may be employed in the art for other functions, e.g., promoting adhesion of the base metal.
The substrates contemplated in the present invention can range from dielectrics, semiconductors, metals and alloys with the standard pretreatment schedule required for the specific substrate prior to the plating step. The metallic matrixes contemplated in this invention are the wide variety of metal and alloys that can be deposited by electrolytic and/or electroless plating techniques. Accordingly, the present invention is not limited to a specific substrate nor to any specific metal to be plated.
DETAILED DESCRIPTION OF THE INVENTION
I have recognized that in order to obtain maximum use of certain apparatus (machinery parts) used in textile manufacturing machines (or machinery parts used in other industries) which comprise a base metal and a functional coating thereof, such that the apparatus is capable of being relatively inexpensively rejuvenated, one must interpose an indicator layer between the wear resistant (functional) layer and the base metal to signal that the functional layer has been, or is about to be, depleted, prior to irreversible degradation of the base metal. As used herein, the term "functional coating" refers to a coating which is generally applied for rendering the substrate with certain improved properties ranging from wear resistance, lubricity and corrosion.
The indicator layer may function in many different ways. For example, it may provide a visual indication by being a different color than the overlying functional layer, e.g., protective wear resistant layer; or it may provide a visual indication by the incorporation of luminescent particles or pigments; or it may provide for a change in the friction forces (either by more, or less, friction) which can be measured or would otherwise be detectable by an operator of the machine, or be measured automatically; or it can cause an alteration in the processed fiber which is detectable as being characteristic of the wear on the part in question.
By way of example of the invention, but in no way intended to be limiting, the invention applied to the coating of a combing roll of the type used in open-end textile spinning machines. It should be understood that the invention is not limited to an apparatus with only an indicator layer and a wear resistant layer. In practice, the novel apparatus may also include other layers, either under and/or over the wear resistant layer and/or indicator layer.
Typically, suitable wear resistant layers include: nitride, carbide, or oxide layers, particularly those of the refractory metals such as titanium, hafnium, and tungsten, or those of aluminum, silicon and boron; metallic layers such as chromium or nickel or alloys thereof; and composite layers comprising a metal such as chromium or nickel having small wear resistant particles codeposited therewith. These particles typically can include: metallic oxides, carbides, or nitrides; diamonds; or lubricating particles such as Teflon, graphite, fluoride particles and the like. The methods for depositing coatings of the types set forth above are well known in the art.
The indicator layer may be selected from a variety of materials, as long as the indicator layer is capable of indicating that the functional layer has eroded. For example, the indicator layer may be a copper layer plated on the substrate such that when the composite layer has worn through, or eroded, the characteristic copper color is visible. For example, the indicator layer may be a material capable of giving off a detectable odor upon erosion of the functional layer, e.g., a layer containing a sulphide therein. Still further, when the wear resistant functional layer is a composite, the indicator layer may contain particles of a different mean size than the particles in the composite layer, or particles of a different type. Here, upon erosion of the composite layer, such different particle size or particle type would be detectable due to a change in the frictional forces on the apparatus or a change in the processed fibers.
Still another example of a suitable indicator layer is a composite layer having luminescence particles therein. Such a layer can be produced, for example, by incorporating a small amount of a fluorescent dye in Teflon particles, and/or fluorescent particles, and/or phosphoresence particles.
The finely divided particulate matter referred herein are particles comprised of atoms or molecules that absorb photons of electromagnetic radiation and reemit the absorbed energy by the spontaneous emission of photons which, however, are not of the same energy as absorbed photons or the same wavelengths. The phenomenon is generally referred to as luminescence, having light emitting properties.
Luminescence is further classified into fluorescence and phosphorescence. If the emitted radiation continues for a noticeable time (generally between 10 -4 to 100 seconds) after the incident radiation is removed, it is referred to as phosphorescence. If the emission cease almost immediately, (10 -4 -10 -9 seconds) after the incident radiation is removed, the process is referred to as fluorescence. Specific examples of such materials include pure solids of known chemical composition or naturally occurring minerals.
It is apparent from the above that a wide variety of materials can usefully be employed as the indicator layer. The only requirement of the indicator layer is that it be capable of expressing or signalling erosion of the functional composite layer.
Broadly, the novel apparatus may be produced by the steps of depositing a indicator layer over at least the portion of the base metal which is exposed to wear or erosion during use. Typically, this layer would be five microns and above in thickness. However, the thickness of this, or any other, layer is not critical; substantially, any desired thickness may be suitable. As previously set forth, additional layers either under, over, or between the indicator and/or wear resistant layers may be formed during the process. The specific techniques for depositing or forming the various layers are well known in the art and need not be set forth in detail herein.
In a preferred embodiment of the invention, the wire for the combing roller is provided with several microns in thickness of an electroless or electroplated copper coating. A wear resistant (functional) nickel layer having diamond particles dispersed therein is electrolessly plated over the copper layer. The wear resistant (functional) layer is typically 0.8 mil thick. In use, when the wear resistant layer is worn away, thereby exposing the copper layer, the presence of the copper layer on the surface may be detected automatically by means of electrodes for detecting the sudden increase in surface conductivity due to the expose copper or by visual means. Based upon the present teachings, it should be recognized that the indicator layer can be a plated composite film derived by either electrolytic or electroless plating methods. Similarly, the working film can be a lubricating film, a wear resistant film, or a corrosion resistant layer. It is also recognized that the plated composite layer bearing the finely divided particulate matter having light emitting properties are new articles not previously available.
The following example is provided to further illustrate the present invention in the process and articles having light emitting properties. 3.3 g/l of finely divided cool white halophosphor powder (calcium halophosphate type) was dispersed into commercial electroless plating bath NiPLATE 300 (sold by Surface Technology, Inc., Trenton, N.J.). The bath was heated to 175° F. and adjusted to a pH value of 6.4. A clean metallic rod was immersed and plated for 1.5 hr. Upon completion of the cycle, the rod was analyzed by two separate means: (1) light from a UV lamp was applied upon the coated surface, resulting in a distinct white visible color, and (2), a portion of the coated rod was cross-sectioned to note the presence of codeposited particles within the metallic matrix. The codeposited particles were a few microns in size. Though this example was executed via electroless metal deposition technique, it is obvious that other techniques can be substituted, such as electroless plating, spray deposition, all yielding similar composites. Further examination of the coating revealed good quality as to adhesion and integrity of the coating. Moreover, the coating appeared to successfully retain its properties even after a heat-treatment cycle at 350° C. Though in this example white halophosphor particles were used, other particles of different colors can similarly be used, still falling within the spirit of this invention. Further surprising was the fact that the particles were compatible within the plating composition without detrimental effects such as poisoning of the bath or their decomposition by ionization. This example was further refined by the selective deposition of the a functional layer onto the above indicator layer. The selective deposition provided an electroless coating with fine windows (dots) of 1 to 2 mm windows exposing the indicator coating. Upon shining a UV light a bright glow (in a dot pattern) was observed.
In another example, a composite nickel layer containing 2 micron diamond is deposited as the wear-resistant layer. This layer is friendly for many textile applications; and it has a thickness of 20 to 25 microns and a weight density of diamond of about 18%. An indicator layer comprising diamond particles of 4 microns is deposited in a similar fashion between the substrate and the wear-resistant (functional) layer. As the wear layer wears out, the new frictional forces attributed to the 4 micron size diamonds affect the yarn properties, thereby signaling to an operator that it is time to replace the part(s). The worn parts are to be replaced with a new parts, in so doing preserving the used worn parts for recoating for a subsequent use.
In another example, calcium tungstate at a concentration of 5 g/l was incorporated along with the NiPLATE 300 electroless plating bath. A rod similar to the above was plated for 1 hour at a pH of 6.4 and a temperature of 78° C. After the plating cycle, irradiation of the rod with a UV light resulting in the emission of blue color.
Other areas where such coating are of potential use is the security area. Specifically, objects can be coated in part or in total and verified for their authenticity via their light-emitting properties. | This invention discloses processes and articles for the manufacturing of composite plated articles comprising finely divided particulate matter dispersed within metallic matrices and having light emitting properties, such articles being useful in the metallization of articles and their reuse through subsequent rejuvenation, without damaging the base metal of said articles. | 8 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is the U.S. national stage of International Application No. PCT/2012/068415, filed Mar. 27, 2014 and claims the benefit thereof and incorporates by reference herein in its entirety.
BACKGROUND
[0002] Described below are a bearing arrangement and methods for determining a load zone of a bearing and for operating a machine and/or system.
[0003] The load zone of bearings plays an important role in the configuration of machines or systems. In this context, the load zone describes the region of the bearing in which increased mechanical loading occurs during operation of the bearing. An incorrect position of the load zone or excessively low bearing loads can lead to faults during operation and even damage to the bearing and to the system components. Methods for determining the load zone of a bearing are typically not used in a steady-state fashion since the measuring equipment is expensive and the methods are complex and susceptible to failure.
[0004] For the measurement of the load zone of a bearing it is possible to use, for example, what is referred to as the orbital measuring method if distance sensors are additionally installed. Since the load zone is typically only dimensioned or configured but not measured, errors can occur during the measurement of machine vibrations. Vibration sensors are to be provided in the surroundings of the load zone of the bearing. If the load zone of the bearing is, however, located in a different region than the expected one, a systematic fault occurs during the vibration measurement. This is the case, in particular, if just one vibration sensor is positioned in the vicinity of the load zone, instead of two vibration sensors arranged orthogonally with respect to one another.
[0005] The thermally induced stresses in the bearing are also not usually monitored nowadays. In this context, strong local heating in the bearing can lead to mechanical stresses in the material and therefore to misshaping faults owing to the different material expansion, which faults disrupt the desired running of the bearing. In addition, thermally induced stresses can lead to the formation of fractures both in the bearing receptacle and in the bearing itself.
[0006] Belt drives are often used in engines. In this context, an incorrect belt tension often leads to problems during operation of the machine. Monitoring the belt tension is typically not carried out in a steady-state fashion but rather only at certain service intervals. It is therefore not possible to detect a change in the belt tension between service intervals. Furthermore, the position of the load zone can also depend on the pretensioning of a bearing within the machine, for example an engine. In this context, external measurements by load cells or similar methods are only satisfactory to a limited degree for determining the load zone.
SUMMARY
[0007] Described below is how to determine a load zone of a bearing in a more simple and reliable way by using a bearing arrangement.
[0008] The bearing arrangement includes a bearing for supporting a movable component in relation to a stationary component and a sensing device for determining a load zone of the bearing, which load zone is formed by a region of the bearing in which, during a movement of the movable component, higher mechanical loading occurs in the bearing compared to an adjacent region, wherein the bearing arrangement has at least two temperature sensors for respectively sensing a temperature, and the sensing device is designed to determine the load zone of the bearing on the basis of the detected temperatures.
[0009] The bearing can be embodied, for example, as roller bearing with which a shaft can be rotatably supported. The load zone describes the region of the bearing in which increased mechanical loading, for example a pressure, is applied to the roller bearings of the bearing. The method described below is based on the realization that in the load zone typically local heating occurs in the bearing. The reason for the heating is the local friction in the load zone. Since the bearing is usually fabricated from metal, the locally generated heat can be transmitted particularly well to the surroundings of the bearing. Depending on the operating condition of the bearing, i.e. depending on the rotational speed, the load and the friction in the bearing, temperature differences of several Kelvin can occur from one side of the bearing to the other side of the bearing. These temperature differences are to be clearly differentiated from the heating of the bearing which occurs during the normal operation of the bearing. As a result of the arrangement of temperature sensors at defined intervals from the bearing, the position of the load zone can be determined directly. In the present case, it is not important to determine the absolute temperature precisely but rather to compare the temperatures detected with the individual temperature sensors.
[0010] In this context, one or more characteristic values which characterize the load zone thermally and in terms of position can be formed with the sensing device. For example, a vector can be formed whose direction characterizes the location and whose length characterizes the temperature difference at the coldest point in the temperature sensor space. It is also conceivable here that temperatures detected with the temperature sensors are determined sequentially or with an additional piece of location information or position information and are made available to the detection device. It is therefore possible to make available very simple and cost-effective measuring equipment with which the load zone of a bearing can be detected.
[0011] The at least two temperature sensors may be arranged on an outer surface of the stationary component. The bearing is usually inserted into a recess of the stationary component. Owing to the good heat transfer between the bearing and the stationary component, which is manufactured, for example, from a metal, it is sufficient to sense the temperature at various positions on an outer surface of the stationary component. In this context, the individual temperature sensors may be arranged on a circuit board. This circuit board can be embodied in an annular shape, wherein it has a circular recess, the diameter of which corresponds to the outer diameter of the bearing. The diameter of the recess can also be larger than the outer diameter of the bearing. The temperature sensors can therefore be arranged on the circuit board in such a way that they are all at the same distance from the bearing. In this context, the temperature sensors can be arranged directly on the outer surface of the stationary component. Alternatively, an element which is capable of conducting heat can be arranged between the outer surface of the movable component and the respective temperature sensors. The temperature sensors can also be arranged in a bearing lid of the bearing. As a result, the temperature sensors can be particularly easily retrofitted.
[0012] In one embodiment, the bearing arrangement has at least one vibration sensor for sensing a vibration of the bearing. Standard ISO 10816-3 prescribes, for example, the installation of vibration sensors directly in the load zone. If vibration sensors are not used, the measurement is not according to the standard. By evaluating the signal of the at least one vibration sensor it is additionally possible to monitor the operating state of the bearing.
[0013] In one refinement, the sensing device is designed to weight and/or check for plausibility sensor signals of the at least one vibration sensor as a function of the detected temperatures of the at least two temperature sensors. On the basis of the temperatures detected with the at least two temperature sensors it is possible to determine the load zone of the bearing. The position of the load zone can be used, for example, for weighting measurements with vibration sensors. If the load zone is at a distance from the vibration sensor, which sensor is intended to be in the vicinity of the load zone, the signal of the vibration sensor is lower than expected since the distance from the sound wave is larger. Accordingly, the sensor signal of the vibration sensor can be correspondingly weighted or amplified. Furthermore, the detected position of the load zone can be used as a plausibility criterion for the sensor signal of the vibration sensor. Using the bearing arrangement described herein it is therefore possible to ensure that the standard described above is satisfied without having to install additional expensive vibration sensors and measuring chains.
[0014] The bearing arrangement may include a display device for visually displaying the load zone. The sensing device with which the load zone is determined can make available, for example, corresponding output signals with which a visual display device can be actuated. In this context it is also conceivable that a rotational speed and/or a rotational direction of the bearing is displayed with the display device. As a result, there is no need for any additional evaluation of sensor signals of the sensing device and the position of the load zone can be easily displayed.
[0015] In a further embodiment, the display device has a multiplicity of light emitting diodes. Light emitting diodes are distinguished in that they have a long service life and are robust. In addition, light emitting diodes are available in various colors. This permits a display device to be made available in a particularly simple way.
[0016] In one embodiment, the light emitting diodes of the display device form the at least two temperature sensors of the sensing device. The use of light emitting diodes is advantageous in particular since the light emitting diodes can, in addition to the use as display elements, also be used for measuring temperature. For this purpose, the light emitting diodes are operated in the on direction. The temperature dependence of the light emitting diodes results from the reduction in the on voltage with the rising temperature. The diode voltage can be determined during operation of the light emitting diodes. As a result, the light emitting diodes can be used to detect the load zone and to display the load zone at the same time.
[0017] In a further refinement, the display device includes a control unit which is designed to supply the light emitting diodes with the same electrical power. The control device can be formed, in particular, by a multiplexer. Since the light emitting diodes heat up during operation and therefore also age, the individual light emitting diodes can be actuated with the control unit in such a way that a corresponding light pattern is produced. All the light emitting diodes may be heated for the same length of time and with the same current strength. As a result, it is possible to make available, for example, a light pattern or a running light which runs toward the load zone.
[0018] Furthermore, a method is described for determining a load zone of a bearing, wherein with the bearing a movable component is supported with respect to a stationary component, and wherein the load zone is formed by a region of the bearing in which, during a movement of the movable component, higher mechanical loading occurs in the bearing compared to an adjacent region, by respective sensing of a temperature at at least two positions on an outer surface of the bearing and/or of the stationary component and determining the load zone of the bearing on the basis of the detected temperatures.
[0019] An operating state of the bearing may be determined on the basis of the detected temperatures. It is therefore possible, for example on the basis of the knowledge of the temperature distribution along the bearing, to detect thermally induced mechanical stresses and to determine their position. For example, the temperature difference and the spatial distance between the hottest and coldest point provide information about the temperature gradient and therefore the mechanically occurring stress as well as material deformations. It is also conceivable here that this data is used in FEM simulation in order to be able to characterize or model the behavior more precisely.
[0020] If a nonhomogeneous distribution of the temperature occurs along the bearing, the reason for this may be nonhomogeneous running of the bearing. This occurs, for example, in the case of damage in the running surface or the bearing bushing. Such a faulty state can be detected by analyzing the temperature profile along the bearing.
[0021] Furthermore, the method is suitable for diagnosing excessive temperatures in the bearing. If the bearing is operated, for example, outside the design state, what is referred to as the bearing air decreases. This results in the friction in the bearing increasing, as a result of which the temperature can additionally rise. Furthermore, the position and/or the width of the load zone change. In addition, viscosity of the lubricant in the bearing is reduced as the temperature rises. If the bearing is operated at an excessive temperature, what is referred to as seizing up of the bearing can occur. As a result of the method, the temperature of the bearing can be monitored and therefore the operating state can be correspondingly diagnosed.
[0022] When the torque or the rotational speed at the movable component changes, the load zone of the bearing typically migrates slightly spatially. This can be directly monitored with the method described here for determining the load zone. As a result, undesired operating states such as, for example, the sliding bearing operation in the mixed friction range can be detected. The operating states or friction states can therefore be characterized.
[0023] A further important aspect is the pretensioning of the bearing. It is to be noted here that the bearing is operated under a defined pretension, which can be different axially and radially depending on the type of bearing, in order to prevent damage thereto. If such a pretension is not present, a defined load zone of the bearing is not formed but instead the load zone changes over time and periodically with the rotational speed. In this case, a defined local heating point does not occur on the bearing. This faulty operation can be detected and represented on the basis of the change in the position of the temperature maximum and in the maximum temperature difference between the temperature sensors.
[0024] In a method for operating a machine and/or system, the machine and/or system includes a previously described bearing arrangement, a setting of at least one operating component of the machine and/or system is adapted as a function of the determined load zone of the bearing. Such an operating component can be, for example, a belt of a machine. The belt tension at the machine brings about shifting of the load zone in the pulling direction. If the belt tension is too low, the load vector typically shifts in another direction. Since, in addition to the belt tension, for example the acceleration due to gravity and the bearing pretension of the machine also act as force vectors, in the design state the force vector may not occur directly in the pulling direction of the belt. As a result, excessively high belt tension can also be detected if the local heating occurs in the pulling direction of the belt and has high values.
[0025] The advantages and developments which are described above in relation to the bearing arrangement can be transferred in the same way to the method for determining a load zone of a bearing and to the method for operating a machine and/or system.
BRIEF DESCRIPTION OF THE DRAWINGS
[0026] These and other aspects and advantages will become more apparent and more readily appreciated from the following description of the exemplary embodiments, taken in conjunction with the accompanying drawings of which:
[0027] FIG. 1 is a schematic plan view of a bearing arrangement;
[0028] FIG. 2 is a schematic plan view of a bearing in the bearing arrangement;
[0029] FIG. 3 is a block diagram of a sensing device of the bearing arrangement in a first embodiment;
[0030] FIG. 4 is a block diagram of a sensing device of the bearing arrangement in a second embodiment; and
[0031] FIG. 5 is a block diagram of a sensing device of the bearing arrangement in a third embodiment.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0032] Reference will now be made to exemplary embodiments described in more detail below which represent preferred embodiments and are illustrated in the accompanying drawings, wherein like reference numerals refer to like elements throughout.
[0033] FIG. 1 illustrates a bearing arrangement which is denoted in its entirety by 10 . The bearing arrangement 10 includes a bearing 12 which is embodied as a roller bearing. The bearing 12 has an outer ring 14 as well as an inner ring 16 . In addition, the bearing 12 includes roller bodies 18 which are embodied here as balls. The bearing 12 serves to support a movable component 20 , which is formed, for example, by a shaft, with respect to an immovable component 22 , which is formed, for example, by a bearing housing or a bearing receptacle.
[0034] Furthermore, the bearing arrangement 10 has four temperature sensors 24 . Pt100 sensors, Pt1000 sensors, PTC thermistors, diodes, light emitting diodes, GaAs diodes or what are referred to as one-wire temperature sensors can be used as temperature sensors 24 .
[0035] The temperature sensors 24 are arranged on a circuit board 26 . The circuit board 26 has an annular shape. The four temperature sensors 24 are arranged distributed uniformly in the circumferential direction of the annular circuit board 26 . In this context, the temperature sensors 24 are each at the same distance from the bearing 12 . The temperature sensors 24 are connected to a sensing device 30 of the bearing arrangement 10 with a respective line 28 . The temperature sensors 24 are coupled thermally here to an outer surface of the stationary component 22 . The temperature sensors 24 can also be arranged on the outer ring 14 of the bearing 12 .
[0036] During operation of the bearing 12 , a load zone is formed in the bearing 12 . The load zone describes the region of the bearing 12 in which increased mechanical loading occurs in the bearing 12 compared to an adjacent region. Owing to the increased mechanical loading, the friction in the bearing 12 is increased, which in turn leads to local heating in the bearing 12 . The heating in the bearing 12 is transferred by thermal conduction to the stationary component 22 and can be detected there with the temperature sensors 24 .
[0037] The sensing device 30 is designed to form, on the basis of the temperatures detected with the temperature sensors 24 , corresponding characteristic values with which the load zone can be characterized thermally and in terms of position. This is illustrated in FIG. 3 . On the basis of the signals of the temperature sensors 24 , the sensing device can detect a region 36 in which local heating occurs. With the temperature sensors 24 a very simple and robust measuring technology can be made available. The load zone in the bearing 12 can be determined in a simple and reliable way. By evaluating the load zone, it is also possible to detect further faulty states in the bearing. It is therefore possible for example to detect if the load zone is located at an incorrect position of the bearing.
[0038] Furthermore, an incorrect operating state such as, for example, the mixed friction in the case of sliding bearings can also be detected. In addition, the bearing arrangement 10 permits an excessively low bearing load, migrating load location or imbalance of the bearing 12 to be detected. Furthermore, corresponding operating components of a machine and/or system in which the bearing arrangement 10 is used can be adapted. It is therefore possible, for example in the case of a belt drive, to detect on the basis of the load zone whether the tension of the belt is too low or too high.
[0039] FIG. 3 illustrates the sensing device 30 of the bearing arrangement 10 in a first embodiment. The sensing device 30 includes a plurality of temperature sensors 24 which are arranged on the circuit board 26 or on a sensor board. The temperature sensors 24 are connected to a computing device 38 , which may be embodied, for example, as a microcontroller. Furthermore, the sensing device 30 has a databus 32 which is connected to a network 40 . The network 40 can be embodied according to the Ethernet or the Profinet standard. The sensing device 30 is additionally designed to weight the signals of further sensors of the bearing arrangement 10 or of sensors outside the bearing arrangement 10 or to check them for plausibility.
[0040] In the present exemplary embodiment, a vibration sensor 42 , which is arranged on the circuit board 26 , and a further vibration sensor 44 are connected to the computing device 38 . The further vibration sensor 44 can be arranged in the bearing arrangement 10 or outside the bearing arrangement 10 . The signals of the vibration sensors 42 and 44 can now be weighted with the sensing device 30 . The weighting can therefore take place in accordance with the distance of the vibration sensors 42 , 44 from the load zone. Furthermore, the signals of the vibration sensors 42 , 44 can be checked for plausibility. If vibration signals made available by the vibration sensors 42 , 44 near to the load zone are lower than those at a distance from the load zone, this is normally not a possible state or desired state. It can therefore be assumed that there is a fault in the vibration sensor 42 , 44 or there is faulty installation of the vibration sensor 42 , 44 .
[0041] FIG. 4 illustrates the sensing device 30 of the bearing arrangement 10 in a further embodiment. In this context, further information is fed to the sensing device 30 via the network 40 . It is therefore possible for information or sensor signals of the vibration sensor 42 , 44 to be fed to the sensing device 30 . This is wherein the block 46 . Furthermore, the sensing device 30 can be transferred information about the load or the torque at the movable component 20 via the network 40 (block 48 ). Likewise, the rotational speed of the bearing 12 can be transferred to the sensing device (block 50 ). Finally, information about the external temperature can be transferred to the sensing device 30 (block 52 ). On the basis of this information it is additionally possible to detect an operating state of the bearing 12 from the information about the position of the load zone.
[0042] FIG. 5 illustrates the sensing device 30 in a further embodiment. In the present example, the temperature sensors 24 are formed by light emitting diodes. The light emitting diodes are simultaneously used to display the load zone of the bearing 12 visually. The temperature sensors 24 are each connected to a control unit 54 which is formed by a multiplexer. With the multiplexer 54 , the temperature sensors 24 can be supplied with the same electrical power. The control unit 54 is connected to a measuring system 60 via a digital signal line 58 . The multiplexer can be actuated by the measuring system via the digital signal line 58 . Furthermore, the multiplexer is connected to the measuring system 60 via an analog line 56 . The measured values of the temperature sensors 24 can be transmitted to the measuring system 60 via the analog line 56 .
[0043] A description has been provided with particular reference to preferred embodiments thereof and examples, but it will be understood that variations and modifications can be effected within the spirit and scope of the claims which may include the phrase “at least one of A, B and C” as an alternative expression that means one or more of A, B and C may be used, contrary to the holding in Superguide v. DIRECTV, 358 F3d 870, 69 USPQ2d 1865 (Fed. Cir. 2004). | A bearing, supporting a movable component in relation to a stationary component, and a detection device are included in a bearing arrangement. The bearing arrangement also includes at least two temperature sensors for respective detection of temperature. The detection device detects a load zone of the bearing, formed by an area of the bearing in which, during a movement of the movable component, a higher mechanical loading occurs in the bearing compared to an adjacent area. The detection device determines the load zone of the bearing by using the detected temperatures. | 6 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims the benefit of Foreign Application Serial No. 2011/02511, entitled “Combustor Liner and Flow Sleeve Tool”, filed Mar. 16, 2011, in Turkey, which is incorporated herein by reference in its entirety.
BACKGROUND OF THE INVENTION
The subject matter disclosed herein relates to turbine systems, and in particular to turbine combustion liners and flow sleeves.
Turbine systems include a combustor portion having a cavity where fuel mixes with compressed gas and is ignited. The fuel enters the combustor portion through fuel nozzles that are arranged in orifices communicative with the cavity. The orifices are exposed to high temperatures and include a removable tubular liner portion and a flow sleeve portion that insulate portions of the combustor and direct gas flow during system operation.
BRIEF DESCRIPTION OF THE INVENTION
According to one aspect of the invention, a tool includes an annular frame portion including a mount portion extending radially from the frame portion, a hook portion arranged on the mount portion, the hook portion sized and shaped to engage a member of a tubular component of a turbine combustor, and a force exertion portion arranged on the mount portion, the force exertion portion operative to engage a portion of the turbine combustor.
According to another aspect of the invention, a method for positioning a tubular component of a turbine combustor includes aligning a tool coaxially with the tubular component, rotating the tool such that an aperture of a hook portion of the tool engages a protruding stopper of the tubular component, operating a force exertion portion of the tool to slidably change the position of the tubular component along a linear axis of the turbine combustor.
These and other advantages and features will become more apparent from the following description taken in conjunction with the drawings.
BRIEF DESCRIPTION OF THE DRAWING
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 features, and advantages of the invention are apparent from the following detailed description taken in conjunction with the accompanying drawings in which:
FIG. 1 illustrates a perspective view of a combustor portion of a turbine system.
FIG. 2 illustrates a perspective view of an exemplary embodiment of a tool.
FIG. 3 illustrates a perspective, partially cut-away view of the tool of FIG. 2 engaging a combustor liner portion.
FIG. 4 illustrates a perspective, partially cut-away view of the tool of FIG. 2 engaging a flow sleeve portion.
FIG. 5 illustrates a perspective view of an alternate embodiment of a tool.
The detailed description explains embodiments of the invention, together with advantages and features, by way of example with reference to the drawings.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 illustrates a perspective view of a combustor portion (compressor discharge case) 102 of a turbine system 100 , the combustor portion 102 includes a plurality of mounting cases (combustion cases) 104 arranged on the combustor portion 102 . The mounting cases 104 are tubular and define an inner cavity that is communicative with the interior of the combustor portion 102 . A combustor liner portion 106 and a flow sleeve portion (not shown) are disposed in each of the mounting cases 104 . In operation, fuel nozzle assembly (not shown) is mounted in each of the mounting cases 104 ; and is operative to emit fuel into the combustor portion 102 .
During installation and maintenance procedures, technicians may remove and reinstall or replace the combustor liner portion 106 and flow sleeve portion. Previous maintenance procedures included using manual winches, chain blocks, and other unshaped tools for removing and installing the combustor liner portion 106 and flow sleeve portion. The previous procedures and tools were inefficient and time consuming.
FIG. 2 illustrates a perspective view of an exemplary embodiment of a tool 200 . The tool 200 includes an annular frame portion 202 having a rotational axis 201 and a planar surface 203 , which includes mount portions 204 that extend radially from the frame portion 202 . The mount portions 204 include orifices that may include for example, threaded inner surfaces that are operative to engage installation and removal means. In the illustrated embodiment, a threaded removal bolt 206 and a threaded installation bolt 208 engage each mount portion 204 . The tool 200 includes liner hooks 210 and flow sleeve hooks 212 . In the illustrated embodiment, the liner hooks 210 and the flow sleeve hooks 212 are arranged on the frame portion 202 proximate to the mount portions 204 , and are secured to the frame portion 202 using fasteners 214 . The hooks 210 and 212 each include a plate 216 having a longitudinal axis 205 , the plate 216 defines an aperture 218 . The aperture 218 defines a first planar surface 220 , a second planar surface 222 , and a third planar surface 224 . The first planar surface 220 is arranged substantially in parallel to the second planar surface 222 and the planar surface 203 (of the frame portion 202 ). The third planar surface 224 is arranged substantially perpendicular to the first planar surface 220 and the second planar surface 222 (and parallel to the rotational axis 201 ). The tool 200 may include handles 216 that are arranged on the frame portion 202 .
FIG. 3 illustrates a perspective, partially cut-away view of the tool 200 engaging the combustor liner portion 106 that is arranged in the mounting case 104 . The combustor liner portion 106 includes installation stoppers 302 that extend radially from the combustor liner portion 106 . The liner hooks 210 are sized and shaped to engage the installation stoppers 302 . FIG. 4 illustrates a perspective, partially cut-away view of the tool 200 engaging flow sleeve stoppers 402 of the flow sleeve portion 304 .
In removal operations, the tool 200 is aligned coaxially with the combustor liner portion 106 and the mounting case 104 , and rotated such that the liner hooks 210 engage the installation stoppers 302 . The removal bolts 206 may be rotated using, for example, a wrench or similar tool (not shown) to exert a force on the mounting case 104 that draws the tool 200 and the engaged combustor liner portion 106 outwardly from the mounting case 104 along the linear axis of the mounting case 104 . Once the combustor liner portion 106 has been partially extracted from the mounting case 104 a force may be exerted on the handles 216 to fully extract the combustor liner portion 106 from the mounting case 104 . Following the removal of the combustor liner portion 106 , a similar procedure may be used to remove the flow sleeve portion 304 . In this regard, the flow sleeve hooks 212 engage installation stoppers (not shown) that are arranged on the flow sleeve portion 304 ; and the removal bolts 206 are rotated to draw the tool 200 and the engaged flow sleeve portion 304 outwardly from the mounting case 104 . The flow sleeve hooks 212 may be removed from the tool 200 prior to removing the liner portion 106 if desired.
In installation operations, the flow sleeve portion 304 is inserted into the mounting case 104 , and the tool 200 is aligned coaxially with the flow sleeve portion 304 and rotated such that the flow sleeve hooks 212 engage the flow sleeve stoppers. The installation bolts 208 engage threaded orifices 306 of the mounting case 104 ; and are rotated to draw the tool 200 and the engaged flow sleeve portion 304 inwardly such that the flow sleeve portion 304 is fully inserted into the mounting case 104 . The combustor liner portion 106 may be installed using a similar installation procedure.
FIG. 5 illustrates a perspective view of an alternate embodiment of a tool 500 . The tool 500 is similar to the tool 200 described above, however the tool 500 includes hydraulic jack members 502 that are arranged on a jack frame portion 504 . A frame portion 506 that includes mounting portions 508 is arranged on the jack members 502 . Flow sleeve hooks 212 and liner hooks 210 are arranged on the mounting portions 508 . The tool 500 operates in a similar manner as the tool 200 , however, the insertion and removal forces are exerted by the hydraulic jack members 502 as opposed to the bolts 206 and 208 (of FIG. 2 )
In the illustrated embodiment, the tools 200 and 500 includes three flow sleeve hooks 212 and three liner hooks 210 that are sized and shaped to engage corresponding stoppers arranged on the flow sleeve portion 304 and the combustor liner portion 106 respectively (of FIGS. 1 and 2 ). Alternate embodiments may include any number of hooks 212 and 210 that may be sixed and shaped to engage alternate arrangements of flow sleeve portions 304 and combustor liner portions 106 having, for example, alternate installation stopper arrangements, shapes, or designs.
While the invention has been described in detail in connection with only a limited number of embodiments, it should be readily understood that the invention is not limited to such disclosed embodiments. Rather, the invention can be modified to incorporate any number of variations, alterations, substitutions or equivalent arrangements not heretofore described, but which are commensurate with the spirit and scope of the invention. Additionally, while various embodiments of the invention have been described, it is to be understood that aspects of the invention may include only some of the described embodiments. Accordingly, the invention is not to be seen as limited by the foregoing description, but is only limited by the scope of the appended claims. | A tool includes an annular frame portion including a mount portion extending radially from the frame portion, a hook portion arranged on the mount portion, the hook portion sized and shaped to engage a member of a tubular component of a turbine combustor, and a force exertion portion arranged on the mount portion, the force exertion portion operative to engage a portion of the turbine combustor. | 8 |
This application is a continuation of application Ser. No. 08/015,703 filed on Feb. 9, 1993, now U.S. Pat. No. 5,385,918.
FIELD OF THE INVENTION
The invention relates to methods and compounds for controlling inflammatory processes in humans through mediation of inflammatory cell proliferation. More particularly, the present invention is a method for suppressing T-lymphocytes using a class of novel compounds.
BACKGROUND
Compounds which retard the production of cytokines such as interleukin-2 (IL-2) are known. For instance, U.S. Pat. No. 4,764,503 assigned to Sandoz Ltd., Basel, Switzerland, describes a compound generically referred to as Cyclosporin A (hereinafter referred to as "CsA"), and U.S. Pat. No. 4,894,366 assigned to Fujisawa Pharmaceuticals, Osaka, Japan, describes a compound they designate as "FK506." Both CsA and FK 506 are claimed to inhibit IL-2 production and bind to cellular receptor proteins that possess Peptidyl Prolyl Isomerase (PPIase) activity (Johansson et al., 1990, Transplantation 50:10017).
It was initially postulated by those skilled in the art that the specific binding by such compounds to PPIase type proteins led to inhibition of the protein's isomerase activity which, in turn, led to inhibition of T-cell proliferation. Thus, these PPIase type proteins were referred to as "immunophilins", with the cellular receptor proteins that bound to CsA and FK506 being referred to as "cyclophilin" and "FK506 binding protein", respectively. FK506 binding protein is also simply referred to as "FKBP"(Harding et al., 1989, Nature 341:758).
Recent publications report that the inhibition of PPIase activity, in and of itself, is not sufficient for immunosuppressant activity. However, there is support in the literature that inhibitory binding to PPIase-type enzymes probably contributes to ultimate T-cell suppression (Sigal et al. 1991, J. Exp. Med. 173:619).
This disclosure presents a new class of synthetic compounds that both suppress the proliferation of T-cells and inhibit the isomerase activity of the FKBP-type of PPIases.
CsA, a cyclic undecapeptide, has received FDA approval for use as an adjunct to organ transplant procedures. However, CsA is administered with caution due to its known toxicity. Currently, CsA is prescribed in situations where the risks of non treatment outweigh the risks of its therapeutic complications.
As a result, efforts to expand the application of CsA into non life threatening indications such as chronic maintenance of autoimmune disorders have been limited by the well-known side effects of this drug. The use of CsA leads to a variety of disorders including: nephrotoxicity, such as impairment of glomerular filtration and irreversible interstitial fibrosis (Kopp et al., 1991, J. Am. Soc. Nephrol. 1:162); neurological deficits, such as involuntary tremors, or non-specific cerebral angina such as non-localized headaches (De Groen et al, 1987, N. Engl. J. Med. 317:861); and vascular hypertension with complications resulting therefrom (Kahan et al., 1989, N. Engl. J. Med. 321:1725).
Recent efforts to investigate the cause of the adverse effects of CsA administration have centered on the role of CsA breakdown into toxic metabolites (Bowers et al., 1990, Clin. Chem. 36:1875; Burke et al., 1990, Transplantation 50:901). The prevailing thought is that CsA toxicity is due to such metabolites and not due to the nature of the CsA binding to the PPIase, cyclophilin (Akagi et al., 1991, J. Int. Med. Res. 19:1; Ryffel et al., 1988, Transplantation 46:905).
Thus, inhibitor compounds that do not resemble CsA structurally, yet bind to PPIases, should be more amenable to therapeutic applications. Such non-toxic immunosuppressors would benefit the art, especially for chronic administration such as required in the treatment of autoimmune disorders.
The compound FK506 is structurally different from CsA and does not produce the same type of toxic metabolites. FK506 has been shown to be effective in some transplant patients who do not respond to CsA (Tucci et al., 1989, J. Immunol. 143:718).
However, testing of FK506 in humans was delayed due to severe vasculitis observed in treatment regimens in dogs and baboons (Collier et al., 1988, Transplant Proc. 20:226). Furthermore, other clinical side effects and complications of FK506 administration are being reported (Frayha et al., 1991, Lancet 337:296; Kitahara et al., 1991, Lancet 337:1234). It has also been reported that "overall, the absolute rate of clinical rejection in FK506 post-organ transplantation! patients is only slightly lower than with current standard therapies" (Holechek, 1991, Anna. J. 18:199).
In an attempt to alleviate the FK506 side effects, many minor modifications to the base structure have been reported. For example, U.S. Pat. No. 5,057,608 assigned to Merck & Co. and WIPO Publication No. WO89/05304 assigned to FISONS PLC Inc. both disclose chemical variations of the FK506 compound.
To date only a few studies on the metabolism of FK506 have been published, and little information has been reported on the toxicity of its metabolites (Johansson et al., 1990, Transplantation 50:1001; Christians et al., 1991, Clinical Biochemistry 24:271; Lhoest et al., 1991, Pharmaceutica Acta Helveticae 66:302). Since it is likely that the pattern of metabolism of the FK506 analogs and derivatives are similar to the parent compound, it is also likely that many of the side effects of FK506 will be shared by the derivatives.
As is true for CsA, the toxicity of FK506 is postulated to be based on its structure and not due to its binding activity with the immunophilin FKBP. It is further postulated that the toxicity of compounds such as CsA and FK506 are due to various chemical groups found in these structures which do not participate in the immunosuppressive activity, such as those groups which result in the toxic metabolites of CsA bio-processing. Thus, relatively compact molecules which do not resemble either CsA or FK506, and which have both immuno-suppressive and PPIase binding activity should be free of side effects associated with CsA and FK506.
The present invention presents a novel class of synthetic inhibitor compounds. The novel class includes synthetic aminomethylene derivatives that bind to human FKBP-type PPIases and demonstrate human peripheral T-lymphocyte inhibitory activity.
Amino-methylene derivatives are known. For example, several claimed amino-methylene HIV inhibitors have been published, including WIPO WO 90/00399 assigned to Smithkline Beckman Corp., EPO EP 038723 1 assigned to Washington University, and EPO EP 0361341 assigned to Miles Inc., by assignment from Molecular Therapeutics, Inc. Similarily, amino-methylene inhibitors of the enzyme, renin have also been published, including EPO EP 0374097 assigned to CIBA Geigy AG. Also published are amino methylene compounds which are claimed to be therapeutics for neurologic dysfunctions such as EPO EP 374,756 assigned to Merck Inc.
As used herein, the term "aminomethylene-prolyl spacer" refers to a peptide fragment in which the carbonyl of the central amide bond has been replaced by an alkyl fragment such as a methylene group. ##STR2##
It is therefore an object of the present invention to provide for compounds and compositions containing such aminomethylene derivatives for suppression of pathological and abnormal human peripheral T-lymphocyte proliferation.
It is also an object of the present invention to provide a novel class of compounds suitable for therapeutic compositions designed to suppress pathological immune responses, such as the hyperimmune response in organ transplantation rejection, the self-destructive autoimmune diseases, and the overproduction and excessive proliferation of immune cells such as in infectious disease states.
More specific objects include provisions for compounds, compositions and methods for treatment and prevention of rejection of transplanted organs or tissues such as kidney, heart, lung, liver, bone marrow, skin grafts, and corneal replacement.
It is a further object to provide compounds, compositions and methods for use in the treatment of autoimmune, degenerative, inflammatory, proliferative and hyperproliferative diseases, such as rheumatoid arthritis, osteoarthritis, other degenerative joint diseases, joint inflammation such as associated with infectious diseases such as suppurative arthritis, and secondary arthritis such as those associated with gout, hemochromatosis, rheumatic fever, Sj6rgens syndrome and tuberculosis.
Another object is to provide compounds, compositions and methods for use in the treatment of lupus erythematosus, systemic lupus erythematosus, Hashimoto's thyroiditis, multiple sclerosis, myasthenia gravis, type 1 diabetes, uveitis, nephrotic syndrome, and of cutaneous manifestations of immunologically-mediated diseases such as psoriasis, atopic dermatitis, contact dermatitis, eczematous dermatitides, seborrheic dermatitis, lichen planus, pemphigus, bollous pemphigoid, epidermolysis bullosa, urticaria, angioedemas, vasculitides, erythemas, cutaneous eosinophilias, and alopecia areata.
Yet another object is to provide compounds, compositions and methods for use in the treatment of abnormal T-cell proliferation such as lymphocytic leukemia; Hodgkin's disease, especially those subtypes involving abnormal T-cell subpopulations; non-Hodgkin's lymphomas, such as mycosis fungoides, convulated lymphocytic lymphoma, and immunoblastic sarcoma; and chronic lymphadenitis.
The above lists are non-limiting, and one skilled in the art could easily adapt the compounds, compositions and methods of the present invention to other indications, such adaptations being within the spirit and scope of the invention which will be described hereinbelow.
SUMMARY OF THE INVENTION
The presently claimed invention relates to an active compound essentially containing at least one of the following structures: ##STR3## where A is either an amino acid derivative ##STR4## where R 4 is a straight or branched alkyl (C1-C8) that may be substituted by a cycloalkyl (C6), carboalkoxy (--CO2R: where R is straight or branched alkyl (C1-C6) which may be substituted by phenyl), a carboxamido, phenyl, phenyl substituted with hydroxy or methoxy, alkoxy (C1-C6), or benzyloxy.
R 5 is acyl, an amino acid, hydrogen, or an alkoxycarbonyl (--CO2R') derivative where R' is an alkyl group (C1-C8) which may be substituted by phenyl or an alkene (C2-C6).
X 2 is oxygen.
m is an integer of 0 or 1.
R 6 is straight or branched alkyl (C1-C12), cycloalkyl (C3-C10), bicycloalkyl (C6-C12), tricycloalkyl (C7-C14), or tetracycloalkyl (C9-C16). These straight or branched alkyl and cycloalkyl derivatives may be substituted by an alkoxycarbonyl (C1-C8), a cycloalkyl (C3-C7), or bicycloheterocycle. This bicycloheterocycle may contain up to four heteroatoms selected from oxygen, nitrogen or sulfur.
R 6 may also be an aryl derivative such as phenyl, naphthyl, or fluorenone. These aryl derivatives may be substituted up to three fold by straight or branched alkyl (C1-C3), alkoxy (C1-C3), acyloxy (C1-C6), or phenyl.
R 6 may also be heteroaryl (six membered with up to 2 nitrogen), or a 5-membered ring heteroaryl such as furan, thiophene. Both heterocycle derivatives may be substituted by straight or branched alkyl (C1-C5), an straight or branched alkoxy (C1-C5) or a halide such as fluoride, chloride, bromide, or iodide.
R 1 is hydrogen or a straight or branched alkyl (C1-C6).
R 2 and R 3 are defined as follows: one of R 2 and R 3 is hydrogen and the other is straight or branched alkyl (C1-C12) that may be substituted by cycloalkyl (C3-C10), phenyl, phenyl substituted by hydroxy or straight or branched alkoxy (C1-C6), alkoxy (C1-C6), or benzyloxy.
n=an integer of 1, 2 or 3.
X 1 is oxygen or NR 7 , where R 7 is hydrogen or straight or branched alkyl (C1-C6)
J is the divalent fragment ##STR5## where R 8 is hydrogen, straight or branched alkyl (C1-C10). The straight or branched alkyl derivatives may be substituted by cycloalkyl (C5-C7), phenyl, straight or branched alkoxy (C1-C8) or arylalkoxy (C7-C11).
K is one of the fragments
--HC═CH--or --(CH.sub.2).sub.p --
where the alkene can be either a cis or trans isomer, and
p=an integer of 1,2,3 or 4.
L is hydrogen, phenyl, or a straight or branched alkyl (C1-C10). These groups may be substituted up to three times by straight or branched alkyl (C1-C6), straight or branched alkoxy, (C1-C8), hydroxy, or an amino group. The amino group could be substituted by an acyl, a benzoyl, or an alkoxycarbonyl. The alkyl portion of the alkoxycarbonyl group is a straight or branched alkyl (C1-C8) that may be substituted by phenyl or a straight or branched alkene (C2-C6).
Included within the scope of the present invention are pharmacuetically acceptable salts of the above mentioned compounds. Pharmaceutically acceptable salts can be derived from mineral acids, carboxylic acids or sulfuric acids preferred from hydrochloric acid, hydrobromic acid, sulfuric acid, methane sulfuric acid, ethane sulfonic acid, toluene sulfonic acid, benzene sulfonic acid, naphthalene disulfonic acid, acetic acid, propionic acid, lactic acid, tartaric acid, citric acid, fumaric acid, maleic acid or benzoic acid. Most preferred are the hydrochlorides.
In the case of the present compounds being carboxylic acids or containing acidic functional groups, the invention includes metal salts and ammonium salts. Preferred are sodium, potassium or ammonium salts. The compounds of this invention exist as stereoisomeric forms, which either behave like image and mirror image (enantiomers) or not (diastereomers). Included within the scope of the invention are the enantiomers, the racemic form as well as diastereomeric mixtures. Enantiomers as well as diastereomers can be separated by methods known to those skilled in the art (compare E. L. Eliel, Stereochemistry of Carbon Compounds, McGraw Hill, 1962).
The presently claimed invention also relates to active compounds which essentially contain at least one of the following structures: ##STR6## where A is either an amino acid derivative ##STR7## where R 4 is a straight or branched alkyl (C1-C6) that may be substituted by a cycloalkyl (C6), carboalkoxy (--CO 2 R: where R is straight or branched alkyl (C1-C4) which may be substituted by phenyl), a carboxamido, phenyl, phenyl substituted with hydroxy or methoxy, alkoxy (C1C4), or benzyloxy.
R 5 is acetyl, an amino acid, hydrogen, or an alkoxycarbonyl (--CO2R') derivative where R' is a straight or branched alkyl group (C1-C6) which may be substituted by phenyl or a straight or branched alkene (C2-C4).
X 2 is oxygen.
m is an integer of 0 or 1.
R 6 is straight or branched alkyl (C1-C10), cycloalkyl (C3-C8), bicycloalkyl (C5-C12), tricycloalkyl (C7-C14), or tetracycloalkyl (C9-C14). These straight or branched alkyl and cycloalkyl derivatives may be substituted by an alkoxycarbonyl (C1-C6), a cycloalkyl (C3-C7), or bicycloheterocycle. This bicycloheterocycle may contain up to four heteroatoms selected from oxygen, nitrogen or sulfur.
R 6 may also be an aryl derivative such as phenyl, naphthyl, or fluorenone. These aryl derivatives that may be substituted up to three fold by straight or branched alkyl (C1-C3), alkoxy (C1-C3), acyloxy (C1-C6), or phenyl.
R 6 may also be heteroaryl (six membered with 2 nitrogen), or a 5-membered ring heteroaryl such as furan, thiophene. Both heterocycle derivatives may be substituted by straight or branched alkyl (C1-C5), an alkoxy (C1-C5) or a halide such as fluoride, chloride, bromide, or iodide.
R 1 is hydrogen or a straight or branched alkyl (C1-C4).
R 2 and R 3 are defined as follows: one of R 2 and R 3 is hydrogen and the other is straight or branched alkyl (C1-C9) that may be substituted by cycloalkyl (C5-C8), phenyl, phenyl substituted by hydroxy or alkoxy (C1-C4), alkoxy (C1-C6), or benzyloxy.
n=an integer of 1, 2 or 3.
X 1 is oxygen or NR 7 , where R 7 is hydrogen or straight or branched alkyl (C1-C4)
J is the divalent fragment ##STR8## Where R 8 is hydrogen, straight or branched alkyl (C1-C8). The straight or branched alkyl derivatives may be substituted by cycloalkyl (C5-C7), phenyl, alkoxy (C1-C6) or arylalkoxy (C7-C9).
K is one of the fragments
--HC═CH-- or --(CH.sub.2).sub.p --
where the alkene can be either a cis or trans isomer, and
p=an integer of 1,2, or 3.
L is hydrogen, phenyl, or a straight or branched alkyl (C1-C8). These groups may be substituted up to three times by straight or branched alkyl (C1-C5), alkoxy, (C1-C6), hydroxy, or an amino group. The amino group could be substituted by an acyl, a benzoyl, or an alkoxycarbonyl. The alkyl portion of the alkoxycarbonyl group is a straight or branched alkyl (C1-C6) that may be substituted by phenyl or an alkene (C2-C4).
Included within the scope of the present invention are pharmacuetically acceptable salts of the above mentioned compounds. Pharmaceutically acceptable salts can be derived from mineral acids, carboxylic acids or sulfuric acids preferred from hydrochloric acid, hydrobromic acid, sulfuric acid, methane sulfuric acid, ethane sulfonic acid, toluene sulfonic acid, benzene sulfonic acid, naphthalene disulfonic acid, acetic acid, propionic acid, lactic acid, tartaric acid, citric acid, fumaric acid, maleic acid or benzoic acid. Most preferred are the hydrochlorides.
Preferred embodiments of the compounds of the present invention can be defined further with the following structure: ##STR9## where A is either an amino acid derivative ##STR10## where R 4 is a straight or branched alkyl (C1-C4) that may be substituted by cycloalkyl (C6).
R 5 is hydrogen, or an alkoxycarbonyl (--CO2R') derivative where R' is an alkyl group (C1-C5) which may be substituted by phenyl or an alkene (C2-C3).
X 2 is oxygen.
m is an integer of 0 or 1.
R 6 is straight or branched alkyl (C1-C8), cycloalkyl (C4-C8), bicyclo alkyl (C5-C12), tricycloalkyl (C7-C14), or tetracycloalkyl (C9-C14). These straight or branched alkyl and cycloalkyl derivatives may be substituted by an alkoxycarbonyl (C1-C4), a cycloalkyl (C4-C6), or a 2-oxo-hexahydro-thieno 3,4-d!imidazol-4-yl group.
R 6 may also be an aryl derivative such as phenyl, naphthyl, or 4-fluorenone. These aryl derivatives that may be substituted up to three fold by methoxy, acetoxy, or phenyl.
R 6 may also be heteroaryl (six membered with 1 nitrogen), or a 5-membered ring heterocycle such as furan, thiophene.
R 1 is hydrogen.
R 2 and R 3 are defined as follows: one of R 2 and R 3 is hydrogen and the other is straight or branched alkyl (C1-C6) that may be substituted by cycloalkyl (C5-C6), phenyl, alkoxy (C1-C6), or benzyloxy.
n=an integer of 1, 2 or 3.
X 1 is oxygen or NR 7 , where R 7 is hydrogen.
J is the divalent fragment ##STR11## where R 8 is hydrogen, straight or branched alkyl (C1-C6). K is one of the fragments
--HC═CH-- or --(CH.sub.2).sub.p --
where the alkene is preferentially the trans isomer, and
p=an integer of 2.
L is hydrogen, phenyl, or a straight or branched alkyl (C1-C6). These groups may be substituted up to three times by straight or branched alkyl (C1-C4), alkoxy, (C1-C4), hydroxy, or an amino group. The amino group could be substituted by an acyl, a benzoyl, or an alkoxycarbonyl. The alkyl portion of the alkoxycarbonyl group is a straight or branched alkyl (C1-C4) that may be substituted by phenyl or an alkene (C3).
Included within the scope of the present invention are pharmacuetically acceptable salts of the above mentioned compounds. Most preferred are the hydrochlorides.
Preferred Method of Synthesis
Synthesis of Dipeptide Derivatives ##STR12##
Imino acid derivatives could be dehydratively coupled to N-protected, amino acid derivatives using standard coupling agents such as PPA, DCC or other reagents as described in standard books on peptide coupling (such as Bodanszky et al. The Practice of Peptide Synthesis: Springer-Verlag, Vol 21, 1984). The group used to protect the nitrogen of these amino acids could be either carbotertbutoxy, carbobenzyloxy, carboallyloxy, or other temporary protecting groups as described in the literature (T. W. Greene et al, Protective Groups in Organic Synthesis, 2nd Edition; John Wiley & Sons, 1991).
Synthesis of Aminomethylenes ##STR13##
A convenient route to prepare the present compounds involves reduction of the central peptide bond of the relevant dipeptide (as depicted in equation 2.0). Standard methods to effect similar transformation have been reported (Cushman, M. et al. J. Org. Chem. 1991, 56, 4161-7.). For example, the intermediate amide bond can be reduced with a borohydride reagent such as borane in a polar solvent such as tetrahydrofuran, ether, or dimethoxyethane.
Alternatively, these derivatives may also be prepared by a procedure in which the amide bond is first converted to a thioamide intermediate using sulfur transfer reagents such as Lawesson's Reagent (Synthesis 1979, 941). The resulting thioamide obtained by this or other procedures may be reduced to the corresponding aminomethylene derivative by treatment with a reducing reagent such as Raney nickel.
In cases where the thioamide derivative is a phenylmethyl ester derivative, reduction of the thioamide may lead directly to the corresponding reduced derivative containing a free carboxylic acid derivative (Eq. 2.1) ##STR14## Formation of Aminomethylene Carboxylic Acids ##STR15##
Although methods as depicted in Eq. 2.1 may allow for the formation of carboxylic acid derivatives directly from the corresponding thioamide phenylmethyl esters, these intermedates are also obtained from the corresponding esters (Eq. 3.0). Conditions used to effect hydrolysis or conversion of ester derivatives to acid derivatives are described in detail in the literature (T. W. Greene et al, Protective Groups in Organic Synthesis, 2nd Edition; John Wiley & Sons, 1991).
C-Terminal Homologation of Aminomethylenes ##STR16##
Aminomethylene-carboxylic acid derivatives derived from Eq. 2.1, Eq. 3.0, or other methods could be dehydratively coupled to a variety of alcohol or amine derivatives to provide the corresponding ester (X=0) or amide derivatives (X=NR). This dehydrative coupling can be achieved with standard coupling agents such as PPA, DCC or other reagents as described in standard books on peptide coupling (such as Bodanszky The Practice of Peptide Synthesis: Springer-Verlag, Vol 21, 1984).
Deprotection of Aminomethylene N-termini ##STR17##
These compounds prepared in Eq. 4.0 may serve as embodiments of this invention or as intermediates for the preparation of additional embodiments of this invention. Thus the compounds of this invention may be deprotected at the N-termini using reagents and procedures described earlier (T. W. Greene et al, Protective Groups in Organic Synthesis, 2nd Edition; John Wiley & Sons, 1991). These methods are useful for the conversion of protected amine derivatives to free amino derivatives.
Acylation of Amine Derivatives ##STR18##
Amine derivatives prepared from methods described in Eq. 5.0 or from other sources may be treated with a variety of carboxylic acids or acid chlorides to provide amide derivatives that fall within the scope of this invention. The coupling may take place in halogenated solvents such as dichloromethane, 1,2-dichloroethane or chloroform to form the corresponding sulfonamides.
The presently claimed compounds were found to be effective at low micromolar doses in both in vivo assays for inhibition of mitogen-induced human T-cell proliferation and NF-AT directed l-galactosidase expression. Moreover, the results from the rat adjuvant arthritis model (described in detail further below) indicate that the present class of compounds exhibit desirable biological properties (prophylactic prevention of paw swelling), at the concentration tested (10 mg/kg/dose).
The present invention encompasses pharmaceutical formulations which, in addition to non-toxic, inert pharmaceutically suitable excipients, contain the compounds of the invention.
The present invention also includes pharmaceutical formulations in dosage units. This means that the formulations are present in the form of individual part, for example, tablets, dragees, capsules, caplets, pills, suppositories and ampules, the active compound content of which corresponds to a fraction or a multiple of an individual dose. The dosage units can contain, for example, 1, 2, 3 or 4 individual doses; or 1/2, 1/3 or 1/4 of an individual dose. An individual dose preferably contains the amount of active compound which is given in one administration and which usually corresponds to a whole, one half, one third or one quarter of a daily dose.
By non-toxic inert pharmaceutically suitable excipients there are to be understood solid, semi-solid or liquid diluents, fillers and formulation auxiliaries of all types.
Preferred pharmaceutical formulations which may be mentioned are tablets, dragees, capsules, caplets, pills, granules, suppositories, solutions, suspensions and emulsions, paste, ointments, glues, creams, lotions, dusting powders and sprays. Tablets, dragees, capsules, caplets, pills and granules can contain the active compounds in addition to the customary excipients, such as (a) fillers and extenders, for example, starches, lactose, sucrose, glucose, mannitol and silicic acid, (b) binders, for example, carboxymethylcellulose, alginates, gelatin and polyvinylpyrrolidone, (c) humectants, for example, glycerol, (d) disintegrating agents, for example, agar--agar, calcium carbonate and sodium carbonate, (e) solution retarders, for example, paraffin and (f) absorption accelerators, for example, quaternary ammonium compounds, (g) wetting agents, for example, cetyl alcohol and glycerol monostearate, (h) absorbents, for example, kaolin and bentonite and (i) lubricants, for example, talc, calcium stearate, magnesium stearate and solid polyethylene glycols, or mixtures of the substances listed under (a) to (i) directly hereinabove.
The tablets, dragees, capsules, caplets, pills and granules can be provided with the customary coatings and shells, optionally containing opacifying agents and can also be of such composition that they release the active compounds only or preferentially in a certain part of the intestinal tract, optionally in a delayed manner. Examples of embedding compositions which can be used are polymeric substances and waxes.
The active compounds can also be present in microencapsulated form, if appropriate with one or more of the abovementioned excipients. Suppositories can contain, in addition to the active compounds, the customary water-soluble or water-insoluble excipients, for example, polyethylene glycols, fats, for example, cacao fat and higher esters (for example, C14--alcohol with C16--fatty acid), or mixtures of these substances.
Ointments, pastes, creams and gels can contain, in addition to the active compounds, the customary excipients, for example, animal and vegetable fats, waxes, paraffins, starch tragacanth, cellulose derivatives, polyethylene glycols, silicones, bentonites, silicic acid, talc and zinc oxide, or mixtures of these substances.
Dusting powders and sprays can contain, in addition to the active compounds, the customary excipients, for example, lactose, talc, silicic acid, aluminum hydroxide, calcium silicate and polyamide powder, or mixtures of these substances. Sprays can additionally contain customary propellants, for example, chlorofluorohydrocarbons.
Solutions and emulsions can contain, in addition to the active compounds, customary excipients, such as solvents, solubilizing agents and emulsifiers, for example, water, ethyl alcohol, isopropyl alcohol, ethyl carbonate, ethyl acetate, benzyl alcohol, benzyl benzoate, propylene glycol, 1,3-butylene glycol, dimethylformamide, oils, in particular, cottonseed oil, groundnut oil, corn germ oil, olive oil, castor oil and sesame oil, glycerol, glycerol formal, tetrahydrofurfuryl alcohol, polyethylene glycols and fatty acid esters of sorbitan, or mixtures of these substances.
For parenteral administration, the solutions and emulsions can also be in a sterile form which is isotonic with blood. Suspensions can contain, in addition to the active compounds, customary excipients, such as liquid diluents, for example, water, ethyl alcohol or propylene glycol and suspending agents, for example, ethoxylated isostearyl alcohols, polyoxyethylene sorbitol and sorbitan esters, microcrystalline cellulose, aluminum methydroxide, bentonite, agar--agar, and tragacanth, or mixtures of these substances.
The abovementioned pharmaceutical formulations can also contain other pharmaceutical active compounds in addition to the claimed compounds of the present invention.
The aforementioned pharmaceutical formulations are prepared in the customary manner by known methods, for example, by mixing the active compound or compounds with the excipient or excipients.
The formulations mentioned can be used either with humans and animals, orally, rectally, bucally, parenterally (intra-venously, intramuscularly or subcutaneously), intracisternally, intravaginally, intraperitoneally or locally (dusting powder, ointment or drops) and for the therapy of infection in hollow spaces or body cavities. Suitable formulations are injection solutions, solutions and suspensions for oral therapy, gels, pour-on formulations, emulsions, ointments or drops. Ophthalmological and dermatological formulations, silver salts and other salts, ear drops, eye ointments, powders or solutions can be used for local therapy.
It is furthermore possible to use gels, powders, dusting powders, tablets, sustained release tablets, premixes, concentrates, granules, pellets, capsules, caplets, aerosols, sprays and inhalates on humans and animals. The compounds according to the invention can furthermore be incorporated into other carrier materials, such as, for example, plastics (e.g., chains of plastic for local therapy), collagen or bone cement.
DETAILED DESCRIPTION
The following describes a preferred way to prepare the compounds of the present invention.
REAGENTS AND INSTRUMENTS
Anhydrous tetrahydrofuran (THF), ethyl ether (Et 2 O), and acetonitrile were distilled from calcium hydride prior to use. Unless otherwise stated, all reagents discussed in the following examples were commercially available from Aldrich Chemical Co, Milwakee, Wis., or Janssen Chimica through the U.S. vender Spectrum Chemicals Mfg. Corp., New Brunswick, N.J.
All reactions were carried out in oven-dried glassware (140° C.) which were cooled under argon prior to use. Crude products were purified by flash column chromatography using 230-400 mesh silica gel (35-70 um) or medium/high pressure liquid chromatography using Shimadzu LC-8A Preparative liquid chromatography system equipped with columns packed with either 20 um or 10 um silica. Thin layer chromatography (TLC) was performed on aluminum-backed silica gel plates, and visualization was accomplished with a UV light or an iodine vapor chamber.
Proton ( 1 H) nuclear magnetic resonance (NMR) spectra were obtained on GN-OMEGA-300 spectrometers at 300 MHz. Carbon ( 13 C) NMR were obtained on the same spectrometer at 75 MHz. Mass spectral data were obtained on a Kratos-MS 80RFA spectrometer using electron impact ionization (EI), chemical ionization (CI), or fast atom bombardment (FAB). Mass Spectral (MS) data were obtained on a Kratos CONCEPT I-H spectrometer, using liquid-cesium secondary ion (LSI) technique, a more modern version of fast atom bombardment (FAB).
Melting points were obtained on a Thomas Hoover capillary melting point apparatus in open-ended capillaries and are not corrected.
Abbreviations used in the following experimental section refer to the following reagents: DCC is 1,3-dicyclohexyl carbodiimide; DMAP is 4-dimethylaminopyridine; TFA is trifluoroacetic acid; HOBT is 1-hydroxybenzotriazole monohydrate;
Amino acid derivatives described as 1- X!-L-Isoleucine are meant to signify a derivative of the the L-isomer of the amino acid Isoleucine, in which the -amino group is attached to the the fragment X. In a similiar fashion, 1- 1- X!-L-Proline!-L-Isoleucine is meant to represent a fragment that can be represented graphically as: ##STR19##
EXAMPLE 1 ##STR20##
1- 2-(S)- (1,1-Dimethylethoxy)carbonyl!amino!-4-methylpentyl!-L-proline 3-(4- N-Carboallyloxy!-aminophenyl)propyl Ester
a) 3-(4-Aminophenyl)propanol.
To a round bottomed flask equipped with a magnetic stirrer was added 4-nitrocinnamyl alcohol (2.0 g, 11.16 mmol), 10% Pd on carbon (200 mg) and absolute ethanol (150 mL). The solution was purged with hydrogen and stirred at 22° C. under a hydrogen atmosphere. When TLC indicated the reaction was complete (4 h), the solution was purged with argon and filtered through Celite. The filtrate was concentrated in vacuo to provide 3-(4-aminophenyl)propanol, 1.72 g (>100%), as a viscous oil which solidified on standing.
R f =0.17 (50% EtOAc in hexane).
b) 3-(4-(N-Carboallyloxyl-aminophenyl)propanol.
To a round bottomed flask was added the 3-(4-aminophenyl)propanol (1.3 g, 8.6 mmol), pyridine (1.0 mL, 12 retool) and dichloromethane (25 mL). The solution was cooled to 0° C. and treated with allyl chloroformate (1.0 mL, 9.4 mmol). After allowing to warm to 22° C. over 1 hour, the reaction mixture was diluted with dichloromethane and washed twice with 1N HCl, followed by sat. NaHCO 3 , water and sat. aq. NaCl. The organic extract was dried (MgSO 4 ) and concentrated in vacuo. Purification by flash chromatography (50% EtOAc in hexane), provided 1.77 g (88%) of the title compound as a clear oil which solidified on standing. The 1 H NMR and Mass spectrum analysis of this compound was consistent with the structure.
R f =0.37 (60% EtOAc in hexane).
c) 1-Thio-1- 2- (1,1-dimethylethoxy)carbonyl!amino!-4-methylpentyl!-L-Proline Benzyl Ester.
This compound was prepared from N-tertbutoxycarbonyl-L-isoleucine-L-Proline benzyl ester in 49% yield using the procedure described earlier (Synthesis, 1979, 941). The 1 H NMR of this compound was consistent with the structure.
Rf=0.61 (2% methanol in dichloromethane).
d)1- 2-(S)- (1,1 -dimethylethoxy)carbonyl!amino!-4-methylpentyl!-L-Proline.
A solution of 1-thio-1- 2(S)- (1,1-dimethylethoxy)carbonyl!amino!-4-methylpentyl!-L-proline benzyl ester (8.14 g) was dissolved in absolute ethanol (30 mL) and treated with #2-Raney nickel (60 mL 1:1 v/v slurry in absolute ethanol) at 22° C. for 2 hours. The reaction was filtered on a glass frit and washed with ethanol (700 mL). The filtrate was concentrated under reduced pressure and chromatographed on silica gel to provide 1.05 g (18%) of the title compound and 835 mg (11%) of the 1- 2-(S)- (1,1-dimethylethoxy) carbonyl!amino!-4-methylpentyl!-L-proline benzyl ester. The 1 H NMR of both these compound were consistent with their structure.
e)1- 2-(S)- (1,1-Dimethylethoxy)carbonyl!amino!-4-methypentyl!-L-Proline 3-(4- N-Carboallyloxy!-aminophenyl)propyl Ester.
In a round bottom flask were added 1- 2-(S)- (1,1-dimethylethoxy)carbonyl!amino!-4-methylpentyl!-L-proline (200 mg, 0.64 mmol), 3-(4-(N-carboallyloxy)-aminophenyl)propanol (200 mg, 0.95 mmol), DCC (197 mg, 0.95 mmol), HOBT (100 mg, 0.64 mmol), DMAP (85.6 mg, 0.70 mmol), CH 2 Cl 2 (3 mL), and DMF (1.0 mL). The reaction was stirred for 12 hours at 20° C., then washed with satd aq NaHCO 3 , satd aq NaCl, dried (MgSO 4 ) and evaporated under reduced pressure. The crude reaction was chromatographed on acidic silica to provide 126 mg (37%) of the title compound. The 1 H NMR and Mass spectrum analysis of this compound was consistent with the structure.
Rf=0.35 (33% EtOAc in hexane). LSIMS=532; (mass calculated for C 29 H 45 N 3 O 6 =531.67).
EXAMPLE 2 ##STR21##
1- 2-(S)- (1,1-Dimethylethoxy)carbonyl!amino!-3-(S)-methylpentyl!-L-homoproline 1-(S)- 2'-(S)-methyl-propyl!-3-phenylprop-2E-enylamide
a) trans 1-Phenyl-3-(S)- (1,1-dimethylethoxy)carbonyl!-amino!-4-(S)-methylhexa-1-ene.
Into a 1-L round bottomed flask equipped with a magnetic stirrer was added diethyl benzylphosphonate (14.3 mL, 15.8 g, 69.37 mmol, 1.2 eq.) and THF (500 mL). The flask was purged with argon and cooled to -78° C. A 1 M solution of NaN(SiMe 3 ) 2 in THF (74.1 mL, 74.1 mmol, 1.2 eq.) was added dropwise to the phosphonate, and the color changed from colorless to pale yellow. After stirring 30 min at -78° C., a solution of Boc-L-isoleucinal (13.6 g, 63.1 mmol; prepared as described earlier: Saari, W. S.; Fisher, T. E. Synthesis 1990, 453-454. ) in THF (50 mL) was added dropwise. The reaction mixture was stirred at -78° C. for 30 min, then allowed to warm up to 0° C. over a 2 hour period. The solution was evaporated to dryness and the resulting colorless oil was dissolved in Et 2 O (250 mL). The ether solution was washed with sat. aq. NH 4 Cl (50 mL), sat. aq. NaCl (25 mL), dried (MgSO 4 ) and evaporated to a residue. The residue was purified by flash chromatography (5% EtOAc in hexane) to provide 8.7 g (48%) of the title compound as a colorless oil.
Rf=0.63 (30% EtOAc in hexane).
b) trans 1-Phenyl-3-(S)-amino-4-(S)-methylhexa-1-ene.
A solution of trans 1-phenyl-3-(S)- (1,1-dimethylethoxy)carbonyl!-amino!-4-(S)-methylhexa-1-ene (8.7 g, 30.27 mmol) was dissolved in CH 2 Cl 2 (50 mL) and treated with trifluoroacetic acid (20 mL). After 20 min stirring at 22° C., the reaction appeared complete (TLC). The reaction mixture was neutralized with excess sat. aq. NaHCO 3 , washed with sat. aq. NaCl (20 mL), dried (MgSO 4 ) and evaporated to a residue. The resulting colorless oil was dissolved in Et 20 (100 mL) and extracted with 1 N HCl (3×50 mL). The aqueous layer was neutralized with 1N NaOH and extracted with Et 2 O (3×50 mL). The organic layer was dried (MgSO 4 ) and concentrated in vacuo to provide 2.8 g (50%) of the title compound as a colorless oil that solidified on standing. The 1 H NMR and Mass spectrum analysis of this compound was consistent with the structure.
Rf=0.04 (30% EtOAc in hexane).
c) 1- 2-(S)- (1,1-Dimethylethoxy)carbonyl!amino!-3-(S)-methylpentyl!-L-homoproline 1-(S)- 2'-(S)-methylpropyl!-3-phenylprop-2E-enylamide.
In a round bottom flask was added 1- 2-(S)- (1,1-dimethylethoxy)carbonyl!amino!-3-(S)-methylpentyl!L-homoproline (213 mg), trans 1-phenyl-3-(S)-amino-4-(S)-methylhexa-1-ene (143 mg), triethylamine (225 uL) and anhydrous dichloromethane (1.5 mL). The reaction was cooled to 4° C., then bis (2-oxo-3-oxazolidinyl)-phosphinic chloride (BOP-Cl, 182 mg) was added and the reaction was stirred 2 hours at 4° C., then warmed to 20° C. and stirred for 12 hours. The reaction mixture was washed with satd aq NaHCO 3 , said aq NaCl, dried (MgSO 4 ) and evaporated under reduced pressure. The crude reaction was chromatographed on acidic silica to give 137 mg (20%) of the title compound. The 1 H NMR and Mass spectrum analysis of this compound was consistent with the structure.
Rf=0.45 (50% EtOAc in hexane). LSIMS=500; (mass calculated for C 30 H 49 N 3 O 3 =499.71).
EXAMPLE 3 ##STR22##
1- 2-(S)- (1,1-Dimethylethoxy)carbonyl!amino!-4-methylpentyl!-L-proline 4-Phenylbutylamide
Using the procedure described in ample 1e, a solution of 1- 2-(S)- (1,1-dimethylethoxy)carbonyl!amino!-4-methylpentyl!-L-proline (200 mg), DCC (197 mg, 0.955 mmol), DMAP (102 mg, 0.83 mmol), HOBT (155 mg, 1.012 mmol), triethylamine (177 uL, 1.27 mmol) in DMF (1.0 mL) and CH 2 Cl 2 (2 mL) was treated with 4-phenylbutylamine (150 uL) to provide 233 mg (82%) of the title compound. The 1 H NMR and Mass spectrum analysis of this compound was consistent with the structure.
Rf=0.26(50% EtOAc in hexane). LSIMS=446; (mass calculated for C 26 H 43 N 3 O 3 =445.62).
EXAMPLE 4 ##STR23##
1- 2-(S)- (1,1-Dimethylethoxy)carbonyl!amino!-3-methylbutyl!-L-proline 4-Phenylbutylamide
Using the procedure described in Example 1e, the coupling of 1- 2-(S)- (1,1-dimethylethoxy)carbonyl!amino!-3-methylbutyl!L-proline (200 mg) and 4-phenylbutyl amine (157 uL) provided 193 mg (67%) of the title compound. The 1 H NMR and Mass spectrum analysis of this compound was consistent with the structure.
Rf=0.27 (50% EtOAc in hexane). LSIMS=432; (mass calculated for C 25 H 41 N 3 O 3 =431.60).
EXAMPLE 5 ##STR24##
1- 2-(S)- (1,1-Dimethylethoxy)carbonyl!amino!-3-(S)-methylpentyl!-L-proline 4-Phenylbutylamide
Using the procedure described in Example 1e, the coupling of 1- 2-(S)- (1,1-dimethylethoxy)carbonyl!amino!-3-(S)-methylpentyl!L-proline (213 mg) and 4-phenylbutylamine (160 uL) provided 166 mg (55%) of the title compound. The 1 H NMR and Mass spectrum analysis of this compound was consistent with the structure.
Rf=0.30 (50% EtOAc in hexane). LSIMS=446; (mass calculated for C 26 H 43 N 3 O 3 =445.62).
EXAMPLE 6 ##STR25##
1- 2-(S)- (1,1-Dimethylethoxy)carbonyl!amino!-3-cyclohexylpropyl!-L-proline 4-Phenylbutylamide
Using the procedure described in Example 1e, the coupling of 1- 3-cyclohexyl-2-(S)- (1,1-dimethylethoxy)carbonyl!amino!propyl!-L-proline (206 mg) and 4-phenylbutyl amine (138 uL) provided 83 mg (29%) of the title compound. The 1 H NMR and Mass spectrum analysis of this compound was consistent with the structure.
Rf=0.27(50% EtOAc in hexane). LSIMS=486; (mass calculated for C 29 H 47 N 3 O 3 =485.69).
EXAMPLE 7 ##STR26##
1- 2-(S)- (Adamantan-1-yl)carbonyl!amino-4-methylpentyl!-L-proline 4-Phenylbutylamide
In a round bottom flask were added 1- 2-(S)-amino-4-methylpentyl!-L-proline 4-phenylbutylamide (20 mg), triethylamine (20 uL) and anhydrous dichloromethane (1 mL). 1-Adamantylcarbonyl chloride (17 mg) was added, and the reaction was stirred at 22° C. for 12 hours. The reaction mixture was washed with said aq NaHCO 3 , said aq NaCl, dried (MgSO4) and evaporated under reduced pressure. The crude reaction was chromatographed with acidic silica to provide 12 mg (42%) of the title compound. The 1 H NMR and Mass spectrum analysis of this compound was consistent with the structure.
Rf=0.46 (EtOAc). LSIMS=508; (mass calculated for C 32 H 49 N 3 O 2 =507.73).
EXAMPLE 8 ##STR27##
1- 2-(S)-(Benzoylamino)-4-methylpentyl!-L-proline 4-Phenylbutylamide
Using the procedure described in Example 7, treatment of 1- 2-(S)-amino-4-methylpentyl!-L-proline 4-phenylbutylamide (20 mg) with benzoyl chloride (10 uL) provided 10 mg (39%) of the title compound. The 1 H NMR and Mass spectrum analysis of this compound was consistent with the structure.
Rf=0.42 (EtOAc). LSIMS=450; (mass calculated for C 28 H 39 N 3 O 2 =449.61).
EXAMPLE 9 ##STR28##
1- 2-(S)- (1-Oxo-2-propylpentyl)amino!-4-methylpentyl!-L-proline 4-Phenylbutylamide
Using the procedure described in Example 7, treatment of 1- 2-(S)-amino-4-methylpentyl!-L-proline 4-phenylbutylamide (20 mg) with di-n-propylacetyl chloride(14 uL) provided 16 mg (60%) of the title compound. The 1 H NMR and Mass spectrum analysis of this compound was consistent with the structure.
Rf=0.52 (EtOAc). LSIMS=472; (mass calculated for C 29 H 49 N 3 O 2 =471.70).
EXAMPLE 10 ##STR29##
1- 2-(S)- (1-Oxo-4-methylpentyl)amino!-4-methylpentyl!-L-proline 4-Phenylbutylamide
Using the procedure described in Example 7, treatment of 1- 2-(S)-amino-4-methylpentyl!-L-proline 4-phenylbutylamide (20 mg) with isovaleryl chloride (14 uL) provided 15 mg (60%) of the title compound. The 1 H NMR and Mass spectrum analysis of this compound was consistent with the structure.
Rf=0.35 (EtOAc). LSIMS=444; (mass calculated for C 27 H 45 N 3 O 2 =443.65).
EXAMPLE 11 ##STR30##
1- 2-(S)- 2-(S)- (1,1-Dimethylethoxy)carbonyl!amino!-1-oxo-3-cyclohexylpropyl!amino!-4-methylpentyl!-L-proline 4-Phenylbutylamide
Using the procedure described in Example 1e, the coupling of 1- 2-(S)-amino-4-methylpentyl!L-proline 4-phenylbutylamide (80 mg) and Boc-(L)-cyclohexylalanine (94 mg) provided 100 mg (73%) of the title compound. The 1 H NMR and Mass spectrum analysis of this compound was consistent with the structure.
Rf=0.50 (EtOAc). LSIMS=599; (mass calculated for C 35 H 58 N 4 O 4 =598.84).
EXAMPLE 12 ##STR31##
1- 2-(S)- 2-(S)-Amino-1-oxo-3-cyclohexylpropyl!amino!-4-methylpentyl!-L-proline 4-Phenylbutylamide
A solution of 1- 2-(S)- 2-(S)- (1,1-dimethylethoxy)-carbonyl!amino!-1-oxo-3-cyclohexylpropyl!amino!-4-methylpentyl!-L-proline 4-phenylbutylamide (62.8 mg, 104 mmol) in dichloromethane (5 mL) was treated with trifluoroacetic acid (3.0 mL). After TLC indicated the reaction was complete, the mixture was concentrated to a residue, taken up in fresh dichloromethane (10 mL) and washed with satd. aq. NaHCO 3 and dried (MgSO 4 ). The solution was concentrated to an oil and chromatographed with acidic silica to provide 48.8 mg of the the title compound. The 1 H NMR and Mass spectrum analysis of this compound was consistent with the structure.
Rf=0.28 (4% MeOH in dichloromethane). LSIMS=499; (mass calculated for C 30 H 50 N 4 O 2 =498.73).
EXAMPLE 13 ##STR32##
1- 2-(R)- (1,1-Dimethylethoxy)carbonyl!amino!-4-methylpentyl!-L-proline 4-Phenylbutylamide
Using the procedure described in Example 1e, the coupling of 1- 2-(R)- (1,1-dimethylethoxy)carbonyl!amino!-4-methylpentyl!-L-proline (1.6 g) and 4-phenylbutyl amine (1.19 mL) provided 1.25g (56%) of the title compound. The 1 H NMR and Mass spectrum analysis of this compound was consistent with the structure.
Rf=0.62 (EtOAc). LSIMS=446; (mass calculated for C 26 H 43 N 3 O 3 =445.62).
EXAMPLE 14 ##STR33##
1- 2-(S)- (1,1-Dimethylethoxy)carbonyl!amino!-4-methylpentyl!-L-homoproline 4-Phenylbutylamide
Using the procedure described in Example 1e, the coupling of 1- 2-(S)- (1,1-dimethylethoxy) carbonyl!amino!-4-methylpentyl!-L-homoproline (2.6 g) and 4-phenylbutyl amine (1.88 mL) provided 1.05 g (29%) of the title compound. The 1H NMR and Mass spectrum analysis of this compound was consistent with the structure.
Rf=0.64 (EtOAc). LSIMS=460; (mass calculated for C 27 H 45 N 3 O 3 =459.65).
EXAMPLE 15 ##STR34##
1- 2-(S)-(3', 4', 5'-Trimethoxy-benzoylamino)-4-methylpentyl !-L-proline 4-Phenylbutylamide
Using the procedure described in Example 7, treatment of 1- 2-(S)-amino-4-methylpentyl !-L-proline 4-phenylbutylamide (117 mg) with 3,4,S-trimethoxybenzoyl chloride(1 16 mg) provided 62 mg (38%) of the title compound. The 1 H NMR and Mass spectrum analysis of this compound was consistent with the structure.
Rf=0.41 (4.8% methanol in dichloromethane). LSIMS=540; (mass calculated for C 31 H 45 N 3 O 5 =539.69).
EXAMPLE 16 ##STR35##
1- 2-(S)-Acetylamino-4-methylpentyl!-L-proline 4-Phenylbutylamide
Using the procedure described in Example 7, treatment of 1- 2-(S)-amino-4-methylpentyl!-L-proline 4-phenylbutylamide (106 mg) with acetic anhydride (40 uL) provided 89 mg (83%) of the title compound. The 1 H NMR and Mass spectrum analysis of this compound was consistent with the structure.
Rf=0.23 (4.8% methanol in dichloromethane). LSIMS=388; (mass calculated for C 23 H 37 N 3 O 2 =387.55).
EXAMPLE 17 ##STR36##
1- 2-(S)-(2'-Acetoxy-benzoylamino )-4-methylpentyl!-L-proline 4-Phenylbutylamide
Using the procedure described in Example 7, treatment of 1- 2-(S)-amino-4-methylpentyl!-L-proline 4-phenylbutylamide (108 mg) with acetylsalicyl chloride (101 mg) provided 38 mg (27%) of the title compound. The 1 H NMR and Mass spectrum analysis of this compound was consistent with the structure.
Rf=0.30 (4.8% methanol in dichloromethane). LSIMS=508; (mass calculated for C 30 H 41 N 3 O 4 =507.65).
EXAMPLE 18 ##STR37##
1- 2-(S)- (Biphenyl-4-carbonyl )amino!-4-methylpentyl!-L-proline 4-Phenylbutylamide
Using the procedure described in Example 7, treatment of 1- 2-(S)-amino-4-methylpentyl!-L-proline 4-phenylbutylamide (112 mg) with 4-biphenyl carbonyl chloride (95 mg) provided 128 mg (83%) of the title compound. The 1 H NMR and Mass spectrum analysis of this compound was consistent with the structure.
Rf=0.56(4.8% methanol in dichloromethane). LSIMS=526; (mass calculated for C 34 H 43 N 3 O 2 =525.70).
EXAMPLE 19 ##STR38##
1- 2-(S)- 5-(2-Oxo-hexahydro-thieno 3,4-d!imidazol-4-yl)-pentanoylamino!-4-methylpentyl!4-proline 4-Phenylbutylamide
Using the procedure described in Example 7, treatment of 1- 2-(S)-amino-4-methylpentyl!-1-proline 4-phenylbutylamide (183 mg) with N-hydroxysuccinimide-biotin (Pierce Chemical: 170 mg) provided 205 mg (75%) of the title compound. The 1 H NMR and Mass spectrum analysis o this compound was consistent with the structure.
Rf=038 (9.1% methanol in dichloromethane). LSIMS=572; (mass calculated for C 31 H 49 N 5 O 3 S=571.08).
EXAMPLE 20 ##STR39##
1- 2-(S)- (Thiophene-2-carbonyl)amino!-4-methylpentyl!-L-proline 4-Phenylbutylamide
Using the procedure described in Example 7, treatment of 1- 2-(S)-amino-4-methylpentyl!-L-proline 4-phenylbutylamide (113 mg) with 2-thiophenecarbonyl chloride (50 uL) provided 74 mg (55%) of the title compound. The 1 H NMR and Mass spectrum analysis of this compound was consistent with the structure. Rf=0.46 (EtOAc). LSIMS=456; (mass calculated for C 26 H 37 N 3 O 2 S=455.60).
EXAMPLE 21 ##STR40##
1- 2-(S)- (9-Oxo-9H-fluorene-4-carbonyl)amino!-4-methylpentyl!-L-proline 4-Phenylbutylamide
Using the procedure described in Example 7, treatment of 1- 2-(S)-amino-4-methylpentyl !-L-proline 4-phenylbutylamide (134 mg) with 9-fluorenone-4-carbonyl chloride (131 mg) provided 35 mg(18%) of the title compound. The 1 H NMR and Mass spectrum analysis of this compound was consistent with the structure.
Rf=0.45 (EtOAc). LSIMS=552; (mass calculated for C 35 H 41 N 3 O 3 =551.70).
EXAMPLE 22 ##STR41##
1- 2-(S)- (Furan-2-carbonyl)amino!-4-methylpentyl!-L-proline 4-Phenylbutylamide
Using the procedure described in Example 7, treatment of 1- 2-(S)-amino-4-methylpentyl!-L-proline 4phenylbutylamide (125 mg) with 2-furoyl chloride (50 uL) provided 27 mg (19%) of the title compound. The 1 H NMR and Mass spectrum analysis of this compound was consistent with the structure.
Rf=0.41 (EtOAc). LSIMS=440; (mass calculated for C 26 H 37 N 3 O 3 =439.58).
EXAMPLE 23 ##STR42##
1- 2-(S)- (Pyridin-3-carbonyl)amino!-4-methylpentyl !-L-proline 4-Phenylbutylamide
Using the procedure described in Example 7, treatment of 1- 2-(S)-amino-4-methylpentyl!-L-proline 4-phenylbutylamide (109 mg) with the hydrochloride salt of nicotinyl chloride (80 mg) provided 49 mg (38%) of the title compound. The 1 H NMR and Mass spectrum analysis of this compound was consistent with the structure.
Rf=0.14 (EtOAc ). LSIMS=451; (mass calculated for C 27 H 38 N 4 O 2 =450.60).
Example 24 ##STR43##
1- 2-(S)- (2-Carboethoxyeth-1-yl)carbonyl!amino!-4-methylpentyl!-L-proline 4-Phenylbutylamide
Using the procedure described in Example 7, treatment of 1- 2-(S)-amino-4-methylpentyl!-L-proline 4-phenylbutylamide (125 mg) with ethylsuccinyl chloride (70 uL) provided 66 mg (42%) of the title compound. The 1 H NMR and Mass spectrum analysis of this compound was consistent with the structure.
Rf=0.37 (EtOAc). LSIMS=474; (mass calculated for C 27 H 43 N 3 O 4 =473.63).
EXAMPLE 25 ##STR44##
1- 2-(S)- (3-Cyclopentyl-propionyl amino )-4-methylpentyl!-L-proline 4-Phenylbutylamide
Using the procedure described in Example 7, treatment of 1- 2-(S)-amino4-methylpentyl!-L-proline 4-phenylbutylamide (110 mg) with 3-cyclopentylpropionyl chloride (67 uL) provided 94 mg (69%) of the title compound. The 1 H NMR and Mass spectrum analysis of this compound was consistent with the structure.
Rf=0.43 (EtOAc). LSIMS=470; (mass calculated for C 29 H 47 N 3 O 2 =469.69).
EXAMPLE 26 ##STR45##
1- 2-(S)- (Naphthalene-1-carbonyl)amino!-4-methylpentyl!-L-proline 4-Phenylbutylamide
Using the procedure described in Example 7, treatment of 1- 2-(S)-amino-4-methylpentyl!-L-proline 4-phenylbutylamide (120 mg) with 1-naphthoyl chloride (71 uL) provided 66 mg (42%) of the title compound. The 1 H NMR and Mass spectrum analysis of this compound was consistent with the structure.
Rf=0.50 (EtOAc). LSIMS=500; (mass calculated for C 32 H 41 N 3 O 2 =499.67).
EXAMPLE 27 ##STR46##
1- 2-(S)- (1,1-Dimethylethoxy)carbonyl!amino!-3-(S)-methylpentyl!-L-homoproline 1-(S)- 2'-(S)-methylpropyl!-3-phenylpropylamide
To a round bottomed flask equipped with a magnetic stirrer was added 1- 2-(S)- (1,1-dimethylethoxy)carbonyl!amino!-3-(S)-methylpentyl!-L-homoproline 1-(S)- 2'-(S)-methylpropyl!-3-phenylprop-2E-enylamide (24 mg ), 10% Pd/C (3 mg) and methanol (5 mL). The reaction was hydrogenated at 1 atmosphere hydrogen gas for 2 hours, filtered and evaporated under reduced pressure to provide 23 mg (95%) of the title compound. The 1 H NMR and Mass spectrum analysis of this compound was consistent with the structure.
Rf=0.50 (50% EtOAc in hexane). LSIMS=502; (mass calculated for C 30 H 51 N 3 O 3 =501.73).
EXAMPLE 28 ##STR47##
1- 2-(S)- (1,1-dimethylethoxy)carbonyl!amino!-4-methylpentyl!-L-homoproline 1-(S)- 2'-(S)-methylpropyl!-3-phenylprop-2E-enylamide
Using the procedure described in example 2c, 1- 2-(S)- (1,1-dimethylethoxy)carbonyl!amino!-4-methylpentyl!-L-homoproline (229 mg), trans 1-phenyl-3-(S)-amino-4-(S)-methylhexa-1-ene (156 mg) were dissolved up in anhydrous CH 2 Cl 2 (2 mL). The flask was cooled to 4° C. and triethylamine (584 uL) was added followed by the addition of n-propylphosphonic acid cyclic anhydride (1.4 mL of a 1 N solution in anhydrous CH 2 Cl 2 ). The reaction was stirred 30 minutes at 4° C., then warmed to 20° C. and stirred at this temperature for 12 hours. The reaction mixture was washed with satd aq NaHCO 3 , satd aq NaCl, dried (MgSO 4 ) and evaporated under reduced pressure. The crude reaction was chromatographed with acidic silica to provide 106 mg (30%) of the title compound. The 1 H NMR and Mass spectrum analysis of this compound was consistent with the structure.
Rf=0.73 (EtOAc). LSIMS=500; (mass calculated for C 30 H 49 N 3 O 3 =499.71).
EXAMPLE 29 ##STR48##
1- 2-(S)- (1,1-Dimethylethoxy)carbonyl!amino!-4-methylpentyl!-L-hoznoproline 1-(S)- 2'-(S)-methylpropyl!-3-phenylpropylamide
Using the procedure described in example 27, hydrogenation of 1- 2-(S)- (1,1-dimethylethoxy)carbonyl!-amino!-4-methylpentyl!-L-homoproline 1-(S)- 2'-(S)-methylpropyl!-3-phenylprop-2E-enylamide. (45 mg) provided 45 mg (99%) of the title compound. The 1 H NMR and Mass spectrum analysis of this compound was consistent with the structure.
Rf=0.71 (EtOAc). LSIMS=502; (mass calculated for C 30 H 51 N 3 O 3 =01.73).
The immunosuppressive properties of the present compounds were evaluated in the following assays:
1) Inhibition of PPIase Activity
This assay follows in principle the procedure described in Kofron et al., 1991, Biochemistry 30:6127. The three main reagents used are PPIase, a substrate for PPIase, and a selected inhibitor compound of the present invention. The basic principle behind this assay is the conversion of the cis isomer of the substrate to the trans form, which conversion is catalyzed by PPIase. Essentially, inhibition of this PPIase activity is measured for the selected compounds. A peptide chymotrypsin substrate containing a proline in the P2 position is only cleaved by chymotrypsin when the Phe-Pro bond is in the trans isomeric configuration. In the presence of excess chymotrypsin, all of the trans peptide isomers are cleaved within approximately five seconds, leaving only cis forms.
The cis peptide will spontaneously convert to the trans isomer at a slow rate. The cis to trans conversion is catalyzed by isomerases at a much faster rate than this spontaneous conversion. Proteins with PPIase activity are examples of such isomerases. After isomerization, the peptide is cleaved by chymotrypsin releasing p-nitroaniline which can be monitored at 390 nm. The rate of release is then calculated using a first order rate plus offset equation utilizing the ENZFITTER program (Leatherbarrow, BIOSOFT, Cambridge, United Kingdom).
EXAMPLE 30
PPIase Inhibition Assay
In a plastic cuvette are added 950 ul of ice cold assay buffer (25 mM HEPES, pH 7.8, 100 mM NaCl), 10 uL of FKBP (2.5 u in 10 mM Tris-Cl pH 7.5,100 mM NaCl, 1 mM dithiothreitol), 25 ul of chymotrypsin (50 mg/ml in 1 mM HCl) and 10 ul of the test compound at various concentrations in dimethyl sulphoxide. The reaction is initiated by addition of 5 ul of substrate (Succinyl-Ala-Phe-Pro-Phe-para-nitroanilide, 5 mg/ml in 235 mM LiCl in trifluoroethanol).
The absorbance at 390 nm versus time is monitored for 90 sec using a Beckman DU70 spectrophotometer. The absorbance versus time data files are transferred to an IBM XT computer and the rate constants determined using the commercial Enzfitter program. For each set of data, the uncatalyzed rate of conversion is measured and the uninhibited enzymatic rate determined. The data are expressed as % Inhibition and are calculated as follows: ##EQU1## where k obs is the rate in the presence of a selected test compound, k uncat is the rate in the absence of enzyme, and k uninh is the rate in the presence of enzyme and absence of inhibitor. Data are plotted as percent inhibition versus concentration of inhibitor.
The values of the concentration of inhibitor required for 50% inhibition of enzyme activity (IC 50 ) were determined by nonlinear least squares regression analysis.
TABLE 1______________________________________ FKBP IC.sub.50Example No. (μM)______________________________________ 1 >5 2 >5 3 >5 4 >5 5 0.17 6 >5 7 6.5 8 >5 9 >510 >511 >512 >513 >514 >515 >516 >517 >518 >519 3.320 >521 >522 >523 2.224 >525 >526 >527 >528 >529 >5______________________________________
Results: The results of the compound testing are presented in Table1, above. As stated previously, it was not initially apparent whether or not inhibition of PPIase activity was necessary and sufficient for immunosuppression. Presently, the prevailing thought is that binding to the PPIase enzyme may be necessary but is not sufficient. Therefore, the data on PPIase inhibition may be viewed as an assay to detect whether or not a given compound is capable of interacting productively with FKBP.
2) Human T Lymphocyte Inhibition
Inhibition of mitogen-induced T-cell proliferation can be used to profile immunosuppressive activity of test compounds. In the description of the assay which follows, mitogen-induced T-cell proliferation was used to test the inhibitory potencies of select compounds of the present invention.
In an assay similar to that described by Bradley in Mishell et al. (Eds.), 1980, Selected Methods in Cellular Immunology, pp 156-161, W.H. Freeman & Co., San Fransisco, Calif., T-cells were stimulated by incubation with phytohemagglutinin (PHA) which binds to cell surface molecules, including the T-cell receptor. This stimulation results in proliferation which can be measured by incorporation of 3 H!-thymidine into cellular DNA.
The immunosuppressive properties of the compounds of the present invention can be determined by adding various concentrations of the compounds to these cultures and measuring the effect on T-cell proliferation.
EXAMPLE 31
Suppression of Human T-Cell Proliferation Assay
Fresh LeukoPaks were obtained from the New York Blood Center, New York, N.Y. The cells, including erythrocytes and leukocytes, were diluted with Hank's Balanced Salt Solution (HBSS) (GIBCO, Grand Island, N.Y.) and layered over Lymphoprep (Nycomed Pharma AS, Oslo, Norway) in sterile 50 ml conical centrifuge tubes. Lymphocytes were isolated at the Hank's/Nycomed interface after centrifugation at 2000×g, 4° C. for 15 min. The lymphocytes were washed with Minimal Essential Medium (GIBCO) containing 2% fetal bovine serum (FBS) (Sigma Chemical Co., St. Louis, Mo.), 1% HEPES buffer (GIBCO) and 1% Penicillin-Stretomycin solution (GIBCO).
T-cells were further purified essentially by sheep erythrocyte (SRBC) rosetting as described by Morimoto et al., 1983, J. Immunol. 130:157. The isolated lymphocytes were adjusted to 2×10 7 cells/ml and 5 ml aliquots of the cell suspension were incubated for 10 minutes at room temperature with 5 ml of a 5% SRBC (Cappel, Organon Technika Corp., West Chester, Pa.) suspension. The cells were gently pelleted by centrifugation at 300 rpm for 10 minutes, followed by a 1 hour incubation at room temperature to allow rosette formation. The cells were gently resuspended, layered over Lymphoprep and centrifuged for 30 minutes at 500×g. The pellet, containing rosetted T-cells and SRBC was treated with ice cold buffered ammonium chloride (GIBCO) to lyse the erythrocytes. T-cells were washed twice with HBSS.
Purified T-cells were resuspended at 2×10 6 cells/ml in complete culture medium composed of RPMI-1640 (Whittaker Bioproducts, Walkerville, Md.) with 10% FBS (Sigma), 2 mM L-glutamine (GIBCO), 1% Penicillin-Streptomycin (GIBCO) and 15 mM HEPES (GIBCO). In 96-well plates (Becton Dickinson, Lincoln Park, N.J.), 0.1 ml aliquots of T-cell suspension were mixed with 0.05 ml of 40 μg/ml PHA-M (Sigma). The compounds of this invention were dissolved in dimethylsulfoxide at 10 mM and various dilutions in complete medium were added in duplicate wells (0.05 ml/well). The plates were incubated at 37° C. in a humidified atmosphere of 5% carbon dioxide and 95% air for 72 hours.
Proliferation was assessed by measurement of 3 H!-thymidine incorporation. During the last 6 hours of incubation, the cells were pulse labelled with 1 μCi/well of 3 H!-thymidine (New England Nuclear, Boston, Mass.). The cells were harvested onto glass fiber paper using a plate harvester and the radioactivity incorporated into cellular DNA corresponding to individual wells was measured by standard liquid scintillation counting methods. The mean counts per minute (CPM) of replicate wells was calculated and linear regression analysis of mean CPM versus compound concentration was used to determine the concentration of compound which would inhibit 3 H!-thymidine incorporation of T-cells by 50% (IC 50 ).
The results of this assay, presented in Table 2, are representative of the intrinsic immunosuppresive activity of the compounds of the present invention. Thus, concentrations less than 10 μM of some of the preferred compounds suppress the T-cell proliferative response by 50%.
TABLE 2______________________________________ Example No. IC.sub.50 (μM)______________________________________ 1 >15 2 2 3 8 4 9 5 6 6 4 7 5 8 3 9 5 10 4 11 3 12 ND 13 3 14 2 15 7 16 >16.5 17 5 18 4 19 10 20 7 21 6 22 6 23 6 24 4 25 3 26 7 27 4 28 4 29 4______________________________________ where ND means "not determined
3) NF-AT Assay
Stimulation of T-cells leads to the appearance of several transcription factors, including one designated "NF-AT". These factors are involved in regulation of gene expression required for immunologic activation. Some of these transcription factors appear to have functions in a wide variety of cell types. By contrast, NF-AT is found primarily in T-cells and its role is restricted to early gene activation. In addition, NF-AT activity is inhibited by the immunosuppressant drugs, Cyclosporin A and FK506 (Schreiber and Crabtree, 1992, Immunology Today 13:136).
Inhibition of NF-AT activity is measured using FGL-5 cells. FGL-5 is a cloned line of stably transfected Jurkat T-cells that contain a construct in which three tandem copies of the NF-AT DNA binding site direct transcription of the lacZ gene, encoding β-galactosidase (Fiering et al., 1990, Genes & Development 4:1823). When these cells are stimulated with phorbol esters which activate protein kinase C and calcium ionophore to raise the intracellular calcium concentration, transcriptionally active NF-AT is produced. In T-cells, this normally leads to the expression of IL-2, T-cell growth factor. However, in FGL-5 cells NF-AT activation leads to the production of β-galactosidase which can be detected using an appropriate substrate.
FGL-5 cells were cultured with phorbol ester, calcium ionophore and the compounds of the present invention to measure inhibition of β-galactosidase activity, as shown below.
EXAMPLE 32
NF-AT Inhibition Assay Directed β-Galactosidase Expression
This assay was performed essentially as described (Bierer et al., 1990, Proc. Natl. Acad. Sci. 87:9231). FGL-5 cells were maintained in medium consisting of RPMI-1640 with 10% FBS, 2 mM L-glutamine, 1% Penicillin-Streptomycin and 15 mM HEPES buffer. The assays were done with exponentially growing cells whose density was not greater than 0.5 million cells/ml. The cells were resuspended to 3 million cells/ml in medium and 0. 1 ml was added to wells of a 96-well plate.
The compounds of the present invention were dissolved in either ethanol or dimethylsulfoxide at 10 mM and 0.05 ml/well of various dilutions in medium were added to cells in duplicate wells. Treatment controls consisted of duplicate wells to which 0.05 ml/well of either medium, ethanol or dimethylsulfoxide was added. The ethanol and dimethyl sulfoxide were at the same concentration as was used for the compounds. Cells were incubated with compounds at room temperature for 10-15 minutes. Phorbol dibutyrate (Sigma) and Ionomycin (Calbiochem) were dissolved at 50 μg g/ml and 2 mM, respectively and stored at -70° C.
FGL-5 cells were stimulated by diluting these reagents with medium to 200 ng/ml and 8 μM, respectively and adding of 0.05 ml/well. For unstimulated cell controls, 0.05 ml/well of medium was added to duplicate wells. The plates were incubated overnight (16-18 hours) at 37° C. in a humidified atmosphere of 5% CO 2 and air.
β-galactosidase activity was measured as the fluorescence generated by the cleavage of 4-methyl unbelliferyl-β-D-galactoside (Sigma) at the β-galactoside bond. After overnight incubation, the cells were centrifuged at 500×g for 3 minutes in the 96-well plates and washed 3 times with PBS. The cells were then resuspended in 0.18 ml/well of reaction medium containing 100 mM sodium phosphate buffer, pH 7.0, 10 mM potassium chloride, 1 mM magnesium sulfate, 0.1% Triton X-100 (Pierce, Rockford, Ill.), and 0.5 mM 4-methylumbelliferyl-β-D-galactoside.
The fluorescence at 460 nm using 355 nm excitation was measured at intervals over 1-2 hours (during which fluorescence increased linearly with time) with a LS50 Luminescence Spectrometer (Perkin Elmer).
The percent inhibition by each concentration of the compounds was calculated as: ##EQU2##
The values of the concentration of compounds required for 50% inhibition (IC 50 ) were determined by linear regression analysis of the percent inhibition at various compound concentrations.
The results of this assay presented in Table 3 are representative of the intrinsic immunosuppresive activity of the compounds of the present invention. Compounds that inhibited NF-AT directed β-galactosidase expression by stimulated FGL-5 cells with IC 50 of 10 μM or less also inhibited mitogen induced T-cell proliferation, e.g., compounds of Example No. 11.
TABLE 3______________________________________ Example No. IC.sub.50 (μM)______________________________________ 1 13 2 >15 3 >15 4 >33 5 >33 6 27 7 32 8 >33 9 24 10 10 11 >33 12 ND 13 >33 14 >33 15 >33 16 >33 17 27 18 >33 19 >15 20 >15 21 >15 22 >15 23 >15 24 >15 25 >15 26 >15 27 >15 28 >15 29 >15______________________________________ where ND means "not determined
4) Adjvant Arthritis
Rats sensitized to mycobacterial antigens in Complete Freund's Adjuvant can develop a rapidly destructive adjuvant arthritis. Adjuvant arthritis appears to be an autoimmune disease. Thus, T lymphocytes from immunized donors can transfer the disease to naive recipients (Pearson and Wood, 1964, J. Exp. Med. 120:547.) and susceptibility is controlled, at least in part, by class II MHC genes (Batisto, et al. 1982, Arthritis Rheum. 25:1194). The induction of adjuvant arthritis can be inhibited by immunosuppressant drugs, e.g., Cyclosporin A (Borel, et al., 1976, Agents and Actions. 6:468) and azaspiranes (Badger, et al. 1989, Int. J. Immunopharmac. 11:839)
EXAMPLE 35
Adjuvant Arthritis Model in the Rat
Complete Freund's adjuvant is made by supplementing extra heavy mineral oil with 10 mg/ml heat killed Mycobacterium butyricum (Difco Laboratories, Detroit, Mich.). Lewis rats (Charles Rivers, Willmington, Mass.) are given a 0.1 ml injection of adjuvant (1 mg/animal mycobacterium) subcutaneously into the right hind footpad. In the injected foot, an acute inflammatory reaction occurs which is characterized by erythema, edema and a predominantly neutrophilic cell infiltrate. This is followed by edema in the uninjected contralateral foot by days 10-12. This secondary response is accompanied by a predominantly mononuclear cell infiltrate, indicating the presence of cell-mediated immunity.
The immune response is quantitated by measuring the change in ankle diameter of the uninjected hind paw from day 0 to day 16 post sensitization. This is accomplished using a hand-held dial micrometer. Animals are administered test drugs, suspended in a vehicle consisting of 5% polyethylene glycol and 0.5% Tween-80 (Sigma Chemical Co., St. Louis, Mo.) in phosphate buffered saline (GIBCO, Grand Island, N.Y.), i.p. on days -1, 0, 2, 5, 7, 9, 12 and 14. Several compounds when administered at 10 mg/kg/dose inhibited the swelling in the uninjected limb compared with the control groups that were sensitized with Complete Freund's Adjuvant but received only the vehicle i.p. (Table 4).
TABLE 4______________________________________Compound ΔAnkle Diameter % Inhibition______________________________________None 3.3 ± 0.5 mm 0Example 10 2.3 ± 0.9 30______________________________________ | Compounds which suppress human T-lymphocyte proliferation are disclosed. The active compounds essentially contain at least the following structure: ##STR1## | 2 |
RELATED APPLICATIONS
[0001] The present application claims priority to and incorporates by reference U.S. Provisional Application No. 61/616,637 filed on Mar. 28, 2012.
BACKGROUND
[0002] 1. Field of the Invention
[0003] This invention relates to a method and apparatus for reading greens. In particular, the invention relates to a method and apparatus for reading greens utilizing a ball marker that includes indicia signifying a degree of slope, wherein a golfer can match the indicia on the ball marker to the actual slope conditions of a shot for the purpose of establishing the proper aim. Of course, a person of ordinary skill in the art will understand that the invention is not necessarily so limited.
[0004] 2. Background of the Invention
[0005] Golf is an extremely popular sport worldwide. The popularity stems from a variety of reasons, including the difficulty of the game. Golfers of all levels enjoy the challenge of the game, which requires development of both athletic ability and mental acuity. This is no more apparent than in what is termed the short game, comprising chipping and putting.
[0006] Again, a wide variety of factors contribute to a successful short game. These include club selection, technical mechanics, gauging how hard to hit the ball (or touch), the type of surface, the geometric variability and orientation of the surface, among other factors. Each of these factors requires an understanding of the interaction between the club, the ball, and the surface which the ball contacts.
[0007] The geometric variability and orientation of the surface is one the most important factors, and one of the most difficult to understand. This factor is commonly referred to as the slope of the green, and it is critical to a short game, and especially for putting where the ball is influenced by the slope the entire time the ball is in motion. The process of evaluating the effect of slope on the ball is called reading the green.
[0008] Greens often included a wide variety contours in a single green, which can make reading the greens troublesome. This is particular a problem for long putts, making them difficult to read. While reading the green is important for long putts, given that the likelihood of making such putts is relatively small, it is actually the shorter and more makeable putts where green reading is at a premium. For example, statistics show that professional touring golfers (the best golfers in the world) make about 50% of eight-foot puts, but only make about 10% of twenty-foot putts. In addition, the vast majority of putts tend to be from distance close to the hole. By some estimates, 75% of all putts are within 15 feet of the hole or less. Thus, it makes sense to focus on improving green reading skills for shorter putts, which are more frequent and which occur in an area that tends to be more uniform in terms of slope than longer putts, and which the player has a better chance of making
[0009] Most commonly, golfers, especially amateurs, read greens without any precise way to estimate the amount that that ball is going to break. They may be able to determine which direction is going to break, but hen typically rely on a gut instinct approach based on a feel for how much the putt is going to break. In some cases, they may use this approach to estimate the amount of break in inches and then adjust their aim accordingly.
[0010] Some prior art methods have used this approach in an attempt to add precision to the process, but they suffer from a number of drawbacks. For example, U.S. Pat. No. 7,988,572 discloses a putting guide and apparatus, which creates a chart comprised of a series of concentric circles that provide the amount of break in inches based on the distance from the hole. This method requires precise knowledge of not only the distance from the hole, but also speed of the green, the slope of the green, and the angle of the putt relative to the direction of the slope. This method requires a great deal or prior knowledge about the conditions of the putt, which is difficult for the golfer to estimate thereby introducing error. Also, the method does not provide any assistance to the golfer with another very difficult problem associated with putting and chipping, namely, aim.
[0011] Knowing the amount of break is a necessary condition to making a putt, but it is not sufficient. This information can allow the golfer to establish a target, but it is of no help if the golfer does not have a reliable way to aim the putt at the target. The prior art method described above does not provide any assistance in this regard, and it has been shown that golfers, including professional tour golfers, cannot repeatable align themselves to a given target whether that is with a driver, iron, or putter.
[0012] Accordingly, a need exists for an improved apparatus and method for determining the amount of break of a golf ball rolling on a surface and for aiming the ball based thereon.
SUMMARY OF THE INVENTION
[0013] An object of the present invention is to provide an improved apparatus and method for determining the amount of break of a golf ball rolling on a surface and for aiming the ball based thereon.
[0014] These and other objects of the present invention will become apparent to those skilled in the art upon reference to the following specification, drawings, and claims. To that end, the present invention comprises a method and apparatus read the break in a surface and adjust aim accordingly. The method utilizes a green key ball marker comprising indicia of slope, and describes how to determine slope. The marker then allows for quantifying break and provides alignment assistance.
BRIEF DESCRIPTION OF DRAWINGS
[0015] FIG. 1 is shows the 9 down green key ball marker.
[0016] FIG. 2 is shows the 9 up green key ball marker.
[0017] FIG. 3 is shows the 10 down green key ball marker.
[0018] FIG. 4 is shows the 10 up green key ball marker.
[0019] FIG. 5 is shows the 11 down green key ball marker.
[0020] FIG. 6 is shows the 11 up green key ball marker.
[0021] FIG. 7 is shows the 12 down green key ball marker.
[0022] FIG. 8 is shows the 12 up green key ball marker.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0023] The present invention is comprised of both a method and an apparatus for implementation of the method. The method is comprised generally of four phases, wherein each phase is comprised of several steps. The phases are: 1) preparation and prediction; 2) decision and problem solving; 3) execution; and 4) feedback.
[0024] At this point, it is advisable to discuss what is meant by slope, which may also be referred to as grade, incline, gradient, pitch, or rise. In mathematical terms slope is a calculation that represents the ratio of “rise “to” run or as a fraction of rise over run, in which run is the horizontal distance and rise is the vertical distance (negative or positive). Slope can be described as an angle of inclination to the horizontal, as a percentage (the formula 100*[rise/run]), as a per mille figure, or as a ratio of one part rise to so many parts run. Unless described differently herein, slope is referenced as a percentage between 0%-100%, where the higher number the greater the vertical inclination. A common rule of thumb for conceptualize slope is that over a 100″ run (approximately 8′), every inch of elevation change represents 1% of slope.
[0025] Typically, greens are in the range of 1-4% of slope, in fact regulations require the hole not be placed in an area of excessive slope, defined as such a slope that would prevent a ball from coming to a rest on the slope. If the slope is too large the ball will not stop, or will stop and then roll backwards, depending on the direction of movement of the ball relative to the slope. Generally, this means that the golf balls rolling on a green will encounter a slope of between 1-4%, usually between 1-3%. Larger slopes do exist, and while the ball may have to roll on such slopes, the hole should not be located on these slopes.
[0026] The preparation and prediction phase begins with a general assessment of the surface, normally a golf green. It is important to note that all greens have some slope or gradient to them, as they essentially cannot be flat. This would prevent adequate drainage, and would promote standing water that is harmful to the green as well as an obstacle to play. It is possible that some small areas of a green may be flat, usually not be design by more likely because of soil compaction or settling, this is not common and is typically to be avoided.
[0027] Thus, all greens are sloped in general. The assessment of slope is visual, and should be made in reference to certain anchor points. The anchor points are the highest and lowest elevation points in the area around the ball. Generally, the area to assess is a circle centered at the hole with a radius equal to the distance from the hole to the ball. The larger the area the easier it is to see the amount of rise, however, if the area is too large the slope may vary making the assessment more difficult. The anchor points should not only help in establishing the amount of rise, but also in establishing the direction of the slope. The direction of slope (or fall line) should run from the high point to the low point.
[0028] The next step in preparation and prediction phase is a further assessment of green shape to look for concave or convex areas in the general area between the hole and the ball. It may be necessary to locate multiple anchor points if the slope is not consistent in the relevant area. The slope may vary between a positive or negative value, or there might be areas of zero slope, for example. In this case, anchor points should be selected for each area of distinct slope, working from the hole outward.
[0029] The next step in the process is to visually locate an inflection point that is closest to the ball. The inflection points can be visualized based a circle with a radius equal to the distance from the ball to the hole, with the 12 o'clock position being the highest anchor point and the 6 o'clock position the lowest anchor point. These are the inflection points. The points where the putt would be either straight downhill (12 o'clock) or straight uphill (6 o'clock), virtually no break would be expected in either case. Break would increase as you move away from the infliction point. Estimating the location of the ball, as a point on a clock or in degrees (0-360), relative to the infliction point is necessary to understand the amount of break.
[0030] The next step is to estimate the slope. Assuming the ball is located on a relatively uniform slope, which is normally the case given that hole locations are suppose to placed in relatively uniform sections of the green. The best reference point for determining slope are the infliction points, and the best distance for estimating slope is an 8′ (100″) section because every inch of elevation change over 8′ equals 1 degree of slope.
[0031] The preparation and prediction phase is now complete and the decision and problem-solving phase begins. The first step in this phase is to confirm the information from the prior phase. This involves walking around the circle described above to confirm the location of the inflection points. Walking around a round the circle from one infliction point to the next provides visual confirmation from differing perspectives that the infliction points were correctly identified. Additionally, it allows the golfer to confirm what they are seeing with what they feel in terms of elevation change as they walk. If the inflection points were not correctly identified the prior phase should be repeated until all sources of input agree.
[0032] During this process, the position of the ball relative to the infliction points should also be confirmed. The position can be determined based on a clock position relative to the infliction point, or an angle with the highest elevation inflection point as 0°/360° and the lowest elevation inflection point as 180° (this is discussed in greater detail herein below).
[0033] Next, the ball location is marked with the green key ball marker and properly aligned, which is described herein below. After marking the ball, the line on the ball can be aligned to the green key ball marker. Most if not all golf balls include circumferential writing on a portion of the ball that can be used as alignment aid. The golfer can simply line up the line on the ball with the angle line on the maker. Also, the golfers can draw lines, or other markings, on the golf balls for the same purpose.
[0034] Furthermore, the golfer can line up any markings on the golf club with the lines on the ball, and/or on the green key ball marker. Such markings are common on putters, for example. This completes the decision and problem-solving phase.
[0035] The next phase is the execution phase, where the golfer executes the shot. Now that the golfer has established a target line, the next step is to commit to the line. In other words, the golfer needs to be convinced that they have selected the proper line, and have properly aligned themselves and the club to the line. Uncertainty can translate into unwanted and harmful adjustments during actual stroke execution. The final step in the execution phase is to complete the golfer's particular pre-shot routine, which may consist of practice strokes a final look at the hole to verify alignment and other routines that might assist the golfer in getting comfortable with the shot. Lastly, the shot is executed.
[0036] The last phase is the feedback phase. In this phase, the golfer can evaluate the results to determine what went right and wrong to enhance future performance. A first feedback step is assess whether the gofer say an afterglow or shadow image of the ball after the stroke. If the golfer is properly focused on the ball, a ghost image of the ball should remain and be visible for a brief period of time after the ball has been struck. If not, this is a sign that the player was not properly focused on the ball prior to impact.
[0037] Another feedback step is to assess whether the golfer's intention with regard to the stroke was clear. This involves assessing whether the golfer had visualized a clear path to the hole that the ball would follow, and did the ball follow the correct path. Other feedback steps include assessing the length of the putt, was it too short or too long. This will help the player determine if the ball was struck with the proper force. Generally, a golfer should strike every putt so that the ball travels about the same distance past the hole, preferably 6 to 12 inches past the hole. Putts hit slower than this will be excessively influenced by the slope at the hole where the ball is traveling at its slowest speed. Putts that travel further than this past the hole will have less chance of going in as they can roll over the edge of the hole without going in, or simply go right over the hole altogether. The golfer should analyze the path of the ball in relation to the expected path to determine if slope was properly estimated.
[0038] In the Figures is shown the green key ball marker. FIG. 1 shows a green key marker, or marker, which comprises a four-sided ball marker with varying angle indicator lines on each side of the mark. Each side of the mark includes a centerline that should be lined up directly with the hole, without regard to the where the ball is in relation to the slope. Then the player will align the shot to the angle line on the marker that best matches the estimated slope and other variables determined in accord with the process set forth herein.
[0039] As stated above, the line on the ball is then aligned to the appropriate angle line. The player takes a stance generally parallel to the appropriate angle line, and any markings on the club can as also be aligned with the appropriate angle line. The marker can be removed after the ball is aligned.
[0040] In particular, FIG. 1 shows the green key ball marker having four sets of angle lines. One set of lines on each of the four sides of the marker. Starting from the bottom of the marker and moving clockwise, each set of angle lines represents an amount of break for a slope of 1%, 2%, 3%, and 4%.
[0041] In other words, if a golfer determines they are on a 1% slope they would use the angle lines at the bottom of the marker. They would line the center line up directly at the hole and then line the ball up on the marking to the right or left or left of the center line depending on whether the putt is expected to break to the left or right respectively (if the putt breaks left you have to aim to the right and vice versa). This correlates to direction of the slope, the golfer should always use the uphill angle lines.
[0042] In all cases (except for the 1% angle lines), there are multiple angle lines on each side of the centerline on any given side of the marker. The exact angle line selected will depend on the where the putt is in relation to the fall line of the slope. Again the fall line is a line that runs directly from the high point of a slope to the low point, or the line which a ball or water would follow down the slope. Assuming a uniform slope, for purposes of illustration if the high point is the top (12 o'clock position or 0°), then the low point would be the bottom (6 o'clock or 180°). The particular angle line is selected based on where the ball is in relation to the 0° and 180° positions.
[0043] If the ball is exactly at the 0° or 180° position the putt is directly downhill or uphill respectively, and no break would be expected in either case. In this case, the golfer would set the marker so that the centerline is directly lined up with the hole, and use the centerline as the alignment line for the putt. As the ball moves away from 0° or 180° positions the ball will break more and more until the maximum break at or near the 90° or 270° positions (as discussed below this is not exactly accurate). Thus, as the position of the ball moves away from the 0° or 180° positions, the golfer uses the angle lines further away from the centerline.
[0044] In FIG. 1, if the slope is determined to be 2% the angle lines on the left side of the marker in FIG. 1 would be used. This marker is used for downhill putts (hence the “Down” on the marker). If the ball is located at 30° or 330° relative to the high point (or 0°) the angle lines closest to the centerline would be used. If the ball is located at 60° or 300° the outermost angle lines should be used. If the putt is located at 90° or 270° the marker in FIG. 2 (the “Up” marker) should be used and outermost angle lines should be used for alignment. Since a putt from 90° or 270° is neither uphill or downhill, (the putt is directly perpendicular to the slope and therefore has no elevation change), but will still break as it crosses the slope, either marker could be used; however, the present invention uses the up marker and for this reason all up markers have up to three sets of lines and all down markers only have up to two sets of angle lines. It should be noted that 1% slope is marked with one set of angle lines on either side of the center line because there is generally not enough room on the marker to place intermediate lines between the 1% line and the center line. If additional angle lines were used they would be so close to each other it becomes difficult for the golfer to select between them.
[0045] The various angle lines on the up markers are used in the same manner as described in reference to the down markers, and are aligned generally in 30° increments between until the ball is positioned directly 180° below the hole in which case the center line would be used.
[0046] The markers in the remaining Figures differ only in that they are designed for different speed of greens, based on the “stimp meter” readings. It is well known that the faster the green, the higher the stimp number, and the more the ball will break. The Figures show up/down markers for stimp values 9 , 10 , 11 , and 12 . The higher the stimp number the greater the spacing between the angle lines to represent more break. Generally, the stimp number for a golf course is known in advance and is available upon request.
[0047] As stated above, the maximum break is not necessarily expected to occur at the 90° or 270° points. This is because downhill putts tend to break more than uphill putts, for the same reason that putts break more on fast greens than on slow green. The slower the ball rolls the more time it takes to get to the hole and the more time there is for the slope to influence the ball. On a faster the surface (whether because it is downhill or a high stimp number) the more gently the ball must be struck to travel the same distance on a slower surface. Thus, the more time it takes the ball to arrive at the hole and the more it will break. For this reason, the spacing of the angle lines on the down markers is wider than on the down markers. This means the greatest break would occur slightly uphill from the 90° or 270° positions.
[0048] The exact spacing can be determined empirically, and/or through interpellation/extrapolation.
[0049] In this manner the system of the present invention substantially overcomes the limitations of the prior art. In particular, in prior systems the golfer determined the amount of break based on nothing but gut instinct, or in inches, however, this latter approach required precise knowledge of the distance from the hole since the amount of break in inches varies proportionally to the distance from the hole. The present invention eliminates these problems by only relying on slope, it does not matter how far the ball is from the hole once the slope is determined. The same angle line is used without regard to distance. Further, the prior art did not account for aim. Thus, even if the golfer could account for the amount of break in inches there was no assurance they would be able to line up properly. The present invention not only quantifies break, but provides for alignment as well.
[0050] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. Although methods and materials similar to or equivalent to those described herein can be used in the practice or testing of the present invention, suitable methods, and materials are described below. All publications, patent applications, patents, and other references mentioned herein are incorporated by reference in their entirety to the extent allowed by applicable law and regulations. In case of conflict, the present specification, including definitions, will control.
[0051] The present invention may be embodied in other specific forms without departing from the spirit or essential attributes thereof, and it is therefore desired that the present embodiment be considered in all respects as illustrative and not restrictive, reference being made to the appended claims rather than to the foregoing description to indicate the scope of the invention. Those of ordinary skill in the art that have the disclosure before them will be able to make modifications and variations therein without departing from the scope of the invention. For example, it should be clear that the method of the present invention can be used putts, chips, and other golf shots where the ball is rolling on a sloped surface for a substantial period of time, and for the same reason the invention is not necessarily limited to shots using a putter but other clubs can be included. Additionally, the angle line marking of the present invention can be adapted for use on the golf ball itself instead of, or in combination with the green key marker. In particular, golf balls are manufactured with dimples that are regularly spaced and therefore can be correlated to slope angles. The writing line on the ball can be used as the center line, and dimples immediately to the right and left of the line can be marked. Each dimple can then be correlated to the degree of slope and used as an aiming device in the manner of the green key marker. | A method and apparatus read the break in a surface and adjust aim accordingly. The method utilizes a green key ball marker comprising indicia of slope, and describes how to determine slope. The marker then allows for quantifying break and provides alignment assistance. | 0 |
CROSS-REFERENCE TO A RELATED APPLICATION
This application is a Continuation and claims priority of U.S. patent application Ser. No. 11/360,874, filed Feb. 23, 2006, now U.S. Pat. No. 7,157,804 B2, which is a Continuation of U.S. patent application Ser. No. 10/923,195, filed Aug. 20, 2004, now U.S. Pat. No. 7,095,133 B2, which claims priority of Japanese Patent Application Serial No. 2004-004900, filed on Jan. 13, 2004.
BACKGROUND OF THE INVENTION
The present invention relates to a rotating electrical machine control unit and power generation system, particular to a control unit and power generation system of a doubly-fed machine.
Doubly-fed machine has conventionally been used as the generator for an aerogeneration system. It is a generator-motor, equipped with 3-phase winding laid in slots provided at equal distance on the stator and rotor, that is operated at variable speed by applying variable-frequency alternating current power particularly to the secondary of the generator-motor. As disclosed in the Japanese Application Patent Laid-Open Publication No. Hei 05-284798 (hereinafter called the Patent Document 1), the doubly-fed machine like the above has a resolver for detecting a rotating position, slip frequency which is the differential between the primary frequency and secondary frequency is calculated, and the output is controlled by a power converter.
[Patent Document 1]
Japanese Application Patent Laid-Open Publication No. Hei 05-284798
SUMMARY OF THE INVENTION
According to the prior art, cost increase of the generator has been inevitable because of the necessity of resolver for detecting a rotating position, which is very expensive, and noise suppression of the rotating position signal line. In addition, the reliability is lower because of increased chances of failure. The present invention is capable of controlling a doubly-fed machine without using a rotor position sensor such as resolver, and accordingly cost increase due to the use of a rotor position sensor such as resolver in a doubly-fed machine can be prevented.
A characteristic of the present invention is to calculate a command value of the voltage to be applied to the rotor winding based on the voltage of the stator winding, current of the stator winding, and current of the rotor winding.
Another characteristic of the present invention is to calculate the information relating to the rotor position based on the voltage of the stator winding, current of the stator winding, and current of the rotor winding.
Other characteristics of the present invention are explained in detail hereunder.
According to the present invention, cost increase due to the use of a rotor position sensor such as resolver in a doubly-fed machine can be prevented.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagram showing a brief construction of an embodiment of the present invention.
FIG. 2 is a diagram showing an equivalent circuit of a doubly-fed machine.
FIG. 3 is a diagram showing vectors based on FIG. 2 .
FIG. 4 is a diagram showing part of a rotor position detector.
FIG. 5 is a diagram showing an embodiment of the generation system according to the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
An embodiment of the present invention is described hereunder, using figures. FIG. 1 is a diagram showing the overall construction of a doubly-fed machine drive system to which the present invention applies.
As shown in FIG. 1 , a doubly-fed machine 4 , mechanically connected with a power source 2 , is a generator-motor, equipped with 3-phase winding laid in slots provided at equal distance on the stator and rotor, that is operated at variable speed by applying variable-frequency alternating current power particularly to the secondary of the generator-motor, that is, a generator-motor which is controlled by comparing the primary voltage with a control variable in the alternating voltage control 44 so as to adjust the secondary voltage. The stator winding 5 of the doubly-fed machine 4 is connected to the electrical power system 1 via a switch 101 .
The rotor winding 6 of the doubly-fed machine 4 is electrically connected with an exciter 7 and the rotor winding 6 is alternatingly excited by the exciter 7 . The exciter 7 comprises an indirect alternating current converter, consisting of converter 8 and inverter 9 , which once converts alternating current power to direct current power and then converts the direct current power to the alternating power of desired frequency.
The converter 8 is controlled by a converter controlling apparatus 30 that generates a gate signal based on the electric power system voltage V 1 detected by a system voltage detector 21 , output voltage of the inverter 8 detected by a current detector 26 , and direct current voltage V dc of the exciter 7 .
The inverter 9 is driven by a gate signal generated by a PWM modulator 50 . This gate signal is generated in the circuitry explained below. The secondary current I 2 of the doubly-fed machine (current through the stator winding) detected by an exciting current detector 25 is converted into I α and I β by a 3-phase/2-phase converter 41 , and the d-axis current and q-axis current exhibited on a dq-axis rotating coordinate when the rotor position θ s obtained from a rotating position calculator 20 is transformed in terms of the coordinate by a rotating coordinate transformer 42 are called I d and I q , respectively. When the rotor position θ s is in the same phase as with the induced electromotive force due to slip, the d-axis current I d represents the excitation component and the q-axis current I q represents the torque component.
A practical manner for the above is to convert 3-phase secondary current I 2 (I 2u , I 2v , I 2w ) into (I α , I β , I 0 ) using Expression 1 below on the 2-phase winding (α, β, 0) of the rotor.
[
I
α
I
β
I
0
]
=
2
3
(
1
-
1
/
2
-
1
/
2
0
3
/
2
-
3
/
2
1
/
2
1
/
2
1
2
)
(
I
u
I
v
I
w
)
[
Epression
1
]
Next, based on Expression 2, (I α , I β , I 0 ) is transformed into a rotating coordinate (I d , I q , I 0 ) using the rotor position θ s . This is nothing but the definition of a general dq transformation.
[
I
d
I
q
I
0
]
=
2
3
(
cos
θ
s
-
sin
θ
s
0
sin
θs
-
cos
θ
s
0
0
0
1
)
(
I
α
I
β
I
0
)
[
Epression
2
]
The electric power system voltage V 1 detected by the system voltage detector 21 is changed into scalar V by a system voltage detector 43 , and the deviation between the voltage control command value V* and V is inputted into an alternating-current voltage controller 44 so as to obtain a d-axis current command value I d *. The alternating-current voltage controller 44 shall preferably be an ordinary PI controller.
The primary current I 1 of the doubly-fed machine 4 (current through the stator winding) detected by a primary current detector 22 and the electric power system voltage V 1 are changed into scalar power P by an effective power detector 45 , and the deviation between the power control command value P* and P* is inputted into an effective power controller 46 so as to obtain a q-axis current command value I q *. The effective power controller 46 shall preferably be an ordinal PI controller.
Each deviation between the d-axis current I d and d-axis current command value I d * and between the q-axis current I q and q-axis current command value I q * are inputted into a current controller 47 so as to obtain a d-axis voltage command value V d * and q-axis voltage command value V q *, respectively. The current controller 47 shall preferably be an ordinary PI controller.
From these voltage command values and rotating position θ s obtained from the rotating position calculator 20 , 2-phase voltage command values V α * and V β * are obtained respectively using an rotating coordinate inverse transformer 48 , and also 3-phase voltage command values V u *, V v *, and V w * are obtained respectively using a 2-phase/3-phase converter. To be concrete, an inverse transformation in Expression 1 and Expression 2 is performed, and then a dq transformation is performed.
The inverter 9 is controlled using these 3-phase voltage command values and gate signal generated by the PWM modulator 50 .
Description about the rotating position calculator 20 is given below, using FIG. 2 , FIG. 3 and FIG. 4 . In these figures, the same symbol is given to the same component/part as in FIG. 1 . FIG. 2 is an equivalent circuit of the doubly-fed machine 4 . The voltage equation of this equivalent circuit is expressed as in Expressions 3, 4, 5, and 6.
V 1 =( R 1 +jωL 1 ) İ 1 +ė 0 [Expression 3]
V′ 2 =ė 0 −( R′ 2 +jω S L′ 2 ) İ′ 2 [Expression 4]
e . 0 = R M j ω L M R M + j ω L M I . 0 [ Expression 5 ] İ 0 =İ′ 2 −İ 1 [Expression 6]
A symbol marked with dot “•” on its top is a scalar and marked with dash “′” is a primary conversion value. In the expressions, j is an imaginary unit, L 1 is inductance, R 1 is primary resistance, L 2 is secondary leak inductance, R 2 is secondary resistance, R M is no-load loss resistance, L M is excitation inductance, e 0 is induced electromotive force, I 0 is excitation current, ω is output frequency, and ω s is slip frequency. FIG. 3 shows the vector diagram of the equivalent circuit. Finding the slip frequency ω s enables to estimate the rotor position. The slip frequency ω s is obtained from Expressions 3 to 6 and expressed as in Expression 7.
ω
s
=
R
M
j
ω
L
M
R
M
+
j
ω
L
M
(
I
.
2
′
-
I
.
1
)
-
R
2
′
-
I
2
′
-
V
.
2
′
j
L
2
′
I
.
2
′
[
Expression
7
]
Accordingly, the slip frequency ω s can be obtained by inputting the detected electric power system voltage V 1 , primary current I 1 , secondary excitation voltage V 2 , secondary current I 2 and system frequency ω into the rotating position calculator 20 . When R<<L applies in Expressions 3 to 7, the primary resistance and secondary resistance can be neglected. A way for finding the slip frequency ω s using the secondary excitation voltage V 2 has been explained herein, but the voltage command values V u *, V v * and V w * can be used instead of the secondary excitation voltage V 2 .
In order to decide the initial value of the slip frequency θ s at the rotor position θ s in case the switch 101 is open, the transformation shown in FIG. 4 is performed. Firstly, position information is set to θ s0 by a time multiplier 201 . Then, from the electric power system voltage V 1 , voltage phase θ i is obtained by a phase detector 202 . The generator voltage V g are then converted into V α and V β by a 3-phase/2-phase converter 203 and, from these V α and V β and the voltage phase θ 1 , the d-axis voltage V d and q-axis voltage V q are obtained by a rotating coordinate transformer 204 . Since the q-axis voltage V q becomes zero if the electric power system voltage V 1 and generator voltage V g are at the same phase, it is compared with zero and the difference is inputted into a phase adjuster 205 . By adding/subtracting its output to/from the position information θ s0 , the phase of the rotor position θ s is adjusted and accordingly, as the electric power system voltage V 1 and generator voltage V g at the switch 101 become equal, the initial phase of the position information θ s 0 is decided. Then, when the switch 101 is closed, the output from the phase adjuster becomes zero because of V 1 =V g and accordingly the routine for deciding the initial phase does not work in the normal generation mode. θ s is decided as above.
FIG. 5 shows an embodiment wherein a windmill 501 is employed as the power source of the present invention. Power source of the invention may include wind power, hydraulic power, engine and turbine, but greater effect of the invention is expected in the case of aerogeneration system of which number of revolutions is very much variable.
According to the above embodiment of the present invention, wherein a doubly-fed machine is controlled without using a rotor position sensor such as resolver, it becomes possible to efficiently control the generator without using a rotor position sensor such as resolver on the doubly-fed machine, and accordingly cost increase of a rotating machine can be prevented. In addition, any noise suppression means is not necessary for the rotor position sensor. | Because of the necessity of resolver for detecting a rotating position, which is very expensive, and noise suppression of the rotating position signal line on a doubly-fed machine, cost increase of the generator and reduced reliability due to possible failures are inevitable. In order to solve such problem, a generation system in the present invention is equipped with an exciter that estimates the slip frequency of the doubly-fed machine from each primary current I 1 and voltage V 1 and secondary current I 2 and voltage V 2 of the doubly-fed machine and excites the secondary of the doubly-fed machine at the estimated slip frequency. | 7 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a divisional of the U.S. application Ser. No. 12/869,066, filed on Aug. 26, 2010, entitled “Faux Wood Building Materials And Articles Therefrom,” the disclosure of which is incorporated herein by reference. This application claims the benefit of the filing date of the U.S. Provisional Patent Application No. 61/275,191, filed Aug. 26, 2009, entitled “Faux Wood Building Materials,” the disclosure of which is hereby incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] The present invention relates in general to faux wood building materials, and more particularly, to building materials formed from synthetic polymer materials having an appearance which simulate natural woods.
[0003] Natural wood, due to its strength and aesthetic characteristics has been used in the construction of various products for both indoor and outdoor application. For example, wood such as oak, maple and pine have been used for indoor cabinetry, flooring material, furniture products and other items. Cedar and teak have found applications for patio furniture for both indoor and outdoor use. Natural wood is a versatile product that has extensive applications for construction of fences, sheds, decking material, indoor/outdoor furniture, railings and numerous other products.
[0004] Natural wood is a highly desirable building material for various products due to its richness. However, some woods are less suitable for certain products and use in outdoor environments which are subject to wet conditions. For example, teak and cedar are commonly used for outdoor furniture due to their weather resistance characteristics. However, even these wood products are susceptible to discoloration, splitting and other effects caused by the outdoor environment. In addition, woods like teak are expensive and are environmentally protected in certain regions.
[0005] Various synthetic polymers have been extruded or molded into flat boards for use in the construction of outdoor furniture, such as Adirondack chairs, picnic tables, picnic benches and other outdoor products. However, the constructions of these products from synthetic polymer material evidences a synthetic plastic look which is less attractive compared to natural wood materials.
[0006] There is therefore a need for the construction of synthetic plastic material which simulates natural wood to provide the richness and desirable aesthetic characteristics of wood products.
BRIEF SUMMARY OF THE INVENTION
[0007] The present invention describes a synthetic polymer building material which simulates a wood product, yet due to its synthetic nature, is suitable for outdoor use in harsh environments such as sun, rain and snow.
[0008] The material of the present invention can be formed from a number of synthetic polymer materials which can easily be fabricated into various shapes such as elongated boards, as well as other geometric shapes such as oval, polygonal, circular and the like. The materials incorporate reinforcement elements such as fibers to enhance the mechanical strength of the resulting product. To decrease the weight of the materials, a blowing agent is blended with the synthetic material during the manufacturing process. The blowing agent in addition to creating voids within the material, may also have the effect of forming a slightly uneven exterior surface which enhances the natural appearance or wood simulating effect of the material.
[0009] The polymers may include various color components which result in the material having a solid color or other effects such as marble look, striations or the like. In the preferred embodiment, the resulting product is coated with a color wash of suitable synthetic polymer material which bonds to the base material. The wash may be applied uniformly, randomly or selectively to create various aesthetic effects.
[0010] In one embodiment of the present invention there is described an article of furniture comprising a frame comprising a body of synthetic polymer material having reinforcement elements dispersed therein, and a plurality of voids within the body whereby the weight of the frame is reduced; and a seat portion coupled to the frame for supporting an occupant.
[0011] The article of furniture further includes a backrest portion coupled to the frame, wherein at least one of the seat portion or the backrest portion comprises a woven panel from a plurality of synthetic polymer yarns. The article further includes a wash having a polymer component and a color component adhered to at least a portion of a surface of the frame. The plurality of voids reduces the weight of the frame by about 10% or greater.
[0012] In another embodiment of the present invention there is described an article of furniture including recycled scrap synthetic polymer material, comprising a frame in the shape of an article of furniture comprising a body of synthetic polymer material having reinforcement elements dispersed therethrough, a plurality of voids within the body whereby the weight of the frame is reduced; and a portion of the synthetic polymer material made from recycled scrap synthetic polymer material having the reinforced elements dispersed therethrough and the plurality of voids therein.
[0013] In another embodiment of the present invention there is described an article of furniture comprising a frame comprising a body of synthetic polymer material having reinforced fibers dispersed therethrough, a plurality of voids within the body whereby the weight of the frame is reduced by about 10% or greater, and a wash having a polymer component and a color component adhered to at least a surface of the frame; a seat portion coupled to the frame for supporting an occupant; and a backseat portion coupled to the frame, at least one of the seat portion or the backrest portion comprising a woven panel from a plurality of synthetic polymer yarns.
[0014] The article of furniture where the color of the frame is different from the color of the color component; and wherein the seat portion and the backrest portion are formed as a bucket seat attached to the frame.
[0015] In another embodiment of the present invention there is described a building material comprising a body of synthetic polymer material having reinforcement fibers disbursed therein; a plurality of voids within the body whereby the weight of the body is reduced by at least 10%; and a wash having a polymer component and a color component adhered to at least a portion of the body.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] The subject matter regarded as the invention is particularly pointed out and distinctly claimed in the concluding portion of the specification. The invention, however, both as to organization and method of operation, together with features, objects, and advantages thereof may best be understood by reference to the following detailed description when read with the accompanying drawings in which:
[0017] FIG. 1 is a perspective view of a segment of a building material in the nature of simulated wood plank or board constructed in accordance with one embodiment of the present invention.
[0018] FIGS. 2A and 2B are perspective views of a segment of a building material in the nature of a simulated wood plank or board constructed in accordance with other embodiments of the present invention.
[0019] FIG. 3 is a perspective view of an outdoor storage chest constructed from the materials of the present invention in accordance with one embodiment thereof.
[0020] FIG. 4 is a perspective view of an article of furniture constructed from the materials of the present invention in accordance with one embodiment thereof.
DETAILED DESCRIPTION
[0021] In describing the preferred embodiments of the invention illustrated in the drawings, specific terminology will be used for the sake of clarity. However, the invention is not intended to be limited to the specific terms so selected, and it is to be understood that each specific term includes all technical equivalents that operate in a similar manner to accomplish a similar purpose.
[0022] Referring to the drawings, wherein like reference numerals represents like elements, there is shown in FIG. 1 a section of an elongated board or plank constructed in accordance with one embodiment of the present invention, and designated generally as reference numeral 100 . The board 100 is formed from synthetic polymer material and mixture thereof which possesses suitable characteristics for its intended use. For example, for various applications such as indoor and outdoor furniture, thermoplastic materials such as polystyrene, polyvinyl chloride, polyethylene and polypropylene are contemplated. The preferred material is polystyrene. The board 100 can be made using conventional die extrusion techniques. It is also contemplated that thermoset polymer materials may be used for creating objects that can be molded into predetermined shapes. Thus, it should be understood that a wide variety of synthetic polymer materials may be used in constructing the materials of the present invention.
[0023] To provide additional mechanical strength, the polymer material may be mixed with reinforcement elements such as fibers 102 as is known in the art of reinforcement of synthetic polymers. The fibers can be constructed as short elongated segments in the nature of fine filaments, or other desirable forms as is known in the reinforcement of synthetic polymers. The fibers can be constructed from a variety of materials, for example, synthetic polymers, fiberglass, carbon, metal and the like. The percentage of loading of the material with the fibers will be dictated by the polymer material composition, as well as the intended application for the finished material, and the load bearing and mechanical strength requirements.
[0024] In manufacturing the board 100 , a blowing agent is also included in order to form voids within the material thereby reducing weight. Blowing agents are commonly used for this purpose as is known in the synthetic polymer processing industry. Suitable blowing agents and their use are known in the polymer arts. The amount of the blowing agent is generally sufficient to reduce the weight of the material by, for example, about 10% or greater. As the amount of voids within the material decreases the mechanical strength, the amount of blowing agent used will be dependent upon the mechanical strength required of the resulting material based on its intended application.
[0025] As shown in FIG. 1 , the blowing agent forms voids 104 within the cross-section of the material, and potentially small pits 106 randomly dispersed on the exterior surface of the finished board 100 . In addition, it is contemplated that the blowing agent may result in the surface 108 of the board 100 to have a slightly irregular planar surface. It is also contemplated that some of the fibers 102 may be visible randomly across the surface of the board 100 . Thus, depending upon on the loading extent of the fibers 102 and the extent of the blowing agent, fibers 102 and pits 106 may or may not appear on the surface of the board 100 . Likewise, the extent of the unevenness or irregularity of the surface of the board 100 will be dependent upon the extent of the blowing agent used.
[0026] Referring to FIG. 2A , there is illustrated a board 108 constructed in accordance with another embodiment of the present invention. The board 108 differs from the board 100 by the inclusion of a wash 110 over the exterior surfaces of the board to provide a more faux wood appearance. The wash 110 is in the nature of a coating or paint composition which adheres or bonds to the surface of the material forming the board 108 . The wash composition typically will include a polymer film forming component, a solvent, and a color component. A variety of colors may be used. The solvent typically will be suitable for dissolving the polymer component, as well as being a solvent for the material forming the board 100 . In a preferred embodiment, the polymer component will also be the same polymer used for constructing the board 100 . In this manner, the wash will adhere strongly to the surface of the board 100 . Examples of suitable wash compositions and methods of applying same to a synthetic polymer material are disclosed in U.S. Pat. No. 7,472,961, the disclosure of which is incorporated herein by reference, and a copy of which is attached hereto.
[0027] As shown in FIG. 2A , the wash is bonded over only a portion of the surface of the board 108 , allowing underlying portions of the board to be exposed. The wash 110 may be applied over the entire surface of the board 108 , and selected and/or random portions removed using a suitable solvent and optionally a rag for removing the wash. In such case, the pits 106 will be filled with the wash composition, becoming filled pits 109 taking on the color of the wash. It is also contemplated that the wash 110 may applied randomly on the surface of the board 108 using any suitable technique desired. In the embodiment shown in FIG. 2A , the wash is not uniformly applied to the board 108 , creating a random painted effect with the imperfections such as pits 109 and fibers 102 being partially visible on the non-coated areas.
[0028] Referring to FIG. 2B , there is shown a board 108 ′ where the wash 100 is applied over the entire surface of the board to form a more uniform coating.
[0029] The boards 100 , 108 , 108 ′ can be constructed in a variety of sizes and shapes. For example, the boards may be rectangular, octagonal, triangular, square, or circular or in other shapes, and continuously extruded in a variety of lengths. The boards may be thick, or thin, depending upon their application. In addition, sheets of the aforementioned material may be formed, and various shapes cut from the sheets as desired. The scrap material by virtue of using thermoplastic material can be recycled. The boards, as previously noted, can be used in a variety of applications, for example, for construction of fences, barns, sheds, indoor and outdoor furniture, patio furniture, frame for chairs, and the like. The surface of the boards in addition to including a wash 110 , may also be machine finished such as having a hammer finish, or using other tooling and engraving machines to create various irregularities or patterns in the surface.
[0030] Turning to FIG. 3 , there is illustrated a storage chest 112 constructed from any one of or combination of the boards 100 , 108 , 108 ′ as previously described. The boards are used as conventional wood boards. In this regard, the boards 100 , 108 , 108 ′ can be cut using conventional sawing techniques, and drilled with holes as may be required. The boards may be attached together using screws intended for plastic materials. In addition, it is also contemplated that adhesives may be used to join the boards together.
[0031] Turning now to FIG. 4 , there is illustrated an article of furniture in the nature of a chair 120 having a frame 122 constructed from the faux wood building materials in accordance with the present invention. By way of illustration only, the frame 122 forms a plurality of legs 124 for supporting the article on an underlying surface. The frame 122 further includes cross braces 126 and, optionally, sidearms 128 . In the illustrative embodiment, the sidearms 128 are formed as an extension of the front legs 124 . A plurality of cross members 130 delineates a seat portion 132 and backrest portion 134 . The seat and/or backrest portions may be formed from a woven panel constructed from a plurality of woven synthetic polymer yarns such as disclosed in, for example, U.S. Pat. No. 7,472,961. The woven panels may be attached directly to portions of the frame 122 or through additional structure which may be attached to the frame 122 . For example, the seat and backrest portions 132 , 134 may be constructed as a bucket seat which is separately manufactured and assembled to a frame 122 previously assembled using the faux wood building materials disclosed pursuant to the present invention.
[0032] Although the invention herein has been described with reference to particular embodiments, it is to be understood that these embodiments are merely illustrative of the principles and applications of the present invention. For example, it is not required that the boards have a faux wood appearance. Rather, the wash may be applied to provide any other appearance that may be desired. In addition, the boards may be used without a wash. In another aspect of the present invention, scrap or unused material left over when making articles may be recycled with virgin material for making articles therefrom. The ability to recycle the scrap material results in the generation of little waste material. It is therefore to be understood that numerous modifications may be made to the illustrative embodiments and that other arrangements may be devised without departing from the spirit and scope of the present invention as defined by the appended claims. | Building materials formed from synthetic polymer materials have an appearance which simulates natural woods. The building materials may be used in the construction of fences, sheds, decking materials, indoor/outdoor furniture, railings and numerous other products. The faux wood material is constructed to include reinforcing fibers and voids for weight reduction. The aesthetic appearance of the finished product can be enhanced by applying a color wash which includes a polymer component and a color component adhering to the surface of the material. | 8 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of, and claims the benefit of the filing date of, co-pending U.S. patent application Ser. No. 10/783,365 entitled METHOD AND APPARATUS FOR PARAMETRIC DESIGN OF CUSTOM DECORATIVE STONEWORK, filed Feb. 20, 2004, which claims priority from U.S. Provisional Patent Application No. 60/449,493 entitled “METHOD AND APPARATUS FOR STONEWORK CONSTRUCTION” filed Feb. 21, 2003 (Attorney Docket No. STNL 2656000), and is related to U.S. patent application Ser. No. 10/783,917, Attorney Docket No. STNL 2656003, entitled “METHOD AND APPARATUS FOR INTERACTIVELY DESIGNING CUSTOM DECORATIVE STONEWORK,” filed on Feb. 20, 2004, and to U.S. patent application Ser. No. 10/783,358, Attorney Docket No. STNL 2656002, entitled “METHOD AND APPARATUS FOR MANUFACTURING OF CUSTOM DECORATIVE STONEWORK,” filed on Feb. 20, 2004, the contents of which are hereby incorporated by reference.
FIELD OF THE INVENTION
[0002] The present invention relates generally to automated design of custom decorative stonework.
DESCRIPTION OF THE RELATED ART
[0003] In the construction industry, decorative stonework has been common feature for a number of years. Larger and larger portions of stone are used in the construction of buildings and houses. Decorative stonework can be made by being cut from natural stone, cut from man-made materials, cast from molds, extruded or any combination of these techniques. Of these techniques, one of the most economical is casting using molds. Generally speaking, casting the stonework allows the aesthetics associated with decorative stonework to be preserved while reducing the overall cost.
[0004] The process of manufacturing cast decorative stonework typically involves pouring a limestone-based material into a mold and allowing it to harden. Once the material has hardened it is removed from the mold as a manufactured decorative stonework piece.
[0005] In some instances, a product may be formed of a single piece. However, more typically, more complex products, such as door frames, are not molded out of one continuous piece of manufactured stone. Instead, several pieces are assembled, usually at the job site, to yield the structure. The molds, then, are usually for the smaller components of the large whole product.
[0006] Architecture is a high art form that has been around since earliest days. The Romans and Greeks were master architects. These groups adopted certain stylistic features that were associated with their architecture. In the traditional organizational scheme, architectural features are each given certain titles. For example, Doric, Ionic, and Corinthian columns are examples of Greco-Roman architectural features. Doric columns are least ornate of the three, having a plain shaft and a simple cap. Ionic columns are more ornate, having flutes caved into the shaft and a more ornate cap, such as scrolls. The Corinthian columns are the most ornate, usually with an extremely ornate cap. However, even through these architectural features accurately describe the features of a structure, the average layperson may not be able to describe a Doric column, let alone know the name of the feature.
[0007] The customer is often a layperson and at the start of a project may not even know specifically what feature he or she desires. In fact, most laypersons would typically have only a holistic knowledge or a feel for what he or she wants. Traditional organizational schemes, though, may not necessarily provide a logical correlation to the average layperson.
[0008] To alleviate the problem associated with logical associations, it would be desirable to have a database organizational scheme can be employed to better assist a lay customer or a professional in choosing the decorative stonework associated with desired architectural features.
[0009] Several problems exist with the design, manufacture, and assembly of manufactured decorative stonework. For a given manufacturer of stone work, the molds can number in the tens of thousands. Changing the proportions of a given architectural feature can be cumbersome. There can be physical limitation as well as aesthetic considerations. Also, by changing the proportions of a given feature, the molds utilized to make the parts that compose the given architectural feature may have to be changed. Compounding the complexity of this problem is the fact that most decorative stonework products are custom designed to fit individual customer's tastes at the time a structure is designed. The decorative stonework products must also meet size and structural requirements dictated by other, non-stonework products (such as a wooden entry door) or natural geographic features of the site. Thus, oftentimes, no two decorative stonework products will be exactly alike.
[0010] The parameters required for designing decorative stonework may not be known until the time a design for the entire structure is substantially complete. Nevertheless, decorative stonework must usually be incorporated into the design of a structure at the concept stage or it may be impractical to add later. Thus, the ability to design decorative stonework products at a very early stage of the conceptualization of a structure extremely quickly, from sometimes incomplete parameters, at least to the point that the appearance of the decorative stonework products in conjunction with the structure can be determined and the cost reliably estimated can be the difference between the structure ultimately including or not including any decorative stonework.
[0011] Decorative stonework is typically very heavy. It can also be prone to damage during transportation if not properly packaged or unnecessarily handled. Typically, it will not be possible to pre-assemble the components at the stonework manufacturer's facility to ensure proper fit. To maintain an economical product, it is necessary to design and manufacture the components for the custom decorative stonework product, which may be one-of-a-kind, from tens of thousands of parts and their molds in an almost unlimited number of sizes, configurations and styles to fit with an unlimited number of structural designs. Then, all the components and their supporting documentation must be transported to the job site in all the correct sizes and at the right time.
[0012] Therefore, there is a need for a method and/or apparatus for facilitating and at least partially automating the process of selection, identification, design and manufacturing of custom decorative stonework products that at least addresses some of the problems associated with conventional methods and apparatuses.
SUMMARY OF THE INVENTION
[0013] The present invention provides a method for designing custom decorative stonework. At least one unit of a plurality of units is selected, wherein each unit of the plurality of units at least corresponds to an architectural feature, and wherein each unit of the plurality of units comprises a plurality of parts. At least a primary view is selected, wherein the primary view is at least the overall shape of the at least one unit. At least one profile of a plurality of profiles is selected, wherein each profile of a plurality of profiles corresponds to at least a primary cross-sectional view of the at least one unit. At least one dimension of a plurality of dimensions is input, wherein the at least one dimension is at least a physical dimension of the at least one unit. At least one dimension corresponding to a unit size is parametrically calculated, wherein calculating the at least one dimension further comprises at least determining relative sizes of the plurality of parts of the at least one unit. Also, at least one scaled drawing is generated, wherein the scaled drawing at least has numbers that corresponds to the plurality of parts of the at least one unit.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] For a more complete understanding of the present invention and the advantages thereof, reference is now made to the following descriptions taken in conjunction with the accompanying drawings, in which:
[0015] FIG. 1 is a block diagram depicting an improved organizational structure;
[0016] FIG. 2 is a block diagram depicting a circle top doorway;
[0017] FIG. 3 is a first example of a profile;
[0018] FIG. 4 is a second example of a profile;
[0019] FIGS. 5 a - 5 d are examples of units;
[0020] FIG. 6 is a block diagram depicting the system for adjusting dimensions of a given unit;
[0021] FIGS. 7 a , 7 b , and 7 c depict a flow chart for adjusting the dimensions of a given unit;
[0022] FIG. 8 is a block diagram depicting a unit generation menu;
[0023] FIG. 9 is a block diagram depicting a dimension input menu;
[0024] FIG. 10 is a block diagram depicting a profile/family selector menu;
[0025] FIG. 11 is a block diagram depicting a link menu;
[0026] FIG. 12 is a block diagram depicting a first structure/profile interface menu;
[0027] FIG. 13 is a block diagram depicting a second structure/profile interface menu;
[0028] FIG. 14 is a block diagram depicting a parts interface menu; and
[0029] FIG. 15 is a block diagram depicting a CAD drawing.
DETAILED DESCRIPTION
[0030] In the following discussion, numerous specific details are set forth to provide a thorough understanding of the present invention. However, those skilled in the art will appreciate that the present invention may be practiced without such specific details. In other instances, well-known elements have been illustrated in schematic or block diagram form in order not to obscure the present invention in unnecessary detail.
[0031] Referring to FIG. 1 of the drawings, the reference numeral 100 generally designates an improved organizational structure. The improved organizational structure 100 comprises a unit description 102 , part descriptions 104 , and profile descriptions 106 .
[0032] When either a professional or a customer begins the process of choosing stonework, typically there is a first association to a specific item, such as a window. This first association is designated as a unit 102 . The unit 102 can be either a very simple or a complex item ranging from a simple feature, such as a window frame, to more complex features, such as gazebos and staircases.
[0033] As it is well known, decorative stonework products are often not composed of a single, continuously molded block. Instead, to maximize the ability to create numerous varieties of units 102 while attempting to minimize costs, individual components or parts 104 are utilized. These parts are sometimes interchangeable and, thus, are capable of being used for a number of units. Furthermore, the parts 104 can be increased in size to create a large individual unit. Therefore, in the improved organizational scheme 100 , each unit 102 is subdivided into numerous parts 104 . Some parts, however, are not properly interchangeable with other parts either for physical or for aesthetic reasons.
[0034] To increase the appeal of each of the units 100 and to include as many architectural styles as is possible, each part 104 has an associated profile 106 . The profile 106 is typically a vertical or horizontal cross-sectional view of a given part 104 . The shapes associated with crown molding are one example of such a profile feature. With crown molding, a piece of wood or stonework is shaped to have curves or shapes on the surface. A cross-sectional view of the crown molding would be a profile. Also, profiles can also be overall views if the surface contains more intricate molded carvings, such as carved leaves.
[0035] By creating the associative database, a lay customer or professional is more capable of choosing desired features in stonework. Instead of sorting through either pictures of buildings or of sets of architectural features, a customer or professional can look through components or units 102 of a design scheme. By allowing a customer, specifically, to sort through the varieties of stonework available by unit 102 , the attention of the customer will more likely be retained. Preservation of a customer's attention clearly can preserve a possible sale that would provide a benefit to the customer and to the manufacturer/retailer.
[0036] Referring to FIG. 2 of the drawings, the reference numeral 200 generally designates an example of a unit. The unit comprises a first part 202 , a second part 204 , a third part 206 , a fourth part 208 , a fifth part 210 , a sixth part 212 , a seventh part 214 , and an eighth part 216 .
[0037] The unit 200 is an example of a stone circle top door frame. The door frame of the unit 200 is not composed of a single, continuous piece of manufactured stone. Instead, the door frame of the unit 200 is composed of eight distinct parts 202 , 204 , 206 , 208 , 210 , 212 , 214 , and 216 . Each of the eight parts 202 , 204 , 206 , 208 , 210 , 212 , 214 , and 216 can vary in size depending on the dimensions of the door frame itself.
[0038] Moreover, the style of the door frame of the unit 200 can be changed by interchanging some parts. For example, if a customer chooses to have an eyebrow door frame instead of a circular door frame, as shown in FIG. 2 , then most of the original parts can be retained. The difference between an eyebrow door frame and a circular door frame is the arc across the top of the frame. The top of the circular door frame has a radius equal to one half the distance between the sides of the doorframe, whereas the top of an eyebrow doorframe is larger than the one half the distance between the sides of the doorframe. Therefore, it is possible to retain the third part 206 , the fourth part 208 , the fifth part 210 , the sixth part 212 , the seventh part 214 , and the eighth part 216 . Hence, the first part 202 and the second part 204 can be replaced with parts that possess a larger arc.
[0039] Providing the customer with an association as expressed can therefore lead to easier choosing of design elements. If circular door frames and eyebrow door frames are associated with different architectural styles, a customer may holistically know that he or she prefers an eyebrow door frame. However, if the customer has a particular affinity for an architectural style that does not incorporate eyebrow door frames, then a customer can become frustrated because he or she does not know the name of the particular style of door frame or the specific architectural style to which the door frame belongs. Hence, organization of stonework into units, such as the door frame of unit 200 , can assist the customer.
[0040] FIGS. 3 and 4 are examples of profiles. Both the first profile 300 and the second profile 400 are horizontal cross-sections of a given part. The dimensions of each profile 300 and 400 are typically measured by three dimensions. The height Y, the upper depth X and the lower depth Z are related to the overall size of the given part 104 . There are profiles that can be utilized in order to provide varying degrees of aesthetic flair.
[0041] FIGS. 5 a - 5 d are examples of units. FIG. 5 a depicts an unfluted Corinthian column, and FIG. 5 c depicts an unfluted Doric column. Specifically, the picture of FIGS. 5 a and 5 c only depict the caps of each of the respective columns because the caps are what differentiate the Corinthian column from the Doric column.
[0042] FIGS. 5 b and 5 d , on the other hand, depict more complex units. Specifically, each of the respective pictures depicts an entryway. FIG. 5 b is denoted as a “Castile Aragon II” that is a style of architecture common to the Aragon region of Northeast Spain. FIG. 5 d is denoted as “Boxwood Manor” that is a style of architecture more indicative of the Southwest United States.
[0043] Referring to FIG. 6 of the drawings, the reference numeral 600 generally designates a system for adjusting dimensions of a given unit. The system 600 comprises a client computer 614 , a computer network 612 , a server 610 , an internal computer 608 , a database of units 604 , a calculation unit 606 , and a database of molds 602 .
[0044] For the system to operate, a user has to access the software capable of selecting and adjusting units for a given architectural style. A client computer 614 will generally use web-based applications to access the software. However, the user may not necessarily be required to use web-based applications. Typically, though, a user will access a web page and input the desired data to obtain the desired drawings.
[0045] In order for the access to take place, a plurality of connections should be made. A client computer 614 is coupled to a computer network 612 through a first communication channel 616 . The computer network 612 can be a variety of computer networks including, but not limited to, the Internet. The computer network 612 is then coupled to the server 610 through a second communication channel 618 . The server is coupled to the internal computer 608 through a third communication channel 620 . The internal computer is then coupled to a database of units 604 , a database of molds 602 , and a calculation unit 606 through a fourth communication channel 624 , a fifth communication channel 626 , and a sixth communication channel 622 .
[0046] Referring to FIGS. 7 a , 7 b , and 7 c of the drawings, the reference numeral 700 generally designates a flow chart for adjusting the dimensions of a given unit.
[0047] In order for the user to utilize the system, the user can input initial data to describe both the uses for the drawings and the basic drawing requirements. In step 702 , the user makes a selection that a new drawing is to be created. Then in step 704 , the user can then select the drawing category. The drawing category is typically defined as the purpose for the drawing, such as development or a Job “Blue Dot.” Once the drawing category has been selected, a drawing type image, such as a parts sheet, is selected in step 706 . Then in step 708 , the user then selects the drawing type detail, such as the front elevation. The last portion of initial data is the job number, which is a business specific number to identify the job that is input in step 710 .
[0048] Once a user has input all of the initial data, the data specifics regarding the scale, quantity and type of materials can be input. The user inputs the scale in step 712 . Then in steps 714 and 716 , respectively, the plot size and “blue dot” number are selected. The user can then select the unit mark or identifier and the part mark or identifier in steps 718 and 720 , respectively. Once all of the data regarding the physical features of the unit or part have been input, the drawing is titled, described, remarked and numbered in steps 722 , 724 , 726 , and 728 , respectively. These choices allow a user to effectively choose the marking, the scale, and the units or parts for a drawing that is to be rendered.
[0049] After the user has input all of the background data, the user is prompted as to whether the drawing should be auto-generated in step 730 . If the user does not wish to auto-generate a drawing, a Computer Aided Design (CAD) software package is opened with all of the initially inputted data in step 732 . The CAD package can be a variety of software packages, such as AutoCAD®. However, if the user wishes to have an auto-generated drawing, then the user will be further prompted for information.
[0050] If the user wishes to have an auto-generated drawing, there is a prompt to create a part or unit in step 734 . The parts and units nomenclature is the same nomenclature utilized in the organization scheme of FIG. 1 . In fact, the system 600 of FIG. 6 is overlaid on the organization scheme of FIG. 1 . Therefore, a user will likely be more willing to utilize the system 600 of FIG. 6 because of the simplicity associated with the logical correlations created in the organizational scheme of FIG. 1 .
[0051] If the user chooses to create a part, then the user is further prompted regarding parts within the organizational scheme of FIG. 1 . In step 736 , the user is prompted to select a part type, such as column cap, wherein the parts are selected from the database of units/parts 604 of FIG. 6 . Then the primary view is selected in step 738 . The primary view of a unit is essentially the overall shape of the unit, for example an eyebrow window frame or a squaretop window frame. For example, a top view is a view of a part from above the part looking down. In step 740 , the part modifiers are selected. The modifiers are additional features that can be added to a unit to provide a certain aesthetic style or aesthetic look, such as a sill added to a window frame. Then, the profile of a part is selected in step 742 . The profile is essentially a cross-sectional view of a part, such as the examples depicted in FIGS. 3 and 4 . However, the profile can be other views, such as a three dimensional carved stone look on a piece of molding. Finally, the orientation is selected in step 744 . The orientation is the specific view of a part from any angle including the primary view.
[0052] Once all of the features of the drawings have been selected, then in step 746 , the drawing is created. The internal computer 608 of FIG. 6 utilizes the database of unit/parts 604 of FIG. 6 to determine the known dimensions and characteristics of the desired part selected. The internal computer 608 of FIG. 6 employs the calculation unit 606 of FIG. 6 to adjust the dimensions of the part. The calculation unit 606 of FIG. 6 utilizes a set of parametric equations to adjust the dimensions of the desired part based on the input dimensions. For example, these equations can include the Pythagoreans theorem, involving sums and squares, and trigonometric equations.
[0053] If the user chooses to create a unit, then the user is further prompted regarding units within the organizational scheme of FIG. 1 . In step 748 , the client is prompted to select a unit type, such as door frame, wherein the units are selected from the database of units/parts 604 of FIG. 6 . Then the primary view is selected in step 750 . The primary is the generally the core or the most characteristic cross-sectional view of a given unit. For example, a top view is a view of a part from above the part looking down.
[0054] In step 752 , the part modifiers are selected which are potential, additional features of a unit. Then, the generic unit with all parts is displayed, wherein the parts are labeled with the standardized alpha-numeric identification strings in step 754 . Once displayed, the profile family of a unit is selected in step 756 . The profile is generally a cross-sectional view of a part, such as the examples depicted in FIGS. 3 and 4 . In the case of a unit, a family of profiles is selected because each part contained within a given unit has a specific profile. Also, the profiles within a given unit may vary slightly or drastically. Finally, the profile offsets are displayed in step 744 .
[0055] After the profile offsets have been displayed, the user is prompted as to whether a previous profile is to be utilized in step 758 . If a previous profile is selected, then a new or previous offset is selected in step 770 . However, if a previous profile is not selected, then a new profile is selected and displayed in steps 772 and 774 , respectively, and new offsets are chosen in step 776 . After the respective profiles and offsets have been chosen, then the profile interface drawing is created in step 778 , and the settings are saved in step 780 .
[0056] Once all of the features of the drawings have been selected, then in step 782 , the drawing is created. The internal computer 608 of FIG. 6 utilizes the database of unit/parts 604 of FIG. 6 to determine the known dimensions and characteristics of the desired unit selected. The internal computer 608 of FIG. 6 employs the calculation unit 606 of FIG. 6 to adjust the dimensions of each part of the unit. The calculation unit 606 of FIG. 6 utilizes a set of parametric equations to adjust the dimensions of each part of the unit based on the input dimensions. Also, if the mortar joint dimensions have changed then the figure is redrawn in step 784 .
[0057] In order to implement the process of selecting the desired units with the desired dimensions, a computer program is employed. The computer program typically utilizes a plurality of menus. The menus provide a graphical interface to a user that is more user friendly. Organization of the menu selections mirrors the procedure depicted in FIGS. 7 a , 7 b , and 7 c . However, a plurality of text command prompts, similar to those utilized is such programs as Simulation Program with Integrated Circuit Emphasis (SPICE) can also be employed.
[0058] Referring to FIG. 8 of the drawings, the reference numeral 800 generally designates a block diagram depicting a unit generation menu. The menu 800 comprises a menu label 802 , a first pull-down selection window 806 , a second pull-down selection window 808 , a third pull-down selection window 810 , a thumbnail window 804 , and a thumbnail image 812 .
[0059] The menu operates by allowing the user to select a desired unit, such as a window frame. The menu label 802 is typically located at the top of the menu to provide guidance to a user so as to better prevent confusion. The first pull-down selection window 806 is to allow the user to select the desired unit. The first pull-down selection window 806 contains a complete list of units that the manufacturer provides. The second pull-down selection window 808 is the primary view of the unit selected in the first pull-down selection 806 . The primary view generally depicts the overall shape of the unit. In the menu 800 , a surroundwindow has been selected as the unit and the primary view is a square top. The selection of a squaretop is the shape of the window frame as opposed to an eyebrowtop, which is a more curved shape.
[0060] In addition to selecting both the unit and the primary view, a modifier can be selected. The modifiers are any additional options that can be added to a unit. The selection of the modifier is made as a result of utilizing the third pull-down selection window 810 . The modifiers are items that can be added to a unit to provide differing styles or looks. For example, the menu 800 has a selection of a sill. The sill is the bottom portion of the window that provides additional styles. Furthermore, there can be multiple pull-down selection windows or a single pull-down selection window, as shown in FIG. 8 , for each of the pull-down selection windows.
[0061] Also included in the menu 800 is a picture window. Contained within the picture window is a picture of the selected unit with all of the included features. As a selection is made, be it a unit, a primary view, or a modifier, the picture is updated. The advantage to having a continually updating picture is to provide real-time feedback to a user. The user, then, can properly select his or her desired features in an efficient manner.
[0062] Referring to FIG. 9 of the drawings, the reference numeral 900 generally designates a block diagram depicting a dimension input menu. The control menu 900 comprises a unit picture 908 , a menu label 902 , a first control dimension input 904 , and a second control dimension input 906 .
[0063] The menu operates by allowing the user to input the desired dimensions of a unit, such as a window frame. The menu label 902 is typically located at the top of the menu to provide guidance to a user so as to better prevent confusion. The first control dimension input 904 and the second input dimension input 906 allow the user to enter n the dimension of the unit. There can be a single dimension or multiple dimensions, as shown in FIG. 9 . There can also be a number of additional dimensions, such as radius, that can be unit specific. Moreover, there are a number of measurement units that can be utilized as input dimensions, such as English, Meter-Kilogram-Second (MKS), Centimeter-Gram-Second (CGS), and so forth.
[0064] Entering a measurement unit into a computer does not necessarily assist a user in attaining his or her desired dimensions. As a matter of fact, it may be difficult to ascertain which dimension each of the inputs refers to. The unit picture 908 , though, provides all of the necessary detail for the user to have a firm understanding of the correlation between the respective control dimensions and the physical measurements of the unit. As an example in FIG. 9 , the first control input dimension 904 corresponds to the inner height of the window frame depicted by the unit picture 904 , and the second control input dimension 906 corresponds to the inner width of the window frame depicted by the unit picture 904 . Therefore, a user is able to visualize a unit, which is composed of manufactured stone, complete with actual physical dimensions, wherein the physical dimensions are calculated through the use of a plurality of parametric equations.
[0065] Referring to FIG. 10 of the drawings, the reference numeral 1000 generally designates a block diagram depicting a profile/family selector menu. The profile menu 1000 comprises a menu label 1002 , a unit picture 1012 , a first profile selection window 1006 , a second profile selection window 1008 , a first image thumbnail 1004 , a second image thumbnail 1010 , and a unit label 1014 .
[0066] The menu operates by allowing the user to input the desired unit profile, such as a window frame. The menu label 1002 is typically located at the top of the menu to provide guidance to a user so as to better prevent confusion. Essentially, usually the profiles are horizontal cross-sectional views of various parts that make up the unit. However, a profile can also be of a variety of other types of profiles such as an overall view of a plurality of three dimensional leaves that appear as a molding. With each selection window there is an associated image thumbnail to depict the shape of the profile to a user. In FIG. 10 , the first profile selection window 1006 is associated with the first thumbnail image 1004 , and the second profile selection window 1008 is associated with the second thumbnail image 1010 . Also, a unit label 1014 is provided. The unit label 1014 can display specific unit nomenclature, such as Surroundwindow Squaretop Sill as shown in FIG. 10 .
[0067] Typically, the number of image thumbnails and selection profiles corresponds to the number of selectable profiles of a unit. For example, the window frame of FIG. 10 has two sections where the profile can be different. It is possible to have a system where a profile for each individual part of a unit is selectable. However, according to the majority of aesthetic conventions, certain portions, such as the top three parts of the window frame of FIG. 10 , have the same profile. Hence, for the sake of simplicity, certain parts of units are presumed to have a uniform profile so as to not overload a user with too many possible selections.
[0068] In the window of FIG. 10 , certain aesthetic conventions have been adhered to so a user can select the desired profiles. Accordingly, the user is prompted to select a profile for the top three parts of the window frame from the first profile selection window 1006 , and the user is prompted to select a profile for the sill of the window frame from the second profile selection window 1008 . Once each of the respective profiles has been selected, then a thumbnail image of the selected profile for each of the top three parts of the window frame appears as the first image thumbnail 1004 , and a thumbnail image of the selected profile for the sill of the window frame appears as the second image thumbnail 1010 . Therefore, a user can mix and match varying profiles of portions of the unit to attain a desire aesthetic look in real-time for the stonework.
[0069] Referring to FIG. 11 of the drawings, the reference numeral 1100 generally designates a block diagram depicting a link menu. The link menu 1100 comprises a menu label 1102 , a unit picture 1104 , a first selection slot 1106 , a second selection slot 1108 , a third selection slot 1110 , a fourth selection slot 1112 , a fifth selection slot 1114 , a sixth selection slot 1116 , a seventh selection slot 1118 , an eighth selection slot 1120 , and a ninth selection slot 1122 .
[0070] The menu operates by allowing the user to input the desired unit additions, such as a window sill. The menu label 1102 is typically located at the top of the menu to provide guidance to a user so as to better prevent confusion. Overall, though, the link menu is typically associated and selected from the profile menu 1000 of FIG. 10 . There can be other features that can be added to a given unit that are characteristically more like a profile, such as a key. These other features are selected at the same time or near the same time that a profile is selected due to that logical association.
[0071] In the example in FIG. 11 , features are added to the window frame. Each of the selection slots, though, corresponds to a different feature of the window. The first slot 1106 is associated with the main surround. The second slot 1108 is associated with a crown. The third slot 1110 is associated with an ear. The fourth slot 1112 is associated with a key. The fifth slot 1114 is associated with the sill. The sixth slot 1116 , the seventh slot 1118 , the eighth slot 1120 , and the ninth slot 1122 are each left blank. The user in the link menu 1100 can select all of the features normally associated with the selected unit. It is possible to have a virtually infinite number of additional features that can be added to any given unit; however, the additional features that can be selected in the link menu 1100 are associated with typical aesthetic conventions.
[0072] Referring to FIG. 12 of the drawings, the reference numeral 1200 generally designates a block diagram depicting a first structure/profile interface menu. The first interface menu 1200 comprises a menu label 1202 , a first selected profile 1204 , a second selected profile 1206 , default back 1208 , an offset back 1210 , an offset choice slot 1216 , and a error point 1214 .
[0073] The menu operates by allowing the user to input the desired adjustments for unit profiles. The menu label 1202 is typically located at the top of the menu to provide guidance to a user so as to better prevent confusion. In the first profile selection menu 1200 , each of the previously selected profiles is displayed. For example, with the window frame, there are two choices for profiles: a profile for the main surround and a profile for the sill. The first profile 1204 corresponds to the profile for the main surround, and the second profile 1206 corresponds to the profile for the sill.
[0074] With each profile, there is a default backing 1208 . The default backing is the default mounting line where the part is adjacent to a wall or other rigid structure. The only exception to having a default backing is a cap. When a default backing exists, though, the default backing 1208 refers to the resting location for the part possessing the profile. However, to provide maximum flexibility, the user is given the option to choose an offset. The offset is entered in the offset choice slot 1216 and is illustrated by the offset back 1210 .
[0075] There are cases, though, where the offset can be too large. If the offset is too large, features of the profile can be disturbed or destroyed. For example, the profile of the sill for the window illustrated by the second profile 1206 may lose a portion of the feature associated with the profile because the offset is too large. The error point 1214 is a measurement of when features of a profile may be disturbed or destroyed. If a calculation is made that a feature of a profile may be disturbed or destroyed, then the user can be alerted of the possible ramifications of the choice of such a large offset. Also, there are a number of measurement units that can be utilized as amounts for an offset, such as English, MKS, CGS, and so forth.
[0076] Referring to FIG. 13 of the drawings, the reference numeral 1300 generally designates a block diagram depicting a first structure/profile interface menu. The second interface menu 1302 comprises a menu label 1302 , a first selected profile 1304 , a second selected profile 1306 , default back 1308 , a user-defined offset 1310 , a first prompt 1314 , a second prompt 1316 , a third prompt 1318 , a fourth prompt 1320 , fifth prompt 1322 , and a sixth prompt 1324 .
[0077] The menu operates by allowing the user to input the desired adjustment for unit profiles. The menu label 1302 is typically located at the top of the menu to provide guidance to a user so as to better prevent confusion. Again with the second profile selection menu 1300 , each of the previously selected profiles is displayed. For example, with the window frame, there are two choices for profiles: a profile for the main surround and a profile for the sill. The first profile 1304 corresponds to the profile for the main surround, and the second profile 1306 corresponds to the profile for the sill.
[0078] With each profile, there is a default backing 1308 and a user-defined offset 1310 . However, to provide maximum flexibility, the profile can also be moved. The user is prompted by the first prompt 1314 to move the first profile 1304 and by the fourth prompt 1320 to move the second profile 1306 . If a desires to move either of the respective profiles, then the user can enter whether the profile is to be moved in a positive or negative direction. The second prompt 1316 corresponds to the direction of motion of the first profile 1304 , and the fifth prompt 1322 corresponds to the direction of motion of the second profile 1306 . Once the direction of motion of the profile is entered by the user, then the user can enter the amount. The third prompt 1318 corresponds to the distance of motion of the first profile 1304 , and the sixth prompt 1324 corresponds to the distance of motion of the second profile 1306 . Also, there are a number of unit measurement that can be utilized as amounts for an offset, such as English, MKS, CGS, and so forth.
[0079] Referring to FIG. 14 of the drawings, the reference numeral 1400 generally designates a block diagram depicting a parts interface menu. The parts interface menu 1400 comprises a menu label 1402 , a first sill view 1404 , a second sill view 1406 , a first surround intersection 1410 , a second surround intersection 1414 , a third surround intersection 1420 , a fourth surround intersection 1424 , a predefined dimension 1412 , a first outer surround boundary 1408 , a second outer surround boundary 1416 , a third outer surround boundary 1418 , a fourth outer surround boundary 1420 , an offset prompt 1428 , and an offset 1422 .
[0080] The menu operates by allowing, the user to input the desired adjustments to the unit dimensions. The menu label 1402 is typically located at the top of the menu to provide guidance to a user so as to better prevent confusion. The first sill 1404 is the default view. The first outer surround boundary 1408 and the second outer surround boundary 1416 match the outer edges of the sill while the predefined dimension 1412 is maintained. The first surround intersection 1410 and second surround intersection 1414 can be seen on the surface of the sill, which depicts the location of the surround relative to the sill. This type of view and menu are typically available for any situation where there can be an adjustment between parts, such as between a unit and a modifier like the window frame and sill.
[0081] To provide maximum flexibility to a user to choose the aesthetic style, the dimensions of the sill, or other parts, can be adjusted relative to the surround, or other units. The first sill 1404 is the adjusted view. The third outer surround boundary 1418 and the fourth outer surround boundary 1426 do not necessarily match the outer edges of the sill; however, the predefined dimension 1412 is maintained. The third surround intersection 1420 and fourth surround intersection 1424 can be seen on the surface of the sill, which depicts the location of the surround relative to the sill. The customer can enter an offset 1422 into the offset prompt 1428 . The offset 1422 in the context of the window frame is defined as the linear distance between the respective outer surround boundary and the edge of the sill; however, the offsets can vary in definition according to the respective usage. It would be more flexible for a user to be able to adjust every distance, but according to normal aesthetic conventions, symmetry is preferred. Also, there are a number of measurement units that can be utilized as amounts for an offset, such as English, MKS, CGS, and so forth.
[0082] Referring to FIG. 15 of the drawings, the reference numeral 1500 generally designates a block diagram depicting a CAD drawing. The CAD drawing 1500 comprises a vertical cross-sectional view 1502 , a cap horizontal cross-section 1504 , and a base horizontal cross section 1506 .
[0083] The CAD drawing depicts a Corinthian column. The vertical cross-sectional view 1502 is typically considered to be the primary view of the column as it would stand in a building. The drawing 1500 , though, is scaled and complete with dimensions (not labeled). Specifically, though, vertical cross section 1502 illustrates both height and width of the column.
[0084] However, in order to yield a complete perspective of the overall shape of the column other perspectives or views are included. The cap horizontal cross-section 1504 and the base horizontal cross section 1506 provide the other perspective views. These other views allow for complete consideration of scale. By examining the dimensions of the cap horizontal cross-section 1504 and the base horizontal cross section 1506 , taper and the respective radii can be determined, giving a user an overall complete view of the unit to be built. An example of an embodiment of the invention is further described in Appendices A to M, the contents of which are hereby incorporated by reference.
[0085] By providing easily usable software to enable either a laymen or more sophisticated professional to choose custom stonework, the economic benefits are substantial. The systems and software allow a user to use graphical interfaces to easily select entire units, like window frames, that are to be custom made of manufactured stone. A user can vary the sizes and styles to fit his or her liking, while eliminating costly procedures involving various craftsmen, such as draftsmen. A computer generates the drawings to scale for the custom stonework that allows a manufacturer to produce the parts of a unit at a greatly reduced cost to a user or consumer. Moreover, the use of a more simplistic, user friendly software package reduces the gargantuan task of designing and producing scaled drawings for manufacturing to a rapid and simple process.
[0086] It is understood that the present invention can take many forms and embodiments. Accordingly, several variations may be made in the foregoing without departing from the spirit or the scope of the invention. The capabilities outlined herein allow for the possibility of a variety of programming models. This disclosure should not be read as preferring any particular programming model, but is instead directed to the underlying mechanisms on which these programming models can be built.
[0087] Having thus described the present invention by reference to certain of its preferred embodiments, it is noted that the embodiments disclosed are illustrative rather than limiting in nature and that a wide range of variations, modifications, changes, and substitutions are contemplated in the foregoing disclosure and, in some instances, some features of the present invention may be employed without a corresponding use of the other features. Many such variations and modifications may be considered desirable by those skilled in the art based upon a review of the foregoing description of preferred embodiments. Accordingly, it is appropriate that the appended claims be construed broadly and in a manner consistent with the scope of the invention. | A method, apparatus, and computer program are provided for custom designing primarily decorative stonework. The system permits design of different aesthetic architectural features, which can be of many types and shapes. The dimensions can also be varied to fit the needs of a client, architect or other user of the system due to the use of a parametric calculation unit. These system features assist users in custom designing primarily decorative stonework, improving speed and quality while reducing costs. | 6 |
TECHNICAL FIELD
The invention relates to a process and apparatus for introducing gaseous mixtures into the sea-water located in the contact tube of a protein skimmer. According to the present invention, the water to be skimmed is itself used for sucking in the gaseous mixture by means of a centrifugal pump and an internal injector projecting into a suction port of this pump, thus to produce gas-bubbles with a diameter of 0.1 to 0.5 mm, to whirl the bubbles in the water and to mix them with the same. The function of the protein skimmer is to remove undesired substances, such as suspended particles, colloids, dissolved protein, protein fragments such as amino acids and aromatic amines as completely as possible from the aquarium water. This takes place according to the flotation principle, in that gas bubbles are attached to the particles and increase the buoyancy of the latter to such an extent that they rise to the top of the contact tube in the direction counter to the water flow direction and are there removed from the circuit by an overflow (flow direction in the contact tube is from top to bottom).
BACKGROUND ART
In known methods and apparatus for mixing gaseous mixtures into the sea water of a protein skimmer there are problems due to the fact that the efficiency of flotation is highly dependent on the size of the gas bubbles used. Thus too small bubbles have an inadequate buoyancy and are entrained downwards by the water flow, whilst too large bubbles rise excessively rapidly and therefore either do not attach to the particles to be removed, or come loose from them again due to their excessively high rate of rise.
As the protein particles and the attached bubbles rise counter to the water flow direction to become removed from the circuit by the overflow of the contact tube, the protein skimmer operates most effectively when used in counter current manner, i.e., the water flows from top to bottom and the gas bubbles from bottom to top, i.e., oppositely to one another. The gaseous mixture required for skimming must be introduced as near to the bottom as possible over the contact tube outlet. In order to permit this, a vacuum or underpressure must be produced, which is higher than the hydrostatic pressure at the point at which suction of the gaseous mixture is to take place.
Hitherto, the air or air-gas mixture has been introduced into the contact tube of a protein skimmer by means of effusers made from lime or linden wood or other fine-pored materials through which compressed air is forced, or according to a second process by means of a centrifugal pump having an open, exclusively water-sucking impeller. In the second method, the gaseous mixture to be admixed with the water sucked by the centrifugal pump is sucked through the water flow from an annular duct, which is spaced from the impeller of the centrifugal pump and surrounds the impeller's periphery.
The first-mentioned process suffers from a poor reproducibility of the air or gas quantity, because in the case of the effusers the pores are either encrusted by salt or so widened by ozone that it is necessary to constantly check and readjust the air pressure and therefore air quantity and bubble size. Furthermore, for the purpose of the ozonization of the aquarium water, the air must be dried because otherwise condensation water is precipitated in the ozonizer and consequently the latter is no longer able to function.
In the case of the pump-operated protein skimmers, although air drying is made superfluous, the energy requirement is 550 to 1100 Watts and the amount of noise produced precludes operation in the home. The size, i.e., an external diameter of 0.5 to 1.0 m and a height of 2.53 to 3.4 m makes it possible to install such a protein skimmer in the home. The pump driving motors require a high power consumption. Due to the complicated operation and the resulting difficult and complicated manufacture, such a skimmer is also much to expensive for most aquarium operators.
DISCLOSURE OF THE INVENTION
The main aim of the present invention is to provide a novel method for skimming contaminations out of liquids, especially for skimming protein particles, similar colloidal constituents and other suspended substances out of the water of sea water aquaria, which is simplified to that known method using a centrifugal pump which is open at its suction side and thus needs an apparatus for admixing air or an air-gas mixture. The method is characterized by smaller dimensions, simpler design, manufacture and maintenance and lower energy requirements as compared with the hitherto known centrifugal pump-operated skimmers. The method also provides a precisely defined, uniform air quantity and mixing with air bubbles of a specific uniform diameter so as to obtain an optimum skimming with a constant water level in the contact tube and an appropriate diameter of the gas bubbles.
This aim is achieved, following the invented method, by sucking and mixing gaseous mixtures into the liquid of a protein skimmer, which flows after coarse mechanical prefiltering through the contact tube of the protein skimmer from its top to its bottom and in a circuit to a reservoir (aquarium) and back to the contact tube.
The gaseous mixtures are sucked into the liquids pumped through the contact tube through an air pipe extending from the outside of the contact tube to an internal injector at an injection point at a distance of at least approximately 30 cm above the water outlet of the contact tube. The internal injector projecting into an axial suction port of a centrifugal pump which is closed at the rest of its suction side, and uses the liquid to be skimmed and to be simultaneously sucked by the centrifugal pump sucking the gaseous mixture. The gaseous mixture is introduced to the contact tube at a suction point in a liquid depth or under a hydrostatic water pressure of approximately 1-1.5 m water column, and as a liquid-gas mixture of approximately 10:1 (volume percentage) produced in the impeller of the centrifugal pump. The whirling of the liquid-gas mixture produces gas bubbles having a diameter of 0.1 to 0.5 mm, and this water-gas mixture mixes with the liquid located in the contact tube, thus to improve the amount of the gas mixture dissolved in the liquid and/or to improve the skimming of the protein particles and the like.
An apparatus for performing the invented method comprises a centrifugal pump, a circuit for pumping the contiminated mechanically prefiltered liquids through the contact tube of a protein skimmer from the top to the bottom, a liquid outlet at the bottom of the contact tube, means for introducing gaseous mixtures to the liquid in the contact tube and means for sucking the contaminated liquid to be skimmed and for mixing this liquid with the introduced gas for attachment of the gas bubbles to the particles of the contaminations and to dissolve the gas in the liquid. The centrifugal pump is attached laterally to the wall of the contact tube by arranging the pump drive motor outside the tube and the hydraulic part of the pump inside. The pump casing or pump flange is arranged and mounted in such a way that the hydraulic part is introduced inside of the contact tube at a distance of at least 30 cm above the liquid outlet of the contact tube. The outlet of the casing on the pressure side of the centrifugal pump has an opening directing the pump discharge in a direction above the top of the centrifugal pump. The impeller of the centrifugal pump has an axial suction port and is closed to the outer periphery of the suction port. In the middle of the suction port and of the impeller is arranged an internal injector to supply the air-gas mixture through a free coaxial mounting of an injection connection inside a suction opening of the suction connection.
The injection connection is connected to the air pipe in the flange of the centrifugal pump or in the wall of the contact tube, by which there is supplied the air-gas mixture to the suction point of the contact tube. An advantageous pump casing outlet directed tangentially to the contact tube circumference is provided and formed by a pressure duct or channel which opens towards the inside of the contact tube at the top and to the front of the impeller. Through a reduction of the counter pressure at the pump casing outlet there is brought about an increase in the water flow and consequently a rise in the vacuum at the suction connection of the impeller.
Advantageously, the suction port of the impeller contains a disk, whose edge rests on the salient rim of the suction port of the impeller and seals the same, so that apart from the openings in the disk, said suction port is sealed and consequently the vacuum required for the operation of the injector is produced in the vicinity of the latter.
Through an appropriate alignment and regulation of the effective flow-through cross-sections of the outlets on the pressure side and the suction ports on the suction side of the centrifugal pump it is possible to regulate the amount of liquid or aquarium water and of air-gas mixture sucked so as to produce a water-gas mixture of approximately 10:1 (volume percentage) in the impeller.
The apparatus for performing the method according to the invention makes it possible to use a small dimension centrifugal pump and contact tube for a protein skimmer (preferred length of the contact tube above the suction point: 95-150 cm, external diameter: 20 cm) which is of simple design and manufacture, and to produce very small air bubbles and a constant air quantity. The parts relevant for producing the bubbles are constantly well rinsed with water, so that they are not oversalted when skimming protein out of sea water and consequently no readjustment is required. The motor has water lubricated friction bearings and is noiseless. In addition, it requires no shaft packing, such as a shaft sealing ring or face seal, which aids the energy balance. Compared with the hitherto known process, a considerable energy saving is achieved because there is no air drying for ozonization purposes and the motor has a power consumption of about 60 or 80 Watt (adjustable). The space requirement is also much less than in the hitherto known protein skimmers, because the contact tube requires an external diameter of about 20 cm and a length of less than about 150 cm. In contrast to the hitherto known centrifugal pump-operated skimmers, the apparatus needs no maintenance.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is described in greater detail hereinafter relative to a preferred embodiment of the apparatus for performing the inventive process and with reference to the attached drawings, which show:
FIG. 1 A plan view of the apparatus which the hydraulic part of the centrifugal pump located in the skimmer contact tube and the external pump motor.
FIG. 2 A view of the hydraulic part as seen from the inside of the contact tube.
FIG. 3 A partial section view along line A-B through the hydraulic part shown in FIG. 2, whilst representing the arrangement of the flange with the hydraulic part of the pump positioned in a contact tube wall opening.
DETAILED DESCRIPTION OF THE INVENTION
According to FIGS. 1 and 3, a centrifugal pump 17 with an external drive motor 12 (60 or 80 Watt, 50 Hz a.c.) and an internal hydraulic part projecting into the contact tube 1 is fitted to the latter by means of a flange 2, which is sealed against the contact tube. An air-gas mixture is supplied to the pump by an air pipe 3 guided from the outside to the inside in flange 2.
According to FIG. 2, the inside portion of flange 2 forms a pressure duct or channel 15, which with a spirally widening outer wall 27 surrounds an impeller 4 and is open towards the inside of the contact tube 1 at the top and front. The point at which the surrounding outer wall of the pressure duct 15 is closest to the circumference of the impeller 4 represents the start of the pressure duct 15 widening in the free cross-section. The pressure duct terminates in opening 9 on the top of the flange.
An injection connection 6 of the internal injector projects roughly 2.5 mm into an axial suction connection 5 of the impeller, which is closed by part 16 in accordance with FIG. 2 and FIG. 3. The injection connection 6 is fixed by means of a web 7 to flange 2 and centred in suction connection 5.
Web 7 exends in a spaced manner transversely over the center of impeller 4 and at the upper edge of the flange may form a guide surface with the rim of the opening 9 of the spiral pressure duct 15 or widen a flange guide surface 18 provided there.
According to FIG. 1, the air pipe 3 is connected to the injection connection 6 by a hose 8 or a tube, enabling the air-gas mixture to be supplied to the injection connection 6. According to FIG. 3, the injection connection 6 and suction connection 5 have their diameters precisely matched to one another. The internal diameter of the suction connection is conically widen by 1 mm towards the front and at its opening 19 has an internal diameter of 7.5 mm, whereas the injection connection is cylindrical and has an external diameter of 5 mm. The connections are coaxially arranged with respect to one another in such a way that the water flowing in between the injection and suction connections sucks the air in the injection connection 6 into the impeller 4.
A disk 10 is fixed in impeller 4 in such a way that it rests with its edge 20 on the impeller suction port 24 and is shaped to form a connection piece which closes the same (FIG. 3).
According to FIGS. 2 and 3, on the periphery of disk 10 are equidistantly spaced sixteen bores 14 with a diameter of 3.5 mm diameter on a concentric circle with a diameter of 25 mm and which are reciprocally displaced by in each case 22.5°. These bores 14 are connected to the suction connection 5 firmly applied to the center of disk 10 by means of in each case one 1.2 mm wide and 4 mm deep radial ducts 13 on the side of said disk facing the inside of impeller 4.
The diameter of the sixteen bores 14 on the peripheral hole circle is a function of the hydrostatic pressure to be overcome in order to suck in the air-gas mixture.
The pump comprises a slotted tube motor with a power consumption of 60 or 80 Watt, 50 Hz a.c. There is chosen the smaller or higher power of 60 or 80 Watt according to the amount of air needed to be sucked by the internal injector. This amount depends upon the hydrostatic pressure and height at which the centrifugal pump is mounted laterally of the contact tube. The number of revolutions is thus increased with the power applied, e.g. from 1700 or 2200 rounds per minute to 2000-2500 rounds per minute.
The shaft and bearings are made from oxide ceramic, whilst the slotted tube and impeller are made from chrome nickel steel. The impeller has an external diameter of 70 mm and the diameter of the suction port 24 is 30 mm. The vertical clearance of the impeller in the suction port is 6.2 mm at the beginning of the passages formed between the vanes and is 3 mm at the periphery. Disk 10 is 15 mm thick and the suction connection 5 firmly applied to the center thereof is 9 mm long, measured from opening 19 to the start of the radial passages 13.
The impeller is connected by means of a collet on the back to the end of the drive shaft and is rotated in operation by motor 12. As a result of the water accelerated by the impeller vanes towards their outer edge and in the back of impeller disk 10 and in its radial ducts 13 to the outside, a vacuum is produced in the passages and ducts and in the impeller, which sucks water through the central suction connection 5 and the bores 14 of the peripheral hole circle. According to the injector principle, the through-flowing water also produces a vacuum in the fixed injection connection 6, which leads to the suction of air or an air-gas mixture via connecting line 8 and air pipe 3.
The gas-water mixture which has entered through the suction connection of the internal injector is now conveyed to the periphery of the disk by the centrifugal force in the rotating impeller. It is mixed there with the water entering through the bores of the peripheral hole circle to prevent a breaking away of the flow and consequently a collapse of the vacuum. After leaving the impeller, the water-gas mixture in the spiral pressure duct 15 is led upwards to the outlet 9 in flange 2 and is returned through the same to the contact tube 1. The water present in the contact tube is rotated by the sloping, upwardly directed arrangement of the outlet 9 and its guide surface 18, 25 tangential to the contact tube. This brings about a partial separation of water and gas bubbles, so that the lighter gas bubbles are mainly displaced towards the centre of the tube, which causes a reduced resuction of the gas bubbles through the injector and consequently to a rise in the air or gaseous mixture suction through raising of water with a limited admixed gas bubble proportion. The air or gas mixture whose volume has been increased by the vacuum and the resulting expansion is whirled in this state and mixed with the water to be skimmed so that bubbles are formed, whose uniform size of 0.1 to 0.5 mm is ideal for the skimming process.
BEST MODE OF CARRYING OUT THE INVENTION
The best mode of carrying out the invention is principally explained in the description of the drawings (FIG. 1-FIG. 3).
According to the process of the present invention, an appropriate gaseous mixture of the above-mentioned very small air bubbles and of a constant air quantity are mixed with sea water in a contact tube of a protein skimmer to cause flotation and skimming of colloidal constituents in the water flowing out of the aquarium to the contact tube. By using a new apparatus including a centrifugal pump and an internal injector axial protruding in a suction port of a closed impeller, which is mounted laterally inside and outside to the contact tube at a height of approximate 30 cm above the tube-bottom and the water-outlet of the contact tube, there is sucked water under a hydrostatic water pressure of approximately 1 m water column from the contact tube. There is also sucked an air-gas mixture through an air pipe 3 from the outside to the suction port 24 of the centrifugal pump 17. Thus, the water-gas mixture of approximately 10:1 (volume percentage) is mixed in the impeller so that gas bubbles with a diameter of 0.1 to 0.5 mm are mixed with the aquarium water located in the contact tube 1 and are attached thereto or dissolved in the water. The water is pumped in a countercurrent manner to the rising air bubbles along the contact tube to cause a stronger flotation.
In this apparatus there is needed no air drying for ozonization purposes. As the external drive motor of the pump there is used a slotted tube motor 12 which merely has a power consumption of 60 and 80 Watts (adjustable). In the U.S.A. there is used a current of 60 Hz, 110 V, instead of 50 Hz, 220 V. Because of the higher motor frequency, there is a higher revolution number of the impeller 4 of the centrifugal pump 17. To counterbalance the higher suction, equivalent to the motor consumption of 60 Watts (2.200 rounds per minute) or of 80 Watts (2.500 rounds per minute), there is preferably used an apparatus whose impeller and internal injector are sized differently from the above described apparatus for using 50 Hz, 220 V. a.c.
Thus it is impossible to suck water from the contact tube and to suck a gaseous mixture from the outside of the tube so as to mix water and gas in the ratio of approximately 10:1 and to form gas bubbles with a diameter of 0.1-0.5 mm when using an a.c. current of 60 Hz, 110 V. When applying a thus slightly modified apparatus, the volume of the gas sucked and mixed into the water is about 300 or 400 liters/hour for 60 or 80 Watts.
There is used a smaller external diameter of the impeller, which instead of 70 mm is 62 mm whereas the diameter of the suction port 24 is still 30 mm. The vertical clearance of the impeller at the beginning of the vanes is still 6.2 mm, but is now approximately 4 mm at the periphery. The diameter of the disk 10 and thus of the suction port 24 is still 30 mm, and the disk 10 has also still a thickness of 5 mm.
The different internal injector used consists of a suction connection 9 mm long and having an inner diameter increased from 6.1 mm to 7.7 mm. The injection connection 6 still has an outer diameter of 5 mm and an inner diameter of 4 mm. The connection projects still roughly 2.5 mm into the axial suction connection 5.
The diameter of the bores 14 is increased from 3.5 mm to 4 mm and the size of the radial ducts 13 is 2 mm wide and 4 mm deep. Thus the ratio of the overall size of the water intake ports on the peripheral circumference of the disk as formed by the bores 14,--to the size of the central opening of the disk as formed between the opening 19 of the suction connection 5 and the outside of the axially projecting injection connection 6, is 2.37:1 (46.57 mm 2 /19.63 mm 2 )
INDUSTRIAL APPLICABILITIY
It is evident according to the above description that the inventive process for the suction and mixing in of gaseous mixtures in the water pumped through the contact tube of a protein skimmer, and also the apparatus needed for this process, has a far range of industrial applicability. | The present invention provides a process and apparatus for mixing gaseous mixtures into sea-water pumped from an aquarium through the contact tube of a protein skimmer. The invention forms air bubbles of a specific uniform diameter so as to obtain an optimum skimming. The apparatus has a centrifugal pump closed about the periphery of the vanes at the suction side. A suction port at the axial part of the impeller forms water intake ports which surround an internal gas injection connection projecting into an axial water suction connection of a central disk fixed within the suction port of the impeller. The height of the water column over the suction point can, within limits, be taken into account by different gas and water suction cross-sections, adjustment of the gas injection connection relative to the water suction connection, and different sizes of the impeller. | 2 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a reading/recording apparatus and a reading/recording control method.
[0003] 2. Description of the Related Art
[0004] In recent years, as terminal apparatuses have been made smaller in size, there have also been demands for miniaturization of information terminal apparatuses. In particular, in a reading/recording apparatus such as a facsimile apparatus for domestic use, a sheet conveying mechanism used for a reading operation and a sheet conveying mechanism used for a recording operation are completely separate from each other, so that a space where a reading unit reads an original (document) during transmission is separate from a space where a recording unit performs the recording operation during reception.
[0005] [0005]FIG. 10 is a cross-sectional view showing the construction of a conventional reading/recording apparatus. In this conventional reading/recording apparatus, recording sheets 301 are placed on a recording sheet holding member 303 and are fed sheet by sheet by a recording sheet feeding roller 304 and a separating mechanism. The fed recording sheet is conveyed to a recording section 306 by a conveying roller 305 and is discharged from the apparatus (in the direction shown by the arrow B in FIG. 10) by a discharge roller 307 while an image is being formed on the recording sheet by a recording section such as an inkjet cartridge.
[0006] On the other hand, originals 302 are placed on an original holding member 308 and are set on a wedge-shaped abutting section formed of an original separating roller 309 and a separating arm 313 . When the original separating roller 309 rotates according to an image reading instruction, out of the originals held at the abutting section, only an original in contact with the original separating roller 309 is separated using friction and is conveyed.
[0007] The separated and conveyed original 302 is further conveyed by an original feeding roller 310 , a discharge roller 312 , and opposing rollers while being held therebetween. While an image on the original 302 is being read by a contact image sensor 311 , the original 302 is discharged from the apparatus (in the direction shown by the arrow A in FIG. 10).
[0008] For a reading/recording apparatus such as a copier or a facsimile apparatus, various functions and improvements have been implemented to make such apparatus more convenient to use, according to demands from customers. One of such demands is for miniaturization of the apparatus. For users who wish to make effective use of limited space, apparatus size is especially important when purchasing equipment.
[0009] However, in the conventional reading/recording apparatus described above, the sheet conveying mechanism for the reading operation and the sheet conveying mechanism for the recording operation are completely separate from each other, that is, the space in which the reading unit reads the original during transmission is separate from the space in which the recording unit performs the recording operation during reception, so that it is necessary to provide separate physical spaces for the reading operation and the recording operation. This makes it difficult to miniaturize the apparatus.
[0010] On the other hand, there is a known technique for reducing apparatus size by using a single reading/recording path mechanism with a shared conveying path on which both originals and recording sheets are conveyed. Specifically, by conveying originals using the same conveying mechanism used for conveying recording sheets, it is possible to omit a feed roller, discharge roller, original driving motor, original detecting sensor, and the like that are used for conveying originals. However, in the case of an inkjet reading/recording apparatus where recording is performed by moving the recording unit, it is necessary to drive the reading unit and the recording unit in different spaces, so that a sufficient reduction in apparatus size cannot be made.
[0011] To further miniaturize a reading/recording apparatus, studies are being performed to make the reading unit freely movable between a reading position located on a shared conveying path for conveying originals and recording sheets and a reading standby position receded from the reading position where the reading unit waits until a read instruction is issued and make the recording unit that moves in the main scanning direction and the reading unit share a moving space. However, if it is simply arranged that the recording unit and the reading share a moving space, when a reading operation and a recording operation occur simultaneously, the reading unit and the recording unit collide, which in some cases results in damage.
[0012] For example, there is the risk that when a reading operation is performed, the reading unit is disposed at the reading position located on the shared conveying path. If on this occasion, a conveyed medium detecting sensor detects a conveyed medium on the shared conveying path, irrespective of the reading operation being performed, the conveyed medium will be erroneously detected as a recording sheet and the recording operation will start. Also, in the case where a recording operation is performed after the reading/recording apparatus has stopped with an original still present on the conveying path due to a jam, power failure, or any other reason, there is the risk of the original being damaged by the recording unit that moves in the main scanning direction.
SUMMARY OF THE INVENTION
[0013] It is an object of the present invention to provide a reading/recording apparatus and a reading/recording control method which are capable of ensuring that a reading device and a recording device do not collide when the apparatus is miniaturized to thereby protect the reading unit and the recording unit by having the reading device and the recording device share a moving space on a shared conveying path used as both a conveying path for an original and a conveying path for a recording sheet.
[0014] To attain the above object, in a first aspect of the present invention, there is provided a reading/recording apparatus comprising a shared conveying path used as both a conveying path for an original and a conveying path for a recording medium, an original conveying device that conveys the original to a reading position on the shared conveying path, a reading device that is freely movable between the reading position and a reading standby position away from the reading position and reads an image of the original at the reading position, a recording medium conveying device that conveys the recording medium to a recording position on the shared conveying path, a recording device that moves within the same space on the shared conveying path as the reading device, is freely movable between the recording position and a recording standby position away from the recording position, and records an image on the recording medium at the recording position, and a control device that inhibits an operation of the recording device at a start of a reading operation by the reading device.
[0015] According to the first aspect of the present invention, it is possible to ensure that the reading device and the recording device do not collide when the apparatus is miniaturized to thereby protect the reading unit and the recording unit by having the reading device and the recording device share a moving space on a shared conveying path used as both a conveying for an original and a conveying for a recording medium.
[0016] Preferably, the reading/recording apparatus comprises an operation mode storage device that stores an operation mode, and wherein the control device is responsive to the stored operation mode having been updated to a reading mode, for inhibiting recording of an image by the recording device.
[0017] Also preferably, the recording device is freely movable in a main scanning direction-on the shared conveying path, and the control device causes the recording device to stay at the recording standby position away from the recording position during the reading operation by the reading device.
[0018] Also preferably, the reading/recording apparatus comprises a rotary shaft extending in a main scanning direction, and wherein the reading device is freely rotatable about the rotary shaft between the reading position and the reading standby position, and the control device is responsive to the reading device having read an image of the original at the reading position on the shared conveying path, for causing the reading device to the reading standby position away from the reading position.
[0019] Also preferably, the reading/recording apparatus comprises a conveyed medium detecting device that detects a conveyed medium on the shared conveying path, and a forcible discharging device operable when the conveyed medium has been detected on the shared conveying path by the conveyed medium detecting device at the start of the reading operation, to forcibly discharge the conveyed medium.
[0020] According to this preferred form, it is possible to avoid damage to the original or the occurrence of a paper jam due to the recording device moving in a state where the original remains on the shared conveying path due to a paper jam, power failure, or other reason. Further, it is also possible to reduce the time spent on exclusive control operation of one of the reading device and the recording device within the shared moving space, thereby suppressing delays in reading and recording operations.
[0021] More preferably, the reading/recording apparatus further comprises a notification device operable when the conveyed medium has been detected on the shared conveying path by the conveyed medium detecting device at the start of the reading operation, to issue a notification that the conveyed medium has been detected.
[0022] To attain the above object, in a second aspect of the present invention, there is provided a reading/recording control method for a reading/recording apparatus including a shared conveying path used as both a conveying path for an original and a conveying path for a recording medium, a reading device that is freely movable between a reading position on the shared conveying path and a reading standby position away from the reading position and reads an image of the original, and a recording device that moves within the same space on the shared conveying path as the reading device, is freely movable between a recording position on the shared conveying path and a recording standby position away from the recording position, and records an image on the recording medium, the method comprises an original conveying step of conveying the original to the reading position, a reading step of reading an image of the original at the reading position by the reading device, a recording medium conveying step of conveying the recording medium to the recording position, a recording step of causing the recording device to record an image on the recording medium at the recording position, and a recording inhibiting step of inhibiting an operation of the recording device at a start of a reading operation by the reading device.
[0023] According to the second aspect of the present invention, substantially the same effects as those by the first aspect described above can be provided.
[0024] The above and other objects of the present invention will become more apparent from the following detailed description taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0025] [0025]FIG. 1 is a perspective view showing the external appearance of a multifunction communication apparatus as a reading/recording apparatus according to an embodiment of the present invention;
[0026] [0026]FIG. 2 is a perspective view showing the internal construction of the multifunction communication apparatus of FIG. 1;
[0027] [0027]FIG. 3 is a perspective view showing the internal construction of the multifunction communication apparatus of FIG. 1 in a state where a recording unit is operating;
[0028] [0028]FIG. 4 is a cross-sectional side view'showing the internal construction of the multifunction communication apparatus of FIG. 1 in the state where the recording unit is operating;
[0029] [0029]FIG. 5 is a perspective view showing the internal construction of the multifunction communication apparatus of FIG. 1 in a state where the reading unit is operating;
[0030] [0030]FIG. 6 is a cross-sectional side view showing the internal construction of the multifunction communication apparatus of FIG. 1 in the state where the reading unit is operating;
[0031] [0031]FIG. 7 is a block diagram showing the electrical construction of the multifunction communication apparatus of FIG. 1;
[0032] [0032]FIG. 8 is a flowchart showing the procedure of a control process for inhibiting a recording operation during a reading operation by the multifunction communication apparatus of FIG. 1;
[0033] [0033]FIG. 9 is a continued part of the flowchart of FIG. 8; and
[0034] [0034]FIG. 10 is a cross-sectional view showing the construction of a conventional reading/recording apparatus.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0035] The present invention will now be described in detail with reference to the accompanying drawings showing a preferred embodiment thereof.
[0036] [0036]FIG. 1 is a perspective view showing the external appearance of a reading/recording apparatus according to the embodiment. The reading/recording apparatus according to the present embodiment is applied to a multifunction communication apparatus that has a facsimile communication function and a copying function. This multifunction communication apparatus has a casing 120 with a discharge opening 127 provided in a front side thereof and an original tray 11 provided on a rear side thereof. A handset 121 , a display 122 , an operating section 106 , an original discharge button (discharge key) 125 , and so forth are provided on an upper surface of the casing 120 .
[0037] The display 122 displays the state of the multifunction communication apparatus, a telephone number, and so forth. The operating section 106 is comprised of a plurality of keys and is used to input a telephone number or various kinds of setting information and to give instructions for operations. The original discharge button 125 is pressed to discharge an original or a recording sheet.
[0038] [0038]FIG. 2 is a perspective view showing the internal construction of the multifunction communication apparatus of FIG. 1. FIG. 2 shows a state where neither a recording sheet nor an original has been set and neither a reading unit nor a recording unit is operating, so that both the units are located in receded positions. FIG. 3 is a perspective view showing the internal construction of the multifunction communication apparatus of FIG. 1 in a state where the recording unit is operating. FIG. 4 is a cross-sectional side view showing the internal construction of the multifunction communication apparatus of FIG. 1 in a state where the recording unit is operating. FIG. 5 is a perspective view showing the internal construction of the multifunction communication apparatus of FIG. 1 in a state where the reading unit is operating. FIG. 6 is a cross-sectional side view showing the internal construction of the multifunction communication apparatus of FIG. 1 in a state where the reading unit is operating.
[0039] In FIGS. 2 to 6 , reference numeral 1 designates an ink cartridge (the recording unit) that carries out recording, 3 a platen that is disposed in opposition to a surface of an original during a reading operation and to a surface of a recording sheet during a recording operation; 3 a a platen supporting member that supports the platen 3 ; 8 a recording sheet tray on which recording sheets 2 are placed; 9 a pressing plate that presses the recording sheets 2 onto a recording sheet separating roller 19 when a recording sheet is to be separated; 10 a feed roller that feeds a conveyed medium (an original or a recording sheet) when reading or recording is carried out; 11 an original tray that holds originals, 13 a separating arm that separates an original 12 ; 15 an original separating roller that applies a force required to separate an original; 16 a pinch roller that supplements a driving force of the feed roller 10 during the feeding of the conveyed medium; 17 a discharge roller that discharges the conveyed medium out of the apparatus during reading and recording; 18 a spur that supplements a driving force of the discharge roller 17 when the conveyed medium is discharged; 19 a recording sheet separating roller that applies a force required to separate a recording sheet; and 21 a conveyed medium detecting sensor (paper edge sensor or “PES”) that detects the presence of a conveyed medium during reading and during recording.
[0040] Further, reference numeral 22 designates a contact image sensor (CS) that carries out a reading operation; 23 an original lower guide member that guides an original 12 ; 24 a chassis; 25 a white reference determining member that determines a white reference level of an image read by the contact image sensor (CS) 22 during an operation that reads an original; and 26 a contact image sensor holder (CS holder) that supports the CS 22 and the white reference determining member 25 , and is also supported for free rotation with respect to the apparatus main body about a rotary shaft 26 a extending in a main scanning direction. A reading unit 30 is comprised of the CS holder 26 , the CS 22 , and the white reference determining member 25 . During a reading operation, the CS holder 26 rotates to a reading position close to a recording section (that is, a recording position) on the platen 3 , and an image of the original that passes a shared conveying path is read by the CS 22 . On the other hand, during a recording operation, the CS holder 26 rotates away from the reading position on the platen 3 to a reading standby position, and a recording unit 1 that is freely movable on the platen 3 in the main scanning direction carries out a recording operation on the recording sheet that passes the shared conveying path.
[0041] Reference numeral 27 designates an original detecting sensor (DS: document sensor) used for detecting the presence of an original on the original tray 11 . During a reading operation, a document is detected by the DS 27 and the PES 21 detects whether a conveyed medium (an original or a recording sheet) has passed a predetermined position on the shared conveying path. It should be noted that when the apparatus is in reading mode in response to a start request for a reading operation being issued, in which an original is conveyed, if the PES 21 is not turned on and the DS 27 remains on, it is judged that an abnormality has occurred during conveying of the original, and an original jam (hereinafter referred to as “a paper jam”) flag is set.
[0042] The recording unit 1 is provided therein with an ink tank and an ink head (recording head), and records an image based on image information by injecting ink from the ink tank onto a recording sheet 2 through nozzles provided on the ink head. The recording unit 1 is detachably attached to a carriage 4 that is guided by a guide rail 7 that is formed in an inverted U-shape integrally with the top of the chassis 24 and a guide shaft 60 supported by side plates 24 a , 24 b at both ends of the chassis 24 . The carriage 4 is fixed to a carriage belt 63 and is driven by a carriage motor to move the recording unit 1 in the main scanning direction.
[0043] The reading operation and recording operation of the multifunction communication apparatus with the above construction will be described next. First, when an original 12 is set on the original tray 11 during a reading operation, the original 12 is detected by the original detecting sensor (DS) 27 that is located near the original separating roller 15 .
[0044] If the user gives an instruction for the start of a reading operation via the operating section 106 in a state where the original 12 has been detected by the original detecting sensor 27 , “reading mode” indicative of a reading operation being carried out is stored in a storage section 107 shown in FIG. 7 (described later) as an operation mode, and a reading operation is started. Under the control of a CPU 100 in FIG. 7, the original separating roller 15 is driven to cause one original 12 to be separated by the separating arm 13 , and the separated original is fed to the reading position.
[0045] At the same time, the CS holder 26 is rotated about the rotary shaft 26 a towards the platen 3 by the driving force of the feed roller 10 , to bring the CS 22 to the reading position. In this state, the feed roller 10 conveys the original 12 on the shared conveying path and the CS 22 reads an image from the original 12 until a trailing edge of the original 12 is detected by the PES 21 . The image read by the CS 22 is converted into image information by a predetermined method and the image information is stored in the storage section 107 shown in FIG. 7.
[0046] When the reading of the image from the original 12 has been completed, the original 12 is discharged from the apparatus by the discharge roller 17 . When the user has given an instruction for a reading operation for a plurality of originals, after the discharging of an original has been completed, the next original 12 is separated and fed and an image of this next original 12 is read in the same way. When the reading of images has been completed for the number of originals 12 indicated by the user, the CS holder 26 is finally rotated to the reading standby position away from the reading position on the platen 3 , and the reading operation is completed.
[0047] Next, in a recording operation, when the user gives an instruction for the start of a recording operation using the operating section 106 , if the CS holder 26 has been rotated to the reading position, before the recording operation starts, the CS holder 26 is receded from the reading position to the reading standby position. After this, “recording mode” indicative of a recording operation being carried out is stored in the storage section 107 shown in FIG. 7 as the operation mode. Consequently, the ink cartridge (recording unit) 1 can move in the main scanning direction at and in vicinity of the recording section on the platen 3 , so that recording can be carried out on the recording sheet 2 that passes on the shared conveying path.
[0048] After this, recording sheets 2 are placed on the recording sheet tray 8 and when one recording sheet 2 , out of the recording sheets 2 that are pressed by the pressing plate 9 , has been separated by the recording sheet separating roller 19 under the control of the CPU 100 shown in FIG. 7, the recording sheet 2 is fed to the recording section (recording position) on the platen 3 .
[0049] Next, until the trailing edge of the recording sheet 2 conveyed by the feed roller 10 is detected by the PES 21 , the recording unit 1 records an image on the recording sheet 2 based on image information stored in the storage section 107 shown in FIG. 7. When the recording of the image has been completed, the recording sheet is discharged from the apparatus by the discharge roller 17 . When a recording operation is to be performed for a plurality of recording sheets 2 , after the discharging of a recording sheet on which an image has been recorded has been completed, the processes for separating and feeding the next recording sheet 2 on which an image is to be recorded, recording an image, and discharging the recording sheet are repeated for the remaining number of sheets.
[0050] Here, when the recording unit 1 is not performing a recording operation, the recording unit 1 stands by at a home position (recording standby position) (a position shown by the arrow A in FIG. 5) and a cap is placed over the recording head of the recording unit 1 to prevent clogging of the recording head caused by drying of the ink. When a recording operation is carried out, the cap is removed, the recording unit 1 is moved to a recovering operation position (a position shown by the arrow B in FIG. 3), and after an initialization operation, such as a recovering operation of the recording head, has been performed, the recording operation starts. Aside from the initialization operation of the recording unit 1 described above, even if no user instruction has been given via the operating section 106 , other initialization operations (such as a recovering operation of the ink cartridge 1 and a remaining ink detecting operation) are executed according to predetermined conditions. Also, as for the timing for carrying out a recording operation, the recording unit 1 starts an initialization operation when the PES 21 detects a recording sheet 2 .
[0051] In this way, in the case where during a reading operation the reading unit 30 including the CS holder 26 moves in the same space in which the recording unit 1 moves during a recording operation, there was conventionally the danger that when a reading operation is carried out, an original 12 detected on the shared conveying path by the PES 21 is mistakenly identified as a recording sheet 2 and an unexpected recording operation would start. With the present embodiment, however, the above situation is avoided.
[0052] [0052]FIG. 7 is a block diagram showing the electrical construction of the multifunction communication apparatus of FIG. 1. This multifunction communication apparatus is comprised of the CPU 100 , a reading section 101 including the reading unit 30 that reads an original, a recording section 102 including the recording unit 1 that records an image on a recording sheet based on image information received via facsimile communication and/or image information of an original read by the reading unit 30 , a conveying section 103 that conveys originals and recording sheets along the shared conveying path, a conveyed medium detecting section 104 including the PES 21 and the DS 27 , a notification section 105 that gives a notification when a conveyed medium has been detected by the conveyed medium detecting section 104 and also notifies a user of various states of the apparatus, an operating section 106 that is operated by the user to input various information and to give instructions for operations of the apparatus, a communication control section 108 that controls transmission and reception of image information and communication carried out by the handset 121 via a telephone line, and the storage section 107 , with these various components being interconnected via a bus 111 . An operation mode such as “reading mode” or “recording mode” is stored in the storage section 107 , along with various states of the apparatus and image information based on images read by the reading unit 30 . A control program, described later, is also stored in a ROM inside the storage section 107 .
[0053] [0053]FIGS. 8 and 9 are flowcharts showing the procedure of a control process for inhibiting a recording operation during a reading operation by the multifunction communication apparatus of FIG. 1. A control program for carrying out this process is stored in the ROM inside the storage section 107 , described earlier, and is repeatedly executed by the CPU 100 at predetermined time intervals.
[0054] First, it is determined whether an original has been detected by the original detecting sensor (DS) 27 located near the original separating roller 15 (step S 1 ). When an original 12 has not been detected, the processing in the step S 1 is repeated.
[0055] On the other hand, when an original 12 has been detected, it is determined whether an instruction for reading operation has been given by the user via the operating section 106 (step S 2 ). When an instruction for a reading operation has not been given, the process returns to the step S 1 . On the other hand, when an instruction for a reading operation has been given, the operation mode is updated to “reading mode” and is stored in an operation mode region in the storage section 107 (step S 3 ).
[0056] Then, it is determined whether a conveyed medium has been detected on the shared conveying path by the PES 21 (step S 4 ). When a conveyed medium has been detected, the feed roller 10 and the discharge roller 17 forcibly discharge the conveyed medium (step S 5 ). This conveyed medium is determined to be a conveyed medium that has been present on the shared conveying path before the reading operation started, hence is not to be read, and is, therefore, forcibly discharged in the step S 5 . Then, the notification section 105 notifies the user that the operation of the recording unit 1 is inhibited (step S 6 ), and after this, control is provided to inhibit the recording unit 1 from operating (step S 7 ). On the other hand, when no conveyed medium has been detected by the PES 21 in step S 4 , the process proceeds directly to the step S 6 and the processing in the steps S 6 and S 7 is carried out in the same way. As a result, according to the detection by the PES 21 , the recording unit 1 is inhibited from carrying out an operation (such as an operation where the conveyed medium is identified as a recording sheet and the recording unit 1 is moved in the main scanning direction) that is not intended by the user.
[0057] After control has been carried out to inhibit the operation of the recording unit 1 in the step S 7 , preparations are made for the start of a reading operation. First, the driving force of the feed roller 10 is used to rotate the CS holder 26 to the reading position near the recording section on the platen 3 , with the original separating roller 15 also being driven to separate one original 12 using the separating arm 13 (step S 8 ) and the separated original being conveyed to the reading position (step S 9 ). When the original 12 has been conveyed to the reading position, one line of an image on the original 12 is read by the CS 22 (step S 10 ), and after one line of the image has been read, the original 12 is fed the equivalent of one line forwards by the feed roller 10 (step S 11 ).
[0058] It is then determined whether the PES 21 has detected the trailing edge of the original 12 (step S 12 ). When the trailing edge of the original 12 has not been detected, the processing in the step S 10 and the processing in the step S 11 are repeated in that order until the trailing edge of the original 12 is detected. On the other hand, when the trailing edge of the original 12 has been detected in the step S 12 , the original 12 is discharged from the apparatus by the discharge roller 17 (step S 13 ) and the present process is terminated.
[0059] As described above, according to the multifunction communication apparatus of the present embodiment, when the reading unit 30 and the recording unit 1 move within a shared space on a shared conveying path used for conveying both originals and recording sheets, a recording operation is inhibited during a reading operation. As a result, it is possible to avoid an erroneous operation where an original is mistakenly identified as a recording sheet and the recording unit 1 moves in the main scanning direction. It is, therefore, possible to prevent the reading unit 30 and the recording unit 1 from colliding.
[0060] Moreover, by forcibly discharging an original when the original has been detected on the shared conveying path by the PES 21 before a reading operation starts, it is possible to avoid damage to the original or the occurrence of a paper jam due to the recording unit 1 moving in a state where the original remains on the shared conveying path due to a paper jam, power failure, or other reason. It is also possible to reduce the time spent on exclusive control operation of one of the reading unit 30 and the recording unit 1 within the shared moving space, thereby suppressing delays in reading and recording operations.
[0061] The present invention is not limited to the above described embodiment and can be applied to any construction that can achieve the functions described in the appended claims or the functions of the construction of the above described embodiment.
[0062] For example, although the present invention is applied to a multifunction communication apparatus with a facsimile communication function and a copying function in the above embodiment, the present invention is not limited to a facsimile apparatus, a copier, or the like, and can be applied to a variety of appliances that can perform a reading operation for an original and a recording operation. | There is provided a reading/recording apparatus capable of ensuring that a reading device and a recording device do not collide when the apparatus is miniaturized to thereby protect the reading unit and the recording unit by having the reading device and the recording device share a moving space on a shared conveying path used as both a conveying for an original and a conveying for a recording sheet. The original is conveyed to a reading position on the shared conveying path. The reading unit is freely movable between the reading position and a reading standby position away from the reading position, and reads an image of the original at the reading position. The recording medium is conveyed to a recording position on the shared conveying path. The recording device moves within the same space on the shared conveying path as the reading unit, is freely movable between the recording position and a recording standby position away from the recording position, and records an image on the recording medium at the recording position. The operation of the recording unit is inhibited at the start of a reading operation by the reading unit. | 7 |
CROSS-REFERENCES TO RELATED APPLICATIONS
This application is a continuation-in-part of application Ser. No. 12/492,779, filed on Jun. 26, 2009, which claims the benefit of provisional Application No. 61/077,104, filed on Jun. 30, 2008; and is also a continuation-in-part of application Ser. No. 11/772,718, filed on Jul. 2, 2007, which was a continuation-in-part of application Ser. No. 11/302,951, filed on Dec. 13, 2005, now U.S. Pat. No. 7,691,127, the full disclosures of which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to medical devices and methods. More particularly, the present invention relates to apparatus and protocols for closing arteriotomies and other vascular wall penetrations.
Angiography, angioplasty, atherectomy, and a number of other vascular and cardiovascular procedures are performed intravascularly and require percutaneous access into the patient's vasculature, most often into the arterial vasculature. The most common technique for achieving percutaneous access is called the Seldinger technique, where access to an artery, typically the femoral artery in the groin, is first established using a needle to form a “tract,” i.e., a passage through the tissue overlying the blood vessel. The needle tract is then dilated, and an access sheath is placed into the dilated tract and through a penetration in the vascular wall, such as an arteriotomy to allow the introduction of guidewires, interventional catheters, catheter exchange, and the like to perform the desired procedure.
Once the desired procedure is completed, the access sheath must be removed and the arteriotomy or other vascular wall penetration closed. For many years, such closure was achieved by applying manual pressure onto the patient's skin over the site of the vascular wall penetration. Patients, however, have often been heparinized to limit the risk of thrombosis during the procedure, and clotting of the vascular wall penetration can often take an extended period, particularly when the penetration is relatively large for performing procedures needing larger diameter catheters. For these reasons, improved methods for closing and sealing vascular wall penetrations have been sought.
In the last decade, a variety of new procedures and devices have been introduced to more effectively seal the arteriotomies and other vascular wall penetrations associated with percutaneous intravascular access. Some of the new protocols rely on suturing, others rely on clipping, plug placement, energy-based closure, and the like. One problem with many of the new procedures, however, is that they leave material behind, and/or induce scar formation at the access site. Both the leaving of materials and the formation of scar tissue can be problematic, particularly if the patient requires subsequent access to the same vascular site for performance of another vascular or cardiovascular procedure.
For these reasons, it would be advantageous to provide protocols and apparatus which would leave no material behind and which would further limit the likelihood of forming scar tissue after the procedure is complete. One device that can meet these objectives in many instances is the Boomerang Catalyst™ system available from Cardiva Medical, Inc., assignee of the present application. The Boomerang Catalyst system includes an expansible element at its tip for providing temporary hemostasis when placed in the blood vessel adjacent to the vascular wall penetration. The catheter further includes a catalytic material on its shaft which helps induce hemostasis and clotting within the tissue tract immediately above the vessel wall penetration. The construction and use of this system is described in copending application Ser. No. 11/302,951; Ser. No. 11/772,718; and Ser. No. 11/614,276, the full disclosures of which are incorporated herein by reference.
Despite the success of the Boomerang Catalyst systems, there may still be some instances where hemostasis is not achieved as rapidly. For this reason, it would be desirable to provide further improved systems and protocols for closing and sealing arteriotomies and other vascular wall penetrations, where the closure may be achieved with rapid hemostasis, with a minimum risk of scar formation, and without leaving any materials or implants permanently behind in the vessel or the tissue tract. At least some of these objectives will be met by the inventions described below.
2. Background of the Invention
U.S. Pat. No. 7,335,219 describes a device for delivering a plug of hemostatic material to a location just above a blood vessel wall penetration. The hemostatic material is encapsulated in a dissolvable structure and a non-expandable control tip assembly helps advance the device through the tissue tract and may also provide hemostasis and bleedback. US2007/0123817 and U.S. Pat. No. 7,008,439 describe apparatus for sealing a vascular wall penetration. Other apparatus for closing blood vessel wall punctures are described in U.S. Pat. Nos. 4,744,364; 5,061,271; 5,728,133; and 7,361,183 and U.S. Published Patent Application Nos. 2003/0125766; 2004/0267308; 2006/0088570; 2007/0196421; and 2007/0299043. The incorporation of anti-proliferative materials in hemostatic materials for blood vessel closure and other purposes is described in U.S. Pat. Nos. 7,025,776 and 7,232,454; 6,554,851; and U.S. Published Patent Application Nos. 2005/0004158; 2005/0038472; 2007/0060895/2007/0032804; and 2008/0039362.
BRIEF SUMMARY OF THE INVENTION
The present invention provides apparatus and methods for sealing a blood vessel wall penetration with little or no material being permanently left behind and with a reduced likelihood of scar tissue formation. The invention relies on placing a hemostatic implant in the tissue tract at a location over the vascular wall penetration while the penetration is temporarily closed with an expansible occlusion element present in the blood vessel lumen. The hemostatic implant is preferably biodegradable, typically over a period of less than one year, preferably over a period of less than six months, more preferably less than three months, and may carry an anti-proliferative agent to reduce scar formation. Additionally or alternatively, the implant may carry a coagulation promoter to accelerate hemostasis and/or radiopaque material to enhance visualization. The use of the hemostatic implant together with the temporary hemostasis provided by the occlusion element increases the likelihood that even relatively large vascular penetrations can be successfully closed and usually reduces the time needed to achieve such closure.
Apparatus according to the present invention for sealing a blood vessel wall penetration disposed at an end of a tissue tract comprise a shaft, an occlusion element, a hemostatic implant, and a protective sleeve. The shaft has a proximal and distal end and is adapted to be introduced through the tissue tract so that the shaft distal end can be positioned within the blood vessel lumen. Usually, the shaft will be adapted so that it can be introduced through the vascular access sheath which is in place after performance of the interventional procedure.
The occlusion element is disposed near the distal end of the shaft and is configured so that it may be shifted between a radially contracted configuration which facilitates introduction through the tissue tract and a radially expanded configuration for deployment within the blood vessel to occlude the penetration and provide temporary hemostasis. The hemostatic element could be a balloon or other inflatable structure, but will more usually be an expansible braid, coil, or other element which may be radially expanded by axial foreshortening. Typically, the shaft comprises an outer tube and an inner rod where a distal end of the occlusion element is attached to a distal end of the rod and a proximal end of the occlusion element is attached to a distal end of the outer tube. Thus, the occlusion element can be expanded and contracted by retracting and advancing the rod relative to the tube, respectively. The preferred occlusion element comprises a braided mesh covered with an elastic membrane. As described thus far, the shaft and occlusion element may be similar or identical to those described in the earlier referenced commonly owned patent applications.
The hemostatic implant of the present invention is disposed over an exterior surface of the shaft proximal to the occlusion element. The protective sleeve is retractably disposed over the hemostatic implant to protect it while the shaft is being introduced to the tissue tract. The hemostatic implant will typically comprise a body or wrapped sheet which partially or fully circumscribes the shaft, but other configurations could also be utilized. In a first embodiment, the hemostatic implant comprises a cylindrical body which is coaxially mounted about the shaft of the delivery device. Such fully circumscribing implants, however, can have difficulty being released from the shaft after they are exposed and hydrated. Thus, it will often be preferable to provide hemostatic implant configurations where the body partially circumscribes the shaft or is disposed in parallel to the shaft. As illustrated hereinafter, the shaft carrying the implant may have an axis and the hemostatic implant may be asymmetrically mounted on an exterior surface of the shaft relative to the axis. When the implant is not disposed about the shaft, release upon rehydration will be greatly simplified as the rehydrated implant will lie adjacent to the shaft, allowing the shaft and the collapsed occlusion element to be drawn proximally past the rehydrated hemostatic implant with minimum interference. The hemostatic implant typically comprises a swellable, biodegradable polymer which swells upon hydration. Hydration is prevented when the polymer is introduced by the protective sleeve. The polymer hydrates and swells when the sleeve is retracted within the tissue tract, exposing the polymer to the body fluids. Suitable polymers include biodegradable hydrogels such as polyethylene glycols, collagens, gelatins, and the like.
An anti-proliferative agent will usually be distributed within or otherwise carried by the material of the hemostatic implant. As most anti-proliferative agents, such as sirolimus, paclitaxel, and the like, are hydrophobic, it will usually be desirable to incorporate the anti-proliferative agents in a carrier, such as a biodegradable polymer, such a polylactic acid (PLA), poly(lactide-co-glycolide), and the like. The anti-proliferative agents may be incorporated into pores of polymeric beads or other structures which are dispersed or distributed within the biodegradable hydrogel or other swellable polymer. In certain embodiments, the anti-proliferative agents may be incorporated into nanoparticles, typically having dimensions in the range from 10 nm to 100 mu.m.
Agents useful as coagulation promoters, such as thrombin, tissue factors, components of the clotting cascade, and the like may also be incorporated into the body of the hemostatic implant. In some instances, it may be desirable to incorporate such coagulation promoters into particulate or other carriers as described above with regard to the anti-proliferative agents.
In addition to the anti-proliferative agents and the coagulation promoters, the hemostatic implants of the present invention may further incorporate radiopaque materials in or on at least a portion of the implant body. For example, a radiopaque material, such as barium, may be incorporated into the polymer, either by dispersion or chemical bonding. Alternatively, radiopaque rings, markers, and other elements, may be attached on or to the hemostatic implant, for example at each end of the implant to facilitate visualization of the implant as it is being implanted. Additionally or alternatively, radiopaque markers may be provided on the tube or shaft which carries the hemostatic implant so that the marker(s) align with a portion of the implant, typically either or both ends of the implant, prior to deployment.
In a preferred aspect of the present invention, the protective sleeve is held in place by a latch mechanism while it is being introduced. A separate key element is provided to release the latch mechanism and permit retraction of the sleeve after the device has been properly placed through the tissue tract and into the target blood vessel. The latch will be disposed on the shaft and will engage the protective sleeve to immobilize the sleeve during introduction. The key, which is usually slidably disposed on the shaft proximal of the latch, is able to shift the latch between a locking configuration where the sleeve is immobilized and an open configuration which allows the sleeve to be proximally retracted. Usually, the latch is spring-loaded to deflect radially outwardly from the shaft in a manner which engages the sleeve. The key is then adapted to radially depress the latch to release the sleeve. In a preferred embodiment, the latch and key mechanism will extend over a proximal portion of the shaft having a length sufficient to allow manual access to the key latch even when the shaft is placed in the tissue tract.
In a further preferred aspect of the present invention, a backstop structure is provided on the shaft to engage the hemostatic implant to immobilize the implant while the sleeve is being proximally refracted. The backstop usually comprises a tube disposed on or coaxially over the shaft and having a distal end which engages a proximal end of the hemostatic implant. The backstop engages the hemostatic implant to prevent accidental dislodgement while the occlusion element is being proximally retracted through the implant. The backstop may include a space or receptacle for receiving the retracted occlusion element, allowing the backstop to be held in place until the occlusion element has been fully retracted through the hemostatic implant.
The protective sleeve of the present invention may comprise an outer sleeve and a separately retractable inner release sheath. The outer sleeve and inner release sheath are usually mounted coaxially so that the outer sleeve may be retracted over the inner release sheath while the inner release sheath remains stationary over the implant and acts as a friction barrier between the outer sleeve and implant. Without the inner release sheath, the protective sleeve, which applies the compressive and constrictive forces to the hemostatic implant, could stick to the hemostatic implant and make retraction of the protective sleeve and deployment of the implant difficult. The inner release sheath is preferably axially split so that, once the outer sleeve is retracted, the inner release sheath opens to release the implant and facilitate retraction of the release sheath. In preferred embodiments, the outer sleeve can engage the inner release sheath after the outer sleeve has been partly retracted. During the remainder of the outer sleeve retraction, the outer sleeve will then couple to and retract the inner release sheath to fully release the hemostatic implant. In addition to the use of the inner release sheath, the distal end of the protective sleeve may be sealed with a biodegradable substance, such as a glycerin gel, which can inhibit premature hydration of the hemostatic implant prior to release.
In a further preferred aspect of the present invention, the key of the latch mechanism can include a coupling element which attaches to the protective sleeve as the key is advanced and the latch is released. After the key couples to the protective sleeve, the key can be used to retract the protective sleeve. That is, rather than having to reposition the hand to grab and retract the protective sleeve which would also retract the mating key, only the key needs to be held and retracted.
Methods according to the present invention for sealing a blood vessel penetration disposed at the end of a tissue tract comprise providing an apparatus including a shaft, an occlusion element, and a hemostatic implant disposed on an exterior surface of the shaft. The shaft is introduced through the tissue tract to position the occlusion element in the lumen of the blood vessel and the hemostatic implant within the tissue tract. The hemostatic implant is covered by a protective sleeve while the shaft is being introduced through the tissue tract, and the occlusion element is deployed to temporarily inhibit blood flow from the blood vessel into the tissue tract. The protective sleeve is then retracted to expose the hemostatic implant, where the implant typically absorbs fluid and expands to provide the desired seal within the tissue tract. After the hemostatic implant has expanded sufficiently, the occlusion element will be collapsed, and the shaft and collapsed occlusion element withdrawn leaving the hemostatic implant in the tissue tract. As described above, it will usually be preferred to position the hemostatic implant laterally or to the side of the shaft which carries the occlusion element. By thus positioning the occlusion element to bypass the hydrated hemostatic implant, withdrawal of the collapsed occlusion element past the hydrated hemostatic implant can be greatly facilitated. Preferably, the material of the hemostatic implant will degrade over time, preferably over a period of less than one year, more preferably over a period of less than six months, usually less than three months, leaving no material behind at the vascular access point.
In a preferred aspect of the methods of the present invention, the protective sleeve is latched to the shaft while the shaft is introduced. By “latched” is meant that the sleeve will be fixed or immobilized to the shaft by some mechanical link, where the link may be selectively disconnected or “unlatched” when it is desired to retract the sleeve and expose the hemostatic implant. Thus, the methods of the present invention will preferably further comprise unlatching the sleeve before retracting the sleeve. In a specific embodiment, the unlatching comprises distally advancing a key over the latch to effect the desired unlatching. As described above in connection with the apparatus of the present invention, an exemplary latch and key comprises a spring-like element which is secured over an exterior portion of the shaft. The spring-like element typically projects radially outward from the shaft when unconstrained. In this way, the spring-like latch element can engage the protective sleeve to prevent proximal retraction of the sleeve. The latch can be released by advancing a cylindrical or other key element distally over the shaft to depress the spring-like latch element.
In a further preferred aspect of the method of the present invention, a proximal portion of the sleeve will be configured to lie proximal to, i.e., outside of, the tissue tract when the occlusion element is deployed in the blood vessel lumen. Usually, the key element will lie further proximal of the sleeve, permitting the user to manually deploy the key to unlock the latch and to further manually retract the protective sleeve by manually clasping an exposed portion of the sleeve and pulling it proximally from the tissue tract. Typically, the sleeve will have a length in the range from 2 cm to 30 cm, more typically from 5 cm to 15 cm.
In a still further preferred aspect of the method, the hemostatic implant will be constrained to prevent it from being displaced proximally while the shaft is being introduced through the tissue tract. In particular, the backstop or other element may be fixed to the shaft in a location selected to engage the hemostatic implant or an extension thereof to prevent the implant from being displaced proximally, either as the shaft is being introduced or more likely as the protective sleeve is being proximally retracted over the implant. Usually, the backstop or other element will be slidably mounted over the shaft so that it may be held in place as the occlusion element is retracted past the hemostatic implant.
In a specific aspect of the method of the present invention, radiopaque markers on or within the shaft or hemostatic implant are used to verify the location of implant prior to release. Inclusion of radiopaque markers on the delivery shaft is particularly useful when no radiopaque material is incorporated within the hemostatic implant. Preferably, there will be at least two distinct radiopaque bands, with one at each end of the implant. By observing the orientation of the two markers, the physician can determine whether the implant is properly aligned adjacent to the vascular penetration or has inadvertently advanced into a lumen of the blood vessel prior to deployment. In particular, by measuring or visually assessing the apparent distance between the bands when the device is being fluoroscopically imaged from an anterior aspect, the apparent distance between the bands will be longer if the hemostatic implant is within the blood vessel lumen than if it is within the tissue tract immediately above the blood vessel wall penetration. Such apparent differences in the positions of the two radiopaque marker bands results from the foreshortening of the vertical angle at the entry through the wall penetration into the blood vessel lumen. For example, if the tissue tract is disposed at a 45.degree. angle with respect to the horizontal orientation of the blood vessel lumen, in an anterior view, the marker bands will appear to be approximately 30% closer to each other than they would in the horizontal view when they are present in the blood vessel lumen.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates an exemplary sealing apparatus constructed in accordance with the principles of the present invention, shown in section.
FIG. 1A is a detailed view of a distal portion of the sealing apparatus of FIG. 1 , shown in partial section.
FIG. 2 is a cross-sectional view of the sealing apparatus of FIG. 1 , shown with an expanded occlusion element.
FIGS. 3-7 illustrate the further steps of deployment of the hemostatic implant from the apparatus of FIGS. 1 and 2 .
FIGS. 8A-8I illustrate placement and deployment of the hemostatic implant using the apparatus of FIGS. 1 and 2 through a vascular sheath placed in a blood vessel.
FIGS. 9A-9C illustrate a sealing apparatus in accordance with the present invention having a protective sleeve including an outer sleeve and an inner release sheath.
FIGS. 10A-10C illustrate a sealing apparatus in accordance with the present invention having a key latch mechanism which engages the protective sleeve and may be used to proximally withdraw the sleeve to deploy the hemostatic implant.
FIGS. 11A and 11B illustrate a hemostatic implant which is coaxially disposed about the shaft of the deployment apparatus of the present invention.
FIGS. 12A and 12B illustrate the hemostatic implant which is laterally disposed relative to the shaft of the deployment mechanism.
FIGS. 13A and 13B illustrate how aligned radiopaque markers may be utilized to determine that the hemostatic implant is properly located prior to deployment.
FIGS. 14A and 14B illustrate how such radiopaque markers would appear when the hemostatic implant is improperly positioned prior to deployment.
FIGS. 15A-15F illustrate an alternative hemostatic implant protocol.
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIGS. 1 and 1A , an exemplary sealing apparatus 10 constructed in accordance with the principles of the present invention comprises a shaft assembly 70 including an outer tube 71 and an inner rod 76 . An expansible occlusion element 90 is mounted at a distal end (to the right in FIGS. 1 and 1A ) of the shaft assembly 70 and includes a radially expansible mesh 74 covered by an elastomeric membrane 96 . A handle assembly 78 is attached to a proximal end of the shaft assembly 70 and is operatively attached to both the outer tube 71 and inner rod 76 so that the inner rod can be axially advanced and retracted relative to the outer tube. The inner rod 76 and outer tube 71 are coupled together at the distal tip of the sealing apparatus 10 by a plug 77 and a proximal anchor 75 , respectively. The occlusion element 90 is held between the plug 77 and the proximal anchor 75 so that axial retraction of the rod in the proximal direction (to the left as shown in FIGS. 1 and 1A ) foreshortens the occlusion element 90 , causing the occlusion element to expand radially, as shown for example in FIG. 2 .
Axial advancement and retraction of the rod 76 relative to the outer tube 71 is effected using the handle assembly 78 . The handle assembly 78 includes a cylindrical body 103 attached to the proximal end of the outer tube 71 by a bushing 104 so that the body 103 will remain fixed relative to the outer tube as the inner rod 76 is retracted and advanced. The inner rod is retracted and advanced by a slide assembly 101 which includes a short tube 110 fixedly attached to an endcap 111 and a slide cylinder 109 . The inner rod 76 is secured by tube element 107 which carries locking element 106 and bearing elements 108 and 109 . Bearing element 109 is attached to proximal grip 101 and the assembly of the grip 101 and tube element 107 can slide freely within the interior of the cylindrical body 103 so that the rod 76 may be proximally retracted relative to the body 103 and outer tube 71 , as shown in FIG. 2 . Once the expansible occlusion element 90 has been radially expanded, the rod 76 will remain retracted and is held in place by locking element 106 which is pulled over a detent 105 , again as shown in FIG. 2 . An alignment bushing 108 is provided in the interior of the cylindrical body 103 to maintain alignment of the slide assembly 101 relative to the cylindrical body.
The sealing apparatus of the present invention may optionally include a tensioning mechanism 80 which includes a coil spring 86 , a gripping element 85 , and a coupling element 87 . The tensioning mechanism 80 may be selectively positioned along the length of shaft assembly 70 , and will provide a tension determined by the constant of coil spring 86 to hold the expanded occlusion element 74 against the vascular penetration, as described in more detail in copending, commonly-owned application Ser. No. 10/974,008, the full disclosure of which is incorporated herein by reference. As described thus far, the construction and use of the sealing apparatus including shaft assembly 70 , handle assembly 78 , tensioning mechanism 80 , and expansible occlusion element 90 are generally the same as illustrated in copending application Ser. No. 10/974,008. The present invention is directed at modifications and improvements to the earlier device for delivering a hemostatic implant into the tissue tract generally above the vascular wall penetration, as will be described in more detail below.
As best seen in FIG. 1A , hemostatic implant 121 , which will typically be a biodegradable polymer as described in more detail above, is carried coaxially or in parallel over the outer tube 71 near the distal end thereof proximal to the expansible occlusion element 90 . While the hemostatic implant 121 is shown to be positioned coaxially over outer tube 71 in FIG. 1A , it will often be desirable to modify or reposition the implant in order to facilitate release from the sealing apparatus after the implant has been deployed. More simply, the hemostatic implant could be axially split to allow it to partially open after it is hydrated and facilitate passage of the collapsed occlusion element 74 as the sealing apparatus is being withdrawn. Alternatively, the hemostatic implant may be reconfigured and carried laterally (i.e., to one side of) with respect to the shaft of the sealing apparatus, as described in more detail hereinafter with respect to FIGS. 9A and 9C . The hemostatic implant 121 could alternatively be carried on the inner surface of a protective sleeve 123 which is slidably carried over the outer tube 71 . The protective sleeve 123 slides over a backstop 127 which is slidably mounted over the outer tube 71 and which is prevented from moving proximally by stop member 125 which is fixed to the outer surface of the outer tube. Backstop 127 has a distal end 128 which engages a proximal end of the hemostatic implant 121 . Thus, by proximally retracting the protective sleeve 123 , the hemostatic implant 121 can be exposed to the tissue tract and released from the sealing apparatus.
Accidental axial retraction of the protective sleeve 123 is prevented by a latch mechanism including a latch element 120 and a key 126 ( FIGS. 1 and 2 ). The latch element 120 is typically a spring-loaded component, for example a conical spring having a narrow diameter end attached to the outer tube 71 and a flared or larger diameter end 129 which engages a stop ring 124 formed on the inner surface of the protective sleeve 123 . So long as the flared end 129 of the latch element 120 remains in its flared or open configuration, as illustrated in FIG. 1A , accidental proximal retraction of the sleeve is prevented. It is further noted that the stop ring 124 engages stop member 125 of the backstop 127 preventing accidental distal movement of the protective sleeve 123 . Thus, when the sealing apparatus 10 is introduced to a tissue tract, as described in more detail below, movement of the protective sleeve 123 in either the distal or proximal direction is inhibited.
To allow selective proximal retraction of the protective sleeve 123 , the key 126 ( FIGS. 1 and 2 ) may be axially advanced to engage the latching element 120 , as illustrated in FIG. 3 . The key 126 fits inside of the protective sleeve 123 and depresses or radially contracts the latch element 120 so that it fits within the interior circumference of the stop ring 124 , thus allowing proximal retraction of the protective sleeve 123 , as shown in FIG. 4 .
Once the key 126 has engaged and constrained the latch element 120 , as shown in FIG. 3 , the protective sleeve 123 may be proximally withdrawn past the hemostatic implant 121 and the backstop 127 , as shown in FIG. 4 . Thus, the hemostatic implant 121 will be released from constraint and exposed to the environment in the tissue tract. The environment in the tissue tract will include blood and other body fluids which can hydrate the hemostatic implant 121 , causing swelling as shown in FIG. 4 . The swelling will continue, as shown in FIG. 5 , and the radially expanded occlusion element 90 can be collapsed using the handle assembly, as shown in FIG. 5 . The collapsed occlusion element 90 can then be proximally withdrawn into distal receptacle 128 of the backstop assembly 127 , as shown in FIG. 6 (where an annular space may be provided to accommodate the occlusion element). When the occlusion element has been fully withdrawn within the backstop 127 , the hemostatic implant is completely released, as shown in FIG. 6 , and the remaining portions of the sealing apparatus can be pulled away from the hemostatic implant, as shown in FIG. 7 .
Referring now to FIGS. 8A-8I , deployment and use of the sealing apparatus 10 of the present invention through an introducer sheath 40 will be described in more detail. Introducer sheath 40 will typically be in place within a blood vessel lumen 41 passing from the skin surface 46 through tissue 45 in a tissue tract. A vascular wall penetration 42 will thus be present in the vascular wall 43 , all as shown in FIG. 8A . The sealing apparatus 10 is then introduced through the access sheath 40 so that the expansible occlusion element 90 passes out through the distal end of the sheath, as shown in FIG. 8B . Handle assembly 78 will remain outside of the sheath and accessible to the user so that the slide assembly 101 may be pulled relative to the cylindrical body 103 to radially expand the occlusion element 90 , as shown in FIG. 8C . The vascular access sheath 40 may then be withdrawn over the exterior of the sealing apparatus 10 while the sealing apparatus is simultaneously withdrawn to seat the expanded occlusion element 90 against the vascular penetration 42 , as shown in FIG. 8D .
At that point, the protective sleeve 123 and key 126 become exposed and available to the user for manipulation. The key may then be distally advanced over the outer tube 71 so that the key engages and depresses the latch 120 ( FIG. 1A ) as illustrated in FIG. 8E . The key 126 and protective sleeve 123 may then be manually pulled in a proximal direction over the outer tube 71 to release the hemostatic implant 121 , as shown in FIG. 8F . The expandable element 90 may then be collapsed, as shown in FIG. 8G , and the collapsed element withdrawn into the receptacle 128 of the backstop 127 of the sealing apparatus, as shown in FIG. 8H . The entire sealing apparatus 10 , except for the hemostatic implant 121 , may then be withdrawn from the tissue tract, leaving the hemostatic implant 121 in place over the now closed vascular wall penetration, as shown in FIG. 8I . The hemostatic implant, which may optionally carry the anti-proliferative, coagulation promoting, and/or radiopaque substances described above, will remain in place inhibiting bleeding and allowing the vascular wall penetration to heal. Over time, the hemostatic implant 121 will preferably biodegrade, leaving a healed tissue tract and vascular wall penetration which are usually suitable for re-entry at a subsequent time.
Referring now to FIGS. 9A-9C , a protective sleeve 123 ′ comprises an outer sleeve 150 and an inner release sheath 152 . The outer sleeve 150 and inner release sheath 152 are separately retractable so that the outer sleeve may first be retracted relative to the hemostatic implant 121 ( FIG. 9B ) while the inner release sheath initially remains over the implant. The release sheath 152 will thus provide an anti-friction interface so that the outer sleeve 150 slides over the implant 121 with reduced sticking The inner release sheath 152 is preferably formed from a relatively lubricious or slippery material and will preferably include an axial opening or slit 158 which permits the distal portion thereof to partially open after the outer sleeve 150 has been retracted, as shown in FIG. 9B . Once the outer sleeve 150 has been retracted to relieve constraint over the hemostatic implant, the inner sleeve may then be retracted to completely release the hemostatic implant, as shown in FIG. 9C . Conveniently, the outer sleeve 150 may be coupled to the inner release sheath 152 so that proximal retraction of the outer sleeve will automatically retract the inner release sheath at the proper point in travel. For example, a cavity or channel 154 may be formed in an inner surface of the outer sleeve 150 and a ring or other engaging element 156 may be formed on the outer surface of the inner release sheath 152 . Initially, the ring 156 will be positioned at the proximal end of the cavity or channel 154 , as shown in FIG. 9A . After the outer sleeve 150 has been retracted so that it no longer lies over the implant 121 , the ring may then engage a distal end of the cavity or channel 154 , as shown in FIG. 9B , and engage the ring 156 , allowing the outer sleeve to then pull the inner sleeve proximally, as shown in FIG. 9C , to fully release the hemostatic implant 121 .
Referring now to FIGS. 10A-10C , it is also possible to selectively couple the key 126 ′ to a protective sleeve 123 ′. The key 126 ′ has a coupling element, such as plurality of proximally disposed barbs 160 at its distal end. The key 126 ′ may be advanced into the protective sleeve 123 ′ where a distal end 162 of the key 126 ′ engages latching element 120 ′ on the outer tube 71 ′. Latching mechanism 120 ′ may conveniently comprise a plurality of barbs so that advancement of the key 123 ′ radially closes the barbs allowing the protective sleeve 123 ′ to be proximally retracted relative to the tube 71 ′. Once the key 126 ′ is fully distally advanced, as shown in FIG. 10B , the proximally disposed barbs 160 will engage an inner lip 164 at the proximal end of the protective sleeve 123 ′. Thus, as the key 126 ′ is proximally retracted, as shown in FIG. 10C , the key will pull the protective sleeve 123 ′ in a proximal direction, thus exposing the implant 121 .
A further aspect of the present invention is illustrated in FIGS. 10A and 10B . Radiopaque marker bands 170 and 172 may be provided at the proximal and distal ends of the implant 121 , respectively. Usually, these bands will be disposed on the outer tube 71 ′, but they could also be disposed on or incorporated within the hemostatic implant 121 . In either case, they are useful to evaluate positioning of the hemostatic implant prior to deployment, as described in more detail below in FIGS. 13A , 13 B, 14 A, and 14 B.
Referring now to FIGS. 11A and 11B , the hemostatic implant 121 may be disposed coaxially over the outer tube 71 and in a rod 76 . By proximally retracting the protective sleeve 123 , the implant 121 is released and can hydrate as shown in FIG. 11B . As described previously, however, it will still be necessary to withdraw the outer tube 71 as well as the collapsed occlusion element 90 past the hemostatic implant 121 . When the hemostatic implant 121 fully circumscribes the outer tube 71 , however, both the tube 71 and the collapsed occlusion element 90 can tend to dislodge the implant within the tissue tract.
Therefore, in some instances, it will be desirable to modify the geometry of the implant to facilitate withdrawal of the outer tube and the collapsed occlusion element. For example, as shown in FIGS. 12A and 12B , hemostatic implant 121 ′ can be formed with a crescent-shaped cross-section so that it does not fully circumscribe the outer tube 71 which carries it. By laterally displacing the outer tube 71 and inner rod 76 within the protective sleeve 123 , as shown in FIG. 12A , the volume of the hemostatic implant 121 will be generally the same as that shown in FIG. 11A . When the protective sleeve 123 is withdrawn, however, as shown in FIG. 12B , the hemostatic implant 121 will hydrate and expand laterally on one side of the outer tube 71 , as shown in FIG. 12B . By disposing the outer tube 71 and collapsed occlusive element 90 to one side of the implant, it is much easier to withdraw the apparatus and collapsed occlusion member past the implant without dislodging the implant within the tissue track.
Referring now to FIGS. 13A and 13B , the radiopaque markers 170 and 172 can be used to determine whether the hemostatic implant 121 is oriented properly prior to deployment. For simplicity, the protective sleeve and other components of the deployment system are not shown in FIGS. 13A and 13B (or in 14 A and 14 B as described below). The radiopaque markers 170 and 172 may be formed as part of the deployment instrument, for example being placed on outer tube 71 , and/or may be formed as part of the hemostatic implant 121 . In either case, when the deployment apparatus is properly oriented as shown in FIG. 13A , the radiopaque markers 170 and 172 will appear to be stacked generally vertically when viewed in an anterior view, as shown in FIG. 13B . In contrast, if the apparatus has been improperly deployed so that the hemostatic implant has been advanced into the vessel lumen past the tissue tract TT as shown in FIG. 14A , then the radiopaque markers 170 and 172 will be spaced apart in the anterior view as shown in FIG. 14B . As these views will be readily distinguishable by the physician using conventional fluoroscopy, the radiopaque markers provide a convenient and reliable indicator of when it is acceptable to deploy the hemostatic implant.
Referring now to FIGS. 15A through 15F , a method for hemostasis of a puncture site in a body lumen employing the device 270 of FIG. 1 is illustrated. FIG. 15A depicts an existing introducer sheath 240 advanced through an opening in a skin surface 246 , tissue tract in fascia 245 and vessel wall 243 and seated in a vessel lumen 241 at the completion of a catheterization procedure. Device 270 is then inserted through the hub of the sheath 240 and is advanced until the expansible member 274 is outside the sheath 240 and in the vessel lumen 241 , as shown in FIG. 15B . This positioning may be indicated by a mark or feature on the catheter 271 or the handle assembly 278 .
As shown in FIG. 15C , the expansible member 274 is then deployed by operation of the handle assembly 278 . The sheath 240 is then slowly pulled out of the body, placing the expansible member 274 against the inner wall of the vessel 243 at the puncture site 242 . As the sheath 240 is removed, the grip member 285 which is slidably disposed over the catheter shaft 271 and the handle assembly 278 are revealed. Sheath 240 is then discarded, leaving deployed expansible member 274 seated at the puncture site 242 and the bio-chemical chamber/region 351 in the tissue tract 247 as shown in FIG. 15D . If the device is equipped with the safety seal 355 as in device 270 , then the safety seal 355 is removed by pulling the tab 356 proximally along the catheter shaft.
Referring now to FIG. 15E , once safety seal 355 is removed, the grip element 285 is grabbed and pulled in a proximal direction. Grip 285 is moved proximally to provide adequate amount of tension to the deployed expansible member 274 to achieve hemostasis. Typically, the amount of tension applied to the expansible member 274 is in the range of 0.5 ounces to 30 ounces. In particular, proximal movement of grip 285 causes simultaneous elongation of the tensioning coil 286 , causing the expansible member to locate and temporarily close the puncture site 242 , and displacement of the bio-chemical seal 353 , exposing the bio-chemical agent 352 to the surrounding tissue at a predetermined distance from the puncture site. The elongated position of coil 86 is maintained by application of a small external clip 250 to the catheter and seated against the surface of the skin 246 , as shown in FIG. 15E . Device 270 is left in this position for a period of time to allow the bio-chemical agent 352 to reconstitute with the fluids in the tissue tract 247 , generating coagulum. Clip 250 is then removed and the expansible member 274 is collapsed by manipulation of the handle assembly 278 . Device 270 is then removed, leaving the active bio-chemical agents 352 and the coagulum in the tract 247 and adjacent the vessel puncture site 242 , as shown in FIG. 15F . Additional finger pressure at the puncture site may be required to allow the coagulum to seal the small hole left in the vessel wall after removal of the device.
While the above is a complete description of the preferred embodiments of the invention, various alternatives, modifications, and equivalents may be used. Therefore, the above description should not be taken as limiting the scope of the invention which is defined by the appended claims. | Apparatus for sealing a vascular wall penetration disposed at the end of the tissue tract comprises a shaft, an occlusion element, a hemostatic implant, and a protective sleeve. The apparatus is deployed through the tissue tract with the occlusion element temporarily occluding the vascular wall penetration and inhibiting backbleeding therethrough. The hemostatic implant, which will typically be a biodegradable polymer such as collagen carrying an anti-proliferative agent or coagulation promoter, will then be deployed from the sealing apparatus and left in place to enhance closure of the vascular wall penetration with minimum scarring. The implant may be radiopaque to allow observation before release. | 0 |
BACKGROUND OF THE INVENTION
The present invention relates generally to waveguide lenses and, more particularly, to waveguide lenses characterized by wide bandwidth and polarization insensitivity.
Waveguide lenses are used to focus electromagnetic energy to or from a feed, or a cluster of feeds. Such a lens generally comprises an assemblage of short waveguide elements positioned side by side in a two-dimensional array, with the combined inner and outer surfaces shaped generally (but not necessarily) to a lens contour, although in a zoned waveguide lens there may be physical step discontinuities between zones. Several varieties of waveguide lenses exist. The zoned variety of waveguide lens is made of hollow waveguides, and its outer surface is stepped in concentric rings of appropriate radii. Other varieties employ various forms of phase shifters in the waveguide elements to produce the phase correction required for focussing.
The design of such lenses where wide bandwidth is desired involved a number of dilemmas, discussed in detail hereinafter. As brief examples of such dilemmas, the constant group delay lens contour surfaces and the constant phase delay lens contour surfaces do not coincide. Physical zoning steps of some designs introduce polarization-sensitive variations, serious phase rotations, and shadowing.
By way of example; the following U.S. patents are identified as disclosing various known forms of waveguide lenses: Kock U.S. Pat. No. 2,562,277; Kock U.S. Pat. No. 2,576,463; Kock U.S. Pat. No. 2,596,251; Kock U.S. Pat. No. 2,599,763; Kock U.S. Pat. No. 2,603,749; Affel, Jr. U.S. Pat. No. 2,607,009; Kock U.S. Pat. No. 2,640,154; Kock U.S. Pat. No. 2,712,067; Crawford U.S. Pat. No. 2,729,816; Kock U.S. Pat. No. 2,733,438; Rust et al U.S. Pat. No. 2,764,757; Kock U.S. Pat. No. 2,769,171; Proctor, Jr. U.S. Pat. No. 2,834,962; Young, Jr. U.S. Pat. No. 2,841,793; Berkowitz U.S. Pat. No. 3,049,708; Dion U.S. Pat. No. 4,156,878; and Coulbourn, Jr. U.S. Pat. No. 4,194,209. Further examples are disclosed in the literature, such as Dion and Ricardi, "A Variable-Coverage Satellite Antenna System," Proc. IEEE, Feb. 1971, pp. 252-262.
Somewhat related to waveguide lenses are dielectric lenses, representative examples of which are disclosed in the following U.S. Patents: McMillian U.S. Pat. No. 2,985,880; Cary et al U.S. Pat. No. 3,886,558; and Beyer U.S. Pat. No. 3,886,561. Other related lenses are disclosed in Cohn U.S. Pat. No. 2,617,936 and Kock U.S. Pat. No. 2,747,184.
As discussed in detail hereinafter, an important characteristic of waveguide lenses in accordance with the invention is wide bandwidth without physical zoning steps, and without sensitivity to polarization. Accordingly, it is relevant to consider specifically several of the patents identified above which employ zoning techniques to achieve a wider bandwidth, but avoid physical zoning steps.
As one specific example, the disclosure of the Proctor, Jr. U.S. Pat. No. 2,834,962 points out that physical zoning steps can be avoided by providing a variable refractive index lens wherein different waveguides of the lens have different refractive indices at a particular frequency. Proctor, Jr. further discloses the provision of two separately-proportioned, differently-loaded regions in each waveguide having different phase velocities and different refractive indices. Proctor, Jr. describes the use of ridging along on in conjunction with a dielectric material for varying the cut-off frequency of the waveguide channels. However, all of the approaches which Proctor, Jr. illustrates are suitable only for a single linear polarization, and not for orthogonal linear polarizations (and hence, not for circular polarization). Furthermore, they involve two distinct sections (focussing and compensating), or sometimes three along the waveguide axis, where the length of each section may vary as a function of its transverse location.
As another specific example, the Dion U.S. Pat. No. 4,156,878 discloses smooth lens contour surfaces between which there are separate delay and phase compensating sections. The Dion lens is zoned in the sense that it employs pins, the rotational angle of which should periodically return to the starting point as radius increases. Due to the nature of the phase shifting mechanism, the Dion lens is fundamentally limited to a single (generally circular) polarization (e.g., right circular but not left). Thus, it is not suitable for polarization diversity. (It is believed to actually reverse the rotation of a circularly polarized wave passing through.) Further, the Dion lens appears restricted as a practical matter to the use of circular waveguides in order to allow mechanical rotation of the phase shifters.
By the present invention there are provided relatively thin waveguide lenses characterized by wide bandwidth, improved phase length match for all ray paths through the lens across the lens without physical zoning steps, and polarization insensitivity.
SUMMARY OF THE INVENTION
Briefly, in accordance with one overall concept of the invention, it is recognized that advantage may be taken of a particular property of electromagnetic waveguides, namely, that phase velocity within a waveguide is a function of cut-off frequency. A waveguide can readily be designed to have a particular cut-off frequency. Thus, to achieve desired group delay and desired phase delay simultaneously, in accordance with the invention, group delay for a particular radial location in the lens is controlled through initial selection of the length of a particular waveguide element, and then whatever phase delay compensation is required for that particular lens radial location is controlled by selecting cut-off frequency.
More particularly then, in accordance with a specific aspect of the invention, herein termed the variable cut-off frequency approach, a waveguide lens comprises a two-dimensional array of individual waveguide elements arranged in proximate juxtaposition extending between inner and outer lens surface contours. At least a portion of the outer surface contour follows a constant group delay surface contour, and the individual waveguide elements are configured so as to compensate the phase lengths of individual waveguide elements to provide constant phase delay. For determining the various cut-off frequencies and thus phase lengths, the individual waveguide elements may have various cross-sectional configurations, various fillings of dielectric material, or both.
Preferably, the portion of the outer surface contour following a constant group delay surface contour includes an annular region in the vicinity of 0.6 times the lens radius, and the radially-central region follows a constant phase delay surface contour.
Briefly, in accordance with another overall concept of the invention, it is recognized that, as a result of the properties of waveguide bandpass filter-type structures (which involve impedance discontinuities), it is possible to achieve independent design control over group velocity and phase velocity.
In accordance then with another more particular aspect of the invention, herein termed the filter-type approach, a waveguide lens comprises a two-dimensional array of individual waveguide elements arranged in proximate juxtaposition extending between inner and outer lens surfaces. Filter structures are provided in selected individual waveguide elements, with the parameters of the individual filter structures selected so as to achieve both minimum group delay distortion and minimum phase delay distortion.
BRIEF DESCRIPTION OF THE DRAWINGS
While the novel features of the invention are set forth with particularity in the appended claims, the invention, both as to organization and content, will be better understood and appreciated from the following detailed description, taken in conjunction with the drawings, in which:
FIG. 1A is a model of a waveguide lens focussing mechanism for a sinusoidal wave;
FIG. 1B is a model of a waveguide lens focussing mechanism for pulses;
FIG. 2 is a representation of a constant group delay surface contour and a plurality of constant phase delay surface contours for waveguide lenses;
FIG. 3 depicts a simple form of prior art waveguide lens;
FIG. 4 depicts a prior art waveguide lens physically zoned for minimum weight;
FIG. 5 depicts a prior art physically zoned broadband waveguide lens;
FIG. 6 is a plot of power distribution as a function of lens radius;
FIG. 7 depicts the cross-section of a lens in accordance with the variable cut-off frequency aspect of the invention;
FIG. 8 defines several geometric parameters of a waveguide lens in accordance with the variable cut-off frequency aspect of the invention;
FIGS. 9A and 9B illustrate variations in waveguide cross section for controlling cut-off frequency;
FIG. 10A is a frequency-phase shift diagram of an unloaded waveguide;
FIG. 10B is a frequency-phase shift diagram of a periodically-loaded waveguide;
FIG. 11 illustrates individual waveguide elements partially filled with dielectric materials;
FIGS. 12A, 12B and 13 illustrate techniques for reducing the impedance mismatch at dielectric interfaces; and
FIGS. 14A, 14B, 15A, 15B and 16 illustrate various forms of artificial dielectric materials.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
It is believed that the concepts and principles of the present invention will be better understood if preceded by a general summary of bandwidth problems in waveguide lenses. Accordingly, a general summary is presented next, below, followed by a detailed description of two separate approaches in accordance with the invention. Various relevant equations are provided in the general summary which immediately follows, and several of these equations are referred to again in the subsequent detailed description.
It will be appreciated that design of a waveguide lens is predicated upon design equations which, to those skilled in the art, sufficiently describe the required parameters of the actual physical embodiments. Accordingly, an equation approach is employed herein as providing the most meaningful information to those skilled in the art.
GENERAL DESIGN OF WAVEGUIDE LENSES
Referring first to FIGS. 1A and 1B, there is shown a simple model of the waveguide lens focussing mechanism. This model comprises a source at the focus 20, an arbitrary lens 22, and a reference plane 24 perpendicular to the axis of the lens 22. As shown in FIG. 1A, for the single-frequency (or narrowband) case it is sufficient that the sinusoidal wave trains 26 corresponding to various paths through the lens be in phase at the reference plane 24. But if the lens is to be broadband, as shown in FIG. 1B, this condition must be satisfied at all frequencies in the band so that the envelope of a pulse 28 comprising frequency components within the band and launched from the focus 20 arrives at the reference plane 24 as pulses 30 at the same time, regardless of the path taken.
In addition to the focussing model of FIGS. 1A and 1B, there are a number of relationships and properties of guided waves which are relevant, and which are expressed in the following equations. These properties are very general and depend only on the fact that the waveguide be uniformly filled with a dielectric (e.g., air or vacuum), and that its cross section (e.g., square, circular or ridged) does not vary along the direction of propagation.
The phase shift per unit length of a wave traveling in the waveguide is: ##EQU1## where β o is the free space value which equals ω/c or 2π/λ o (c is the velocity of light through the dielectric filling), f is the operating frequency, and f c is the cut-off frequency which is a function of the mode, dielectric and waveguide cross section.
The phase shift for a length 1 is thus:
φ=β1 (2)
Alternatively the phase velocity v p (the velocity at which a wave crest appears to move) is given relative to the velocity of light c outside of the waveguide by: ##EQU2## Since the operating frequency f is greater than the cut-off frequency f c , the phase velocity v p exceeds the velocity of light c in free space.
On the other hand, the envelope of a pulse travels at the group velocity which is given by: ##EQU3## The group velocity v g is always less than the free space velocity of light. Then, ##EQU4## so that increasing the phase velocity v p (by moving the operating frequency f closer to cut-off f c ) decreases the group velocity v g .
If the waveguide of physical length t is assumed, from Equations (2), (3) and (5) it can be seen that the phase shift for this waveguide is equivalent to a free space length, l p , which is given by ##EQU5## and is always less than the physical length t. If the free space length is removed, the resultant represents an effective change (shortening) of the phase length due to replacement of the free space path with a waveguide. That is, ##EQU6##
Because a sinusoidal wave can be shifted by a period without any change in appearance, the definition of differential phase length is not unique. The complete family is given by:
d.sub.pn =d.sub.p +nλ.sub.o (8)
where n is any positive or negative integer.
In a similar manner, a differential group length d g may be defined as ##EQU7## That is, replacement of a free space path by waveguide is the same as increasing the free space path length by d g as far as group delay is concerned. Because the envelope is not periodic, there is no group delay equation analogous to Equation (8).
The manner in which the preceding equations relate to the properties of waveguide lenses may be illustrated by an assumed example of a waveguide lens having a spherical inner surface of radius R i . The path length relative to a ray through the center of the lens is related to the radial location at which the ray enters the lens by ##EQU8## The phase shift may be compensated by inserting a waveguide section having a differential phase length (negative) from Equation (7), which cancels the increased path length. That is,
d.sub.p +1(r)=0 (11) ##EQU9##
If Equation (7) is generalized by Equation (8), the entire family of possible lengths becomes: ##EQU10## where t po is an arbitrary fixed length which may be added to all waveguides without altering the relative phase performance.
With reference now to FIG. 2, the contours expressed in Equation (13) of possible lens thicknesses for phase compensation are shown as "constant phase delay" surfaces or contours 32. As illustrated in FIG. 2, the constant phase delay surfaces 32 are thin in the lens center, and thick at the rim.
In addition to the lens contour or thicknesses for constant phase delay, there are contours or lens thicknesses for constant group delay. The lens thickness which yields a constant group delay can be derived from Equation (9) to yield the following: ##EQU11##
It is significant to note that the sign of the radially-dependent term of Equation (14) for constant group delay surfaces is opposite that of Equation (13) for constant phase delay surfaces. Also, in Equation (14) the radially-dependent term is multiplied by the factor v g /c.
FIG. 2 illustrates only one constant group delay surface 34, the one for minimum lens thickness. Minimum thickness occurs when t g goes to zero at the rim (r=a). In this case: ##EQU12##
Contrasting Equations (13) and (14), as reflected in FIG. 2 depicting the opposite curvatures of the constant phase delay surfaces 32 and the exemplary constant group delay surface 34, the bandwidth dilemma of waveguide lenses is dramatized. The thicker rim of the constant phase delay surfaces 32 increases the velocity of the rays, allowing them to catch up with the shorter-path rays through the center. However, a phase velocity greater than the velocity of light is a sort of sleight-of-hand which loses significance when a broadband signal is involved. The constant group delay surface 34 is thicker in the middle, thereby retarding the envelope in this region relative to the longer path rays which are retarded less. This is the more fundamental approach since it is theoretically possible to have the phase and group velocities equal to one another if both are less than the velocity of light; unfortunately an unloaded piece of waveguide does not satisfy this condition by virtue of Equation (5).
With the foregoing as background, several specific forms of prior art waveguide lenses will now be mentioned, and then contrasted to those of the subject invention.
Preliminarily, it should be noted that the specific lenses described herein are for convenience depicted only as inner and outer surfaces, contoured or stepped, as the case may be. It will be appreciated however that all of these lenses comprise a two-dimensional assemblage or array of individual waveguide elements in proximate juxtaposition, with the length of each waveguide element being the distance between the inner and outer lens surfaces. These lengths typically vary as a function of radius, although uniform-thickness lenses are also employed. In the case of a uniform-thickness lens, all of the individual waveguide elements have the same length, differing in some other respect such as diameter, cross-section, or internal loading elements.
As depicted in FIG. 3, a simple form of waveguide lens has an inner surface 36 which typically is a portion of a spherical surface, and an outer surface 38 which follows a constant phase delay surface. The minimum center thickness is set by mechanical considerations, and a constant-thickness "bias" is accordingly provided between the actual inner surface 36 and a theoretically-possible inner surface 40. The inner surface 36 faces the feed point 20 (FIGS. 1A and 1B). The FIG. 3 lens has very limited bandwidth due to the divergent phase and group surfaces (FIG. 2).
Depicted in FIG. 4 is a variation of FIG. 3 comprising a physically zoned lens in which the outer surface 42 abruptly changes from one phase surface to another in steps 44 in order to maintain minimum thickness. This zoning, although apparently conceived for mechanical reasons, yields a lens surface which approximates a constant group delay surface (FIG. 2) better than an unzoned one. Thus, ray-tracing techniques indicate better bandwidth. However, the abrupt surface changes introduce polarization-sensitive variations in the phase shift and radiation patterns of the nearby waveguides, thereby degrading the lens performance.
As shown in FIG. 5, the physical zoning concept may be carried a step further by thickening the center of the lens to obtain a surface which oscillates about a constant group delay surface. This approach further improves the apparent phase match across the frequency band, but also increases the number of zones and their attendant aberrations. A similar lens is disclosed in the above-identified Coulbourn, Jr., U.S. Pat. No. 4,194,209.
In FIG. 5, the physical length of the zoning steps may be seen from Equation (13) to be: ##EQU13## This length may be converted into an equivalent free space group length by replacing t in Equation (9) by S; the result is: ##EQU14## The equivalent length may in turn be readily converted into a relative phase change as a function of deviation from center frequency by: ##EQU15##
Thus, in the lens of FIG. 5 if it is assumed that the lens surface varies between ±S/2 of the group delay surface (which yields zero phase error), the relative phase error will vary between ±Δφ/2. On the other hand, if some of the zones are removed to obtain the configuration of FIG. 4, an additional error of Δφ will be incurred for each zone deleted. Similarly, the unzoned lens of FIG. 3 will have a (band-edge) phase deviation from center to rim of approximately ±NΔφ/2 where N is the number of zones in the FIG. 5 lens.
AVOIDING PHYSICAL ZONING STEPS
As pointed out hereinabove with reference to FIG. 4, the abrupt surface changes of physical zoning steps 44 introduce polarization-sensitive variations in the phase shift and radiation patterns of the nearby waveguides, thereby degrading the lens performance. The effect of perturbations introduced by physical zoning discontinuities, particularly where polarization insensitivity is desired, deserves careful consideration to avoid false design conclusions. For example, the ray tracing approach may indicate that an additional zoning step improves the patterns. But if this step introduces a 90° phase error for one polarization in the adjacent guide--a not unreasonable estimate based on one model of the solution--there may be little or no net improvement. Accordingly, for these and other reasons, it is believed highly desirable to avoid physical zoning steps.
POWER DISTRIBUTION
In accordance with the invention, advantage is taken of the manner in which power is distributed across a waveguide lens (as a function of radius). Power density may be assumed to vary approximately parabolically across the aperture. That is ##EQU16## where r n is a radius which presumably lies just outside of the rim at which the power density drops to zero according to this approximation.
Taking into account that the circumference and hence the number of waveguides at any radius increases linearly with r, the total power through all of the waveguides at some radius r is proportional to ##EQU17##
With reference to FIG. 6, the curve of Equation (20) is plotted. The maximum value occurs at 0.58 r n . For a 10 db power taper, the rim of the lens corresponds to 0.95 r n .
In accordance with the invention, it is recognized that, as a result of the power distribution depicted in Equation (20) and FIG. 6, it is most important to optimize the lens parameters in the vicinity of 0.6 times the rim radius. The center of the lens is less important because of its small area, and the rim is less important because of the power taper. Due to this reduced sensitivity of the lens center, a larger deviation from the group delay surface may be tolerated. For example, a lens could be designed with the center a full zoning step inside of the group delay surface in order to obtain a larger unzoned central portion and to reduce the physical size. The remainder of the lens is then designed to oscillate about the group delay surface as indicated in FIG. 5.
VARYING WAVEGUIDE CUT-OFF FREQUENCY
An important aspect of the invention is achieving phase control by varying the cut-off frequency of selected waveguides (without physical zoning steps) by techniques such as adding a ridge, loading with dielectric, increasing waveguide size, and rounding the waveguide corners.
The prior art lens of FIG. 5 provides an appropriate starting point for purposes of example. In accordance with the invention, the physical zoning steps of FIG. 5 are eliminated.
FIG. 7 illustrates the general cross-section of one form of lens in accordance with the invention, evolved from FIG. 5 as discussed next below.
Initially, in view of the "Power Distribution" considerations discussed hereinabove, it is necessary to optimize primarily in the vicinity of 0.6 times the rim radius. The center configuration of FIG. 5 is accordingly left unchanged to generate the FIG. 7 central region 46.
Next, a smooth outer surface 48 is developed by using one of the longer waveguides in each physical zone of FIG. 5 to establish a contour point. A constant "bias", e.g., one-fifth of a zoning step, may be added to each contour point. Physical waveguide lengths are lengthened or shortened as required to lie on the smooth contour surface 48. Thus the FIG. 7 contour 48 follows a constant group delay surface (as discussed hereinabove with reference to FIG. 2). In contrast, the outer surface of the prior art FIG. 5 lens oscillates about a constant group delay surface.
Lastly, the phase lengths are equalized (phase characteristics corrected) by altering the cut-off frequency in selected waveguides. This is possible because, from equation (1), the phase shift per unit length depends on cut-off frequency.
Presented next below is TABLE I which sets forth specific parameters of such a design (for one cross-section plane) (for a center frequency of 8150 MHz), followed by a more detailed discussion of design procedures.
TABLE I______________________________________DESIGN PARAMETERS FOR FIG. 7 LENS Δφ at Cut-offRadius Thickness Lower Band Frequency(inches) (inches) Edge (MHz)______________________________________0. 5.69 12° 6449.70.91 5.71 12° 6449.71.83 5.79 11° 6449.72.74 5.91 11° 6449.73.66 6.07 10° 6449.74.57 6.29 9° 6449.75.49 6.55 7° 6449.76.40 6.87 5° 6449.77.32 7.23 3° 6449.78.23 7.64 1° 6449.79.15 8.11 0° 6449.710.06 8.43 -4° 6503.710.98 8.09 -9° 6760.711.89 7.71 5° 5872.312.81 7.30 0° 6259.613.72 6.86 -6° 6662.714.64 6.38 6° 5625.615.55 5.86 0° 6236.116.47 5.32 -8° 6851.217.38 4.73 3° 5718.618.30 4.11 -4° 6680.019.21 3.45 4° 5004.420.13 2.75 -3° 6673.521.04 2.01 3° 3497.321.96 1.23 -6° 7334.0______________________________________
In detail, a generalized design procedure in accordance with the invention is provided by the following five steps:
Step 1. The frequency and aperture dimensions are set as determined by system requirements.
Step 2. Select the following three parameters: R i , for the inner surface; the width of the individual waveguide channels which determines the cut-off frequency, f c ; and the thickness of the lens at the rim, t go . FIG. 8 depicts the geometry of R i and t go , as well as several other parameters.
Step 3. Determine the group delay thickness (FIG. 2) which should be approximated by the lens thickness by employing Equation (14), plus Equations (10) and (4), where ##EQU18##
Step 4. Determine the phase delay thicknesses (FIG. 2) by employing Equation (13). In Equation (13), the arbitrary constant t po locates the constant phase delay surfaces relative to the constant group delay surface.
Step 5. Modify properties of selected waveguide channels to equalize the phase lengths. This step is necessary since the constant group delay surfaces and the constant phase delay surfaces are not the same shape, as discussed in detail hereinabove, and since it is desired to have a smooth lens surface to avoid the drawbacks of physical zoning steps. Specifically, lens thickness is defined as the delay thickness t g (r), and the phase shift is corrected in one of three ways (I, II and III, below) for those waveguides in which the delay and phase surfaces do not coincide. (For the central region of the lens, the phase surface may be a sufficiently close approximation to the delay surface so that the lens shape of FIG. 7 results.)
The phase lengths may be modified by the following approaches:
I. Varying the waveguide cross-section to vary f c . E.g., as shown in FIG. 9A, the corners can be rounded to increase f c . Or, as shown in FIG. 9B, ridges can be added to lower f c .
II. Filling the waveguide with a real or artificial dielectric material. Compared to a dielectric lens, these dielectric materials have properties much closer to free space. An exemplary artificial dielectric material is fine metallic whiskers suspended in foam.
III. Both I and II.
Approaches I and II modify the group velocity somewhat in correcting the phase thereby reducing the bandwidth, although this effect can be small with Approach II. With Approach III it is possible to match both phase and group delay.
In the foregoing five steps, the relevant equations are as follows:
The modified cut-off frequency f c ' for Approach I becomes ##EQU19## where t p is one of the phase thicknesses, presumably the one which is slightly shorter than the delay thickness or the one just longer.
The required (relative) dielectric constant for Approach II is ##EQU20## in which case t p must be chosen to yield an ε≧1. Approach III yields less phase error particularly if ##EQU21## and ##EQU22## where f c ' is defined as the cut-off frequency of the modified shape but before the waveguide is filled with the dielectric. This approach has extremely low phase errors.
BROADBAND FILTER
Although the "Varying Waveguide Cut-off Frequency" approach of the invention as described above provides an effective waveguide lens without physical zoning steps, there is still a residual phase error due to a lack of independent control over group and phase velocity (except for Approach III). With constant cross-section waveguides of any shape, there is a restrictive relationship between phase and group velocities, as expressed by Equation (5). In the "Varying Cut-off Frequency" approaches described above, it is assumed that the cross section shape and dielectric filling of each waveguide channel is uniform along its entire length (but varies from channel-to-channel dependng on the radial location).
In accordance with another aspect of the invention, herein termed the "filter-type approach", variation of the dielectric filling or waveguide cross-section along selected waveguides is provided. Also, the waveguides may be periodically loaded with obstacles such as inductive irises to form filter circuits.
For reasons discussed hereinabove, in order to optimally achieve wide bandwidth, it is necessary to be able to select independently during design a particular group velocity v g and a particular phase velocity v p . It is believed that the manner in which such independent control during design is achieved in accordance with the filter-type approach of the invention may be understood with reference to FIGS. 10A and 10B, which depict frequency-phase shift (ω/β) diagrams of an unloaded waveguide and a periodically-loaded waveguide, respectively. Contrasting the FIG. 10A and FIG. 10B diagrams illustrates general properties of periodically-loaded waveguides which make them useful in the practice of the invention.
With specific reference to FIG. 10A, a typical frequency-phase shift diagram of an unloaded waveguide is illustrated for purposes of comparison. Essentially only a single degree of freedom in design is provided, this being cut-off frequency, f c , for a homogeneous dielectric medium.
In FIG. 10A, the phase-shift-as-a-function-of-frequency characteristic of a particular waveguide is represented by the curved line 50. The characteristic curve 50 approaches the velocity of light, c, represented by a straight line 52 extending from the origin, asymptotically. It will be appreciated that the characteristic curve 50, being for a particular waveguide having a particular lower cut-off frequency only, may be varied by design. Variations will result in changing the starting point of the line 50 along the frequency (ω) axis, but it will always approach the velocity of light c line 52 asymptotically. The limiting case would be for a TEM (coaxial) transmission line, in which case the characteristic curve 50 would coincide with the velocity of light c line 52.
An operating frequency is selected, which then determines an operating point 54 on the characteristic curve 50. The reciprocal of the slope of a line 56 from the origin through the operating point 54 represents phase velocity (v p ), as is expressed in Equation (3). The reciprocal of the slope of a line 58 tangent at the operating frequency point 54 represents group velocity (v g ), as is expressed in Equation (4). From Equations (3) and (4), both phase velocity (v p ) and group velocity (v g ) approach the velocity of light (c) asymptotically (but from opposite sides) as operating frequency increases along the characteristic curve 50.
Although only one characteristic curve line 50 (for one particular cut-off frequency) is shown in FIG. 10A, it will be appreciated that an essentially infinite number of others may be drawn. For each of the possible characteristic curves, at a given operating frequency there will be a certain phase velocity v p and a certain group velocity v g . A wide selection range is therefore available. Nevertheless, since all the possible characteristic curves approach the velocity of light c line 52 asymptotically, completely independent design control over v p and v g is not available.
Thus, from FIG. 10A, it can be seen for an air-filled waveguide that a limited degree of design freedom is available, i.e., varying cut-off frequency.
Although not specifically illustrated, a second degree of freedom is available by selecting a dielectric and uniformly filling the waveguide. In FIG. 10A the result would be to rotate the velocity of light c asymptote line 52 about the origin towards the phase shift (β) axis. This second degree of freedom is useful, but still does not permit completely independent design control over v p and v g when all waveguides have the same cross-sectional shape.
Finally, if the waveguides need not be filled with a homogeneous dielectric material, a third degree of freedome is possible. (However, such variations introduce reflections and consequent frequency pass bands and frequency rejects bands. These must be considered, and the operating frequency placed in a pass band.)
With specific reference now to FIG. 10B, a representative frequency-phase shift diagram of a waveguide with periodic loading is shown. FIG. 10B is intended to show that it is possible, through suitable filter design, to have two operating frequency points with the same group velocity v g , but different phase velocity v p 's. This provides sufficient additional design freedom to independently control v p and v g .
FIG. 10B shows two separate representative characteristic curves 60 and 62 for two different microwave filters placed in two different waveguides in respective different radially-defined locations in a lens. FIG. 10B thus allows comparison of the two filters, and shows that the resultant waveguides (at different lens radial locations) can have the same group velocity v g , but different phase velocities v p 's. (The illustrated curves 60 and 62 are for the first pass bands only, and abruptly terminate when phase shift reaches 180°, at which point a stop band begins.)
More particularly, an operating frequency is selected, defining operating points 64 and 66 on the curves 60 and 62, respectively. As in FIG. 10B, the reciprocals of the slopes of lines 68 and 70 from the origin through the operating points 64 and 66 represent respective velocities v p1 , and v p2 . The reciprocals of the slopes of lines 72 and 74 tangent at the operating points 64 and 66 represent respective group velocities v g1 , and v g2 . Significantly, through suitable filter design, characteristic curves can in effect be shifted along the frequency axis with little change in curvature at frequencies of interest. Thus, the tangent lines 72 and 74 representing group velocity v g have nearly the same reciprocal of the slope.
It should also be noted that there is a region along each characteristic curve 60 and 62 within the depicted pass band of relatively constant group velocity v g , the value of which varies essentially directly with the bandwidth or, in other words, with the degree of loading. In summary, varying the operating frequency changes the phase velocity as indicated by v p1 , and v p2 . If the operating frequency is fixed, the phase velocity is adjusted by sliding the entire response along the frequency scale. Hence loaded waveguide filter circuits provide the independent control of phase velocity and group velocity required in accordance with the invention.
With the foregoing as background, the design of a filter-type waveguide lens in accordance with the invention will now be described, employing as a starting point a variable cut-off lens, such as is depicted in FIG. 7.
The first step in the transition to the filter-type structure is to vary the thickness of the dielectric filling. For example, in one sample calculation the required dielectric constant varied from 1.0 (i.e. free space of no filling) to a maximum of approximately 1.40.
FIG. 11, showing the cross-section of half a lens and individual waveguide elements therein, depicts a practical alternative to the problem of fabricating a range of (artificial) dielectric materials to cover this range. In FIG. 11, a material having the maximum dielectric constant value is employed. The waveguides requiring a smaller value are filled over only a fraction of their total lengths. (Some waveguides would have no filling.) The approximate relationship is:
(ε-1)t=(ε.sub.e -1)t.sub.e (26)
where ε and t are the dielectric constant and thickness required for full length filling, and ε e and t e are the (higher) dielectric constant and the length of the filling.
Further, in order to reduce the impedance mismatch at the interfaces, the dielectric material can be stepped, as in FIGS. 12A and 12B, or tapered, as in FIG. 13.
In order to minimize weight, it is preferred that artificial dielectrical materials be employed. These typically consist of metallic whiskers or other shapes suspended in a low density foam or etched on a circuit board, or even attached directly to the waveguide walls. In any case, their spearations are small relative to a wavelength. By way of specific example, FIGS. 14A and 14B illustrate small metallic "plusses" supported in foam. FIGS. 15A and 15B illustrate metallic whiskers attached to the waveguide walls. FIG. 16 illustrates random metallic whiskers supported in foam.
In general, the filter circuits comprise a smaller number of obstacles, each of which has a larger effect. The spacings are of the order of one-quarter to one-half of a guide wavelength, and should be maintained to reasonable tolerances. Other possible forms of filter obstacles are pins attached to a dielectric board support, "inductive" irises comprising transverse conducting partitions with either circular or rectangular apertures.
It is important to note that, if a polarization-insensitive lens is desired, filter symmetry is required. The ability to achieve polarization-insensitivity is an important aspect of the invention.
These filters are designed to have equivalent phase and delay performance to the section of dielectric filled waveguide that they replace according to microwave filter design theory. Since independent phase and delay is achievable (as explained hereinabove with reference to FIG. 10B), the physical length (or thickness) is not a constraint. However, the more lens thickness deviates from the constant delay surface of the uniform waveguide lens, the more complicated the filter circuits become.
As a specific design example the following TABLE II shows the required number of sections (the number of obstacles or irises required is N+1), bandwidth, and filter synchronous frequency f o as a function of radial position (for one cross-section plane) for a sample uniform thickness lens with a band-center of 8150 MHz.
TABLE II______________________________________ FILTERRADIUS N BANDWIDTH F.sub.o(Inches) SECTIONS (MHz) (MHz)______________________________________0. 4 1559. 7662.0.91 4 1561. 7674.1.83 4 1569. 7710.2.74 4 1581. 7770.3.66 4 1598. 7857.4.57 4 1622. 7971.5.49 4 1651. 8115.6.40 3 1083. 7763.7.32 3 1111. 7965.8.23 3 1145. 8208.9.15 3 1185. 8498.10.06 5 2694. 7639.10.98 5 2821. 7999.11.89 4 2122. 7767.12.81 4 2255. 8253.13.72 3 1552. 8094.14.64 5 3678. 7133.15.55 5 4046. 7847.16.47 4 3234. 7772.17.38 3 2379. 7747.18.30 2 1286. 7799.19.21 1 1092. 7986.20.13 4 7369. 8458.21.04 3 7496. 9739.21.96 1 6122. 6305.______________________________________
In an optimum design, the characteristics of these filters would not be of a standard type since each filter would be operated over only a portion of its total bandwidth. Thus, it would be most efficient to match only this portion of the band. Also it might be desirable to have filters that do not possess the typical end-to-end symmetry in order to improve the transition between guides as the number of filter sections changes from N to N+1. Furthermore, the most sophisticated design would incorporate the impedance mismatch at the guide-to-free-space transitions into the filter design in order to achieve phase, group, and impedance matching simultaneously.
However, in order to make a preliminary estimate of the required filter parameters, a conventional 0.1 db equal ripple response has been assumed. It has also been assumed that the total bandwidth of each filter must be at least ten percent and that the operating point lies sufficiently close to the center of the response to avoid band-edge distortions. The physical length of each section of a waveguide filter as described in TABLE II is between one-quarter guide wavelength for wideband filters and one-half for narrow ones. Thus, a lens thickness of somewhat less than two and one-half wavelengths or five inches is probably adequate to house these filters (for this example).
While "variable cut-off" and "broadband filter" approaches are separately described hereinabove, various hybrids are also possible. For example, in the FIG. 7 lens the cut-off frequency of some of the guides is varied in order to obtain a smooth outer surface. Periodic loading of these guides is an alternative. In this case relatively few obstacles (in only a portion of the guides) might well be adequate since the smooth length variations have already accomplished much of the required phase/group matching.
While specific embodiments of the invention have been illustrated and described herein, it is realized that numerous modifications and changes will occur to those skilled in the art. It is therefore to be understood that the appended claims are intended to cover all such modifications and changes as fall within the true spirit and scope of the invention. In particular embodiments of any of the lenses described, it is expected that a computer optimization program will be used to minimize the amount of dielectric filling, number of filter elements, and so forth. The resulting configuration would deviate somewhat from the predictions of the design equations. | Waveguide lenses characterized by wide bandwidth, polarization-insensitivity, and absence of physical zoning steps. A waveguide lens constructed in accordance with the variable cut-off frequency approach of the invention comprises a two-dimensional array of individual waveguide elements arranged in proximate juxtaposition extending between inner and outer lens surface contours. At least a portion of the outer surface contour follows a constant group delay surface contour, and the individual waveguide elements are configured so as to have cut-off frequencies individually selected so as to compensate the phase lengths of individual waveguide elements to provide constant phase delay. For determining the various cut-off frequencies and thus phase lengths, the individual waveguide elements may have various cross-sectional configurations, various fillings of dielectric material, or both. Preferably, the portion of the outer surface contour following a constant group delay surface contour includes an annular region in the vicinity of 0.6 times lens radius for typical illuminationtaperings and the radially-central region follows a constant phase delay surface contour. A waveguide lens in accordance with the filter-type approach of the invention comprises a two-dimensional array of individual waveguide elements arranged in proximate juxtaposition extending between inner and outer lens surfaces. Filter structures are provided in selected individual waveguide elements, with the parameters of the individual filter structures selected so as to achieve both minimum group delay distortion and minimum phase delay distortion. | 7 |
FIELD OF THE INVENTION
The present invention relates to a novel polyimide, a method for manufacturing the same, a gas separation membrane using the novel polyimide and the method for manufacturing the same.
The gas separation membrane of the present invention has not only excellent selective permeability performance but also good moisture resistance, chemical resistance, etc. Moreover, gas separation using the present membrane is useful in various fields because it is effective in terms of energy efficiency as compared with other gas separation methods. The membrane of the present invention is used for, for example, separation and collection of hydrogen at the time of synthesizing ammonia; collection of carbon dioxide or elimination of sulfur oxide and nitrogen oxide from exhaust gas emitted from a thermal electric power plant and an incineration plant; collection of carbon dioxide from off gas of an oil field; elimination of hydrogen sulfide and carbon dioxide or separation of helium from natural gas; collection of gasoline leaked from a gasoline station; pervaporation separation in a liquid mixture comprising volatile materials; elimination of gas dissolved in liquid; separation between oxygen and nitrogen in air, and the like.
BACKGROUND OF THE INVENTION
Hitherto, as a gas separation membrane, a cellulose acetate membrane has been well known. However, the cellulose acetate membrane is insufficient in chemical resistance, thermal resistance, etc. Therefore, it cannot be said that the cellulose acetate membrane has a practically sufficient performance. Moreover, as a membrane whose thermal resistance property is improved, a polysulfone semipermeable membrane is industrially manufactured, but it also is insufficient in permeation performance. Moreover, a silicone membrane is well known as a selective permeation membrane of oxygen. However, silicone cannot provide a sufficient mechanical strength and be industrially satisfactory.
Recently, researches and developments of a polyimide resin separating membrane excellent in strength, heat resistance and gas selective permeability have been conducted.
Journal Polymer Science Polymer Physics (J.polym. Scie. Polym. Phys., 28, 2291 (1990)) describes an aromatic polyimide membrane having high gas permeability and selectivity, which is made from a phenylenediamine component in which one ortho position amine functional group is replaced by an alkyl group. Moreover, U.S. Pat. No. 4,717,394 and Japanese Patent Application Tokkai No. Sho 63-123420 describe an aromatic polyimide membrane having high gas permeability, which is made from phenylenediamine in which all ortho position amine functional groups are replaced by alkyl groups.
However, a polyimide having higher permeation performance and high separation selectivity and a gas separation membrane using such polyimide are still demanded.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a novel polyimide having more excellent permeation performance, high permeability and high separation selectivity, and having excellent chemical resistance and moisture resistance, etc., a method for manufacturing the same, a gas separation membrane using the novel polyimide and a method for manufacturing the same.
The present inventors have intensively investigated in order to avoid the above mentioned problems of the conventional gas separation membranes, and reached a polyimide obtained by condensation polymerizing tetracarboxylic acid dianhydride, which is a precursor of a quadrivalent residual group for forming polyimide and 2-(2,4-diaminobenzyl) pyridine as a diamine component forming a divalent residual group, and a gas separation membrane using the above polyimide, thereby completing the present invention.
In other words, the polyimide of the present invention has the repeating structure unit expressed by the following general formula (1):
General Formula (1) ##STR2## where R denotes a quadrivalent organic group.
It is preferable in the above mentioned polyimide that the quadrivalent organic group is at least one organic group selected from the group consisting of organic groups expressed by the following general formulas (2) to (4):
General Formula (2) ##STR3##
General Formula (3) ##STR4##
General Formula (4) ##STR5## where X denotes at least one group selected from the group consisting of --C(CF 3 ) 2 --, --C(CF 3 )(C 6 H 5 )--, --C(CH 3 )(C 6 H 5 )--, --CH 2 --, --C(CH 3 ) 2 --, --CO--, --SO 2 --, --O--, --S--, --NH--, --COO--, --CONH--, --Si(CH 3 ) 2 --, --O--C 6 H 4 --C(CH 3 ) 2 --C 6 H 4 --O--, --O--C 6 H 4 --O--, --O--CH 2 --CH 2 --O--, --CF 2 CF 2 CF 2 --, --CO--C 6 H 4 --CO--, and --O--C 6 H 4 --S--C 6 H 4 --O--.
Furthermore, in the above mentioned polyimide, the glass transition temperature is about 303° C.
Furthermore, in the above mentioned polyimide, gas permeability coefficients of the polyimide (Barrer=10 -10 cm 3 (STP) cm/cm 2 /sec/cmHg, where cm 3 (STP) shows a volume of gas that permeates under normal temperature (0°C.) and normal pressure (1 atm), cm shows a thickness of a film, cm 2 shows an area of a film, sec shows a time (second), and cmHg shows a pressure, and where the values are measured at 25° C. and 1 atm) are about 7.22 Barrer for O 2 , about 1.67 Barrer for CH 4 , about 1.34 Barrer for N 2 and about 54.9 Barrer for CO 2 .
Furthermore, it is preferable in the above mentioned polyimide that the polyimide can be dissolved in a polar solvent. The polar solvent may be one solvent selected from the group consisting of N-methyl-2-pyrrolidone, N,N-dimethylacetamide, dimethyl sulfoxide, and N,N-dimethylformamide.
Next, the method for manufacturing a polyimide of the present invention is characterized in that a polyimide having a repeating structure unit expressed by the following general formula (7) is obtained by condensation polymerizing a tetracarboxylic acid dianhydride expressed by the following general formula (5) and diamine expressed by the following general formula (6):
General Formula (5) ##STR6## where R denotes a quadrivalent organic group;
General Formula (6) ##STR7##
General Formula (7) ##STR8## where R denotes a quadrivalent organic group.
It is preferable in the above mentioned method that the quadrivalent organic group is at least one organic group selected from the group consisting of organic groups expressed by the following general formulas (8) to (10);
General Formula (8) ##STR9##
General Formula (9) ##STR10##
General Formula (10) ##STR11## where X denotes at least one group selected from the group consisting of --C(CF 3 ) 2 --, --C(CF 3 )(C 6 H 5 )--, --C(CH 3 )(C 6 H 5 )--, --CH 2 --, --C(CH 3 ) 2 --, --CO--, --SO 2 --, --O--, --S--, --NH--, --COO--, --CONH--, --Si(CH 3 ) 2 --, --O--C 6 H 4 --C(CH 3 ) 2 --C 6 H 4 --O--, --O--C 6 H 4 --O--, --O--CH 2 --CH 2 --O--, --CF 2 CF 2 CF 2 --, --CO--C 6 H 4 --CO--, and --O--C 6 H 4 --S--C 6 H 4 --O--.
It is also preferable in the above mentioned method that the condensation polymerization is conducted in a polar solution. It is preferable that the polar solvent is one solvent selected from the group consisting of N-methyl-2-pyrrolidone, N,N-dimethylacetamide, dimethyl sulfoxide and N,N-dimethylformamide. The preferable amount of use of the polar solvent is in the range of 70 to 90 weight % concentration with respect to the weight of the reaction system.
It is also preferable in the above mentioned method that the condensation polymerization comprises the steps of synthesizing polyamic acid by mixing diamine component and tetracarboxylic acid dianhydride component to react below room temperature (in the range of 0 to 20° C.) for 5 to 50 hours; and polyimidizing the polyamic acid.
It is also preferable in the above mentioned method that the polyamic acid is polyimidized by adding a cyclodehydrating agent to the reacting solution and reacting for 5 to 24 hours during said step of polyimidizing the polyamic acid.
It is also preferable in the above mentioned method that the cyclodehydrating agent is at least one compound selected from the group consisting of acetic anhydride, pyridine and triethylamine.
It is also preferable in the above mentioned method that the step of polyimidizing polyamic acid comprises heating polyamic acid to 180 to 200° C.; and adding a solution azeotropic with water to react for 5 to 10 hours while removing water generated due to the cyclization of amic acid out of the system by azeotropy.
It is also preferable in the above mentioned method that the solution azeotropic with water is at least one solution selected from the group consisting of benzene, toluene, xylene, chlorobenzene and dichlorobenzene.
It is also preferable in the above mentioned method that the polyimide is dissolved in a polar solvent.
It is also preferable in the above mentioned method that the polar solvent is at least one solvent selected from the group consisting of N-methyl-2-pyrrolidone, N,N-dimethylacetamide, dimethyl sulfoxide, and N,N-dimethylformamide.
Next, the gas separation membrane of the present invention comprises a polyimide having a repeating structure unit expressed by the following general formula (11) in the gas separation layer:
General Formula (11) ##STR12## where R denotes a quadrivalent organic group.
It is preferable in the gas separation membrane that the quadrivalent organic group is at least one organic group selected from the group consisting of organic groups expressed by the following general formulas (12) to (14):
General Formula (12) ##STR13##
General Formula (13) ##STR14##
General Formula (14) ##STR15## where X denotes at least one group selected from the group consisting of --C(CF 3 ) 2 --, --C(CF 3 )(C 6 H 5 )--, --C(CH 3 )(C 6 H 5 )--, --CH 2 --, --C(CH 3 ) 2 --, --CO--, --SO 2 --, --O--, --S--, --NH--, --COO--, --CONH--, --Si(CH 3 ) 2 --, --O--C 6 H 4 --C(CH 3 ) 2 --C 6 H 4 --O--, --O--C 6 H 4 --O--, --O--CH 2 --CH 2 --O--, --CF 2 CF 2 CF 2 --, --CO--C 6 H 4 --CO--, and --O--C 6 H 4 --S--C 6 H 4 --O--.
It is preferable in the above mentioned gas separation membrane that the glass transition temperature of the polyimide is about 303° C.
It is preferable in the above mentioned gas separation membrane that the gas permeability coefficients of the polyimide (Barrer=10 -10 cm 3 (STP) cm/cm 2 /sec/cmHg, where cm 3 (STP) shows a volume of gas that permeates at normal temperature (0° C.) and normal pressure (1 atm), cm shows a thickness of a film, cm 2 shows an area of a film, sec shows a time (second), and cmHg shows a pressure, and where the values are measured at 25° C. and 1 atm) are about 7.22 Barrer for O 2 , about 1.67 Barrer for CH 4 , about 1.34 Barrer for N 2 and about 54.9 Barrer for CO 2 .
It is preferable in the above mentioned gas separation membrane that the gas permeable selectivity of the polyimide membrane are about 5.38 for O 2 /N 2 ; about 1.25 for CH 4 /N 2 ; and about 40.9 for CO 2 /N 2 .
It is preferable in the above mentioned gas separation membrane that the thickness of the polyimide membrane is in the range of 0.03 to 20 μm.
It is preferable in the above mentioned gas separation membrane that the polyimide membrane is formed on a surface layer of a supporting member having a smooth surface.
It is preferable in the above mentioned gas separation membrane that the polyimide membrane is at least one membrane selected from the group consisting of a flat membrane and a hollow fiber membrane.
It is preferable in the above mentioned gas separation membrane that the polyimide is dissolved in a polar solvent.
It is preferable in the above mentioned gas separation membrane that the polar solvent is at least one solvent selected from the group consisting of N-methyl-2-pyrrolidone, N,N-dimethylacetamide, dimethyl sulfoxide and N,N-dimethylformamide.
It is preferable in the above mentioned gas separation membrane that the intrinsic viscosity of the polyimide is in the range of 0.4 to 1.5 dL/g when measured with a solution in which 0.5 g of polyimide is dissolved in 1 dl of N-methyl-2-pyrrolidone is at 30° C.
Next, the method for manufacturing the gas permeation membrane of the present invention comprises dissolving polyimide having a repeating structure unit expressed by the following general formula (15) in a polar solvent; and forming at least one membrane selected from the group consisting of a flat membrane and a hollow fiber membrane
General Formula (15) ##STR16## where R denotes a quadrivalent organic group.
It is preferable in the above mentioned method that the quadrivalent organic group is at least one organic group selected from the group consisting of organic groups expressed by the following general formulas (16) to (18):
General Formula (16) ##STR17##
General Formula (17) ##STR18##
General Formula (18) ##STR19## where X denotes at least one group selected from the group consisting of--C(CF 3 ) 2 --, --C(CF 3 )(C 6 H 5 )--, --C(CH 3 )(C 6 H 5 )--, --CH 2 --, --C(CH 3 ) 2 --, --CO--, --SO 2 --, --O--, --S--, --NH--, --COO--, --CONH--, --Si(CH 3 ) 2 --, --O--C 6 H 4 --C(CH 3 ) 2 --C 6 H 4 --O--, --O--C 6 H 4 --O--, --O--CH 2 --CH 2 --O--, --CF 2 CF 2 CF 2 --, --CO--C 6 H 4 --CO--, and --O--C 6 H 4 --S--C 6 H 4 --O--.
It is also preferable that the above mentioned method comprises casting a solution containing polyimide onto the surface layer of a supporting member having a smooth surface; and then removing the solvent.
It is also preferable in the above mentioned method that the step of removing the solvent is one process selected from the group consisting of a process of heating and drying, a process of drying under reduced pressure, and a process in which the solvent is dissolved by dipping in an organic solvent that is a poor solvent for the polyimide.
As explained above, the polyimide gas separation membrane of the present invention has high gas permeation property and selectivity, and is excellent in weather resistance and chemical resistance, so that it can be used as a gas separation membrane in a wide variety of fields.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an analysis chart by nuclear magnetic resonance (NMR) of the polyimide according to Example 1 of the present invention.
FIG. 2 is an analysis chart by infrared analysis (IR) of polyimide according to Example 1 of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
The compound expressed by the above mentioned general formula (1) can be manufactured by equimolar condensation polymerization of diamines expressed by general formulas (5) and (6). The polymerization method is not particularly limited, and general polymerization methods can be employed. As the solvent for polymerization, N-methyl-2- pyrrolidone, N,N-dimethylacetamide, dimethyl sulfoxide, N,N-dimethylformamide, and the like are examples. The solvents may be used singly or in combinations thereof. The amount of solvent to be used with respect to a raw material is not particularly limited, but it is generally in the range of 70 to 90 weight % concentration. The first method for manufacturing a polyimide comprises synthesizing polyamic acid by mixing a diamine component and tetracarboxylic acid dianhydride to react therewith below room temperature for, in general, 5 to 50 hours; and adding a cyclodehydrating agent such as acetic anhydride, pyridine, triethylamine, etc. to the reaction solution to further react at room temperature for, in general, 5 to 24 hours. Another method for manufacturing polyimide comprises heating the polyamic acid to 180 to 200° C.; adding a hydrocarbon system or chloride system solution that can be azeotropic with water, for example, benzene, toluene, xylene, chlorobenzene and dichlorobenzene; and reacting for 5 to 10 hours to polyimidize the polyamic acid while removing the water generated due to the cyclization of amic acid as an azeotrope out of the system. The obtained polyimide is soluble in N-methyl-2-pyrrolidone, N,N-dimethylacetamide, dimethyl sulfoxide, and N,N-dimethylformamide, or the like.
Next, the gas separation membrane comprising the polyimide of the present invention can be manufactured by condensation polymerizing tetracarboxylic dianhydride expressed by the aforementioned general formula (5) and diamine expressed by the aforementioned general formula (6) as a diamine component.
Hereinafter, polyimide forming a gas separation membrane will be explained in detail. The polyimide of the present invention may be any polymers obtained by condensation polymerizing tetracarboxylic dianhydride expressed by the general formula (5) and diamine component expressed by the general formula (6).
Herein, as the compound expressed by the general formula (5), for example, 4,4'-(hexafluoroisopropylidene) diphthalic acid dianhydride, 3,3'-biphenyl tetracarboxylic acid dianhydride or pyromellitic dianhydride are preferably used. As the diamine expressed by the general formula (6), 2-(2,4-diaminobenzyl) pyridine is used.
As mentioned above, the polyimide of the present invention is a polymer obtained by randomly condensation polymerizing tetracarboxylic acid dianhydride as a raw material and a diamine component. Therefore, the polyimide has a plurality of repeating structure units depending on varieties of raw materials and their blending ratio, etc.
In the present invention, in the polyimide in which both tetracarboxylic acid dianhydride and diamine are aromatic and have heat resistant properties; as a basic material of tetracarboxylic acid dianhydride, pyromellitic dianhydride can be mentioned, and as a diamine, 2-(2,4-diaminobenzyl) pyridine can be mentioned. The weight ratio of tetracarboxylic acid dianhydride and diamine component in the polymer obtained by randomly condensation polymerizing thereof is 54.2 wt. % and 45.8 wt. %, respectively.
Moreover, in another embodiment; as a tetracarboxylic acid dianhydride, a mixture comprising the same amount of pyromellitic dianhydride and 4,4'-(hexafluoroisopropylidene) diphthalic acid dianhydride can be mentioned; and as a diamine, 2-(2,4-diaminobenzyl) pyridine can be mentioned. The weight ratio of tetracarboxylic acid dianhydride and diamine in the polymer obtained by randomly condensation polymerizing thereof is 64.3 wt. % and 35.7 wt. %, respectively.
In the polymer obtained by randomly condensation of the present invention, in a case where a plurality of tetracarboxylic acids are used, kinds or mixing ratio of the combination of tetracarboxylic acid dianhydrides are not particularly limited as long as the total molar amount of tetracarboxylic acid dianhydride is equal to the total amount of diamine component.
In the present invention, pyromellitic dianhydride preferably used as the tetracarboxylic acid dianhydride, is a material constituting a minimum molar amount among a tetracarboxylic acid dianhydrides. On the other hand, in the present invention, as diamine, 2-(2,4-diaminobenzyl) pyridine is preferably used. Therefore, in the present invention, as long as 2-(2,4-diaminobenzyl) pyridine is used as a diamine, the weight ratio of the component in the polymer obtained by randomly condensation of tetracarboxylic acid dianhydride and 2-(2,4-diaminobenzyl) pyridine as a diamine, which have the same molar weight, is not less than 54.2 wt. % and not more than 45.8 wt. %, respectively.
As the polyimide used in the second invention, a polyimide whose intrinsic viscosity is in the range of 0.4 to 1.5, preferably in the range of 0.5 to 1.0 when measured with the solution in which 0.5 g of polyimide is dissolved in 1 dl of N-methyl-2-pyrrolidone at 30° C. is preferred. If the polyimide of too small intrinsic viscosity is used and made into a gas separation membrane, the membrane is inferior in the self-supporting property and lacks in the mechanical strength. On the other hand, if the intrinsic viscosity is too large, a uniform membrane-forming solution cannot easily be obtained and a membrane formation becomes difficult.
The gas separation membrane of the present invention can be manufactured by various methods. A method for manufacturing a uniform membrane comprises dissolving the polyimide expressed by the general formula (1) in a solvent for forming membrane to make a uniform membrane-forming solution; casting the obtained solution onto the appropriate supporting base materials; and then evaporating the solvent by means of a heating process or a heating process under reduced pressure. In order to attain the practical gas permeation performance, namely, to attain a large permeation rate, the membrane is required to be sufficiently thin. However, from the viewpoint of the mechanical strength and the occurrence of pinholes, the thickness of membrane is preferred to be in the range of 0.03 μm to 20 μm. As the solvent for forming membrane, the same as those of the polymerization reacting agent, organic solvent such as N-methyl-2-pyrrolidone, N,N-dimethylacetamide, dimethyl sulfoxide, N,N-dimethylformamide or the like, are preferred. The supporting base materials to which the membrane forming solution is applied are not particularly limited. The examples of such supporting base materials include members having smooth surfaces, such as heat resistant polymer, glass, metal, ceramic, etc. The heating temperature after the membrane forming solution is applied to the supporting base material depends on the kinds of solvents of membrane forming solution. However, in the case of the above mentioned organic solvent, the heating temperature is in the range of 80 to 200° C., preferably in the range of 100 to 150° C. More preferably, after almost all of the solvent is evaporated at the above ranging temperature, all solvent is completely evaporated by heating at 200 to 300° C. Moreover, a non-uniform membrane can be formed by applying the membrane forming solution onto the supporting base material; then dipping with water or organic solvent that can be mixed with the above mentioned organic solvents (poor solvent for polyimide); and drying at the above mentioned temperatures. The methods for forming the membrane or the form of the membrane are not limited. The membrane may be a composite membrane. As to the membrane form, flat membrane, hollow fiber membrane, etc. are possible.
The terms for describing the membrane performance of the present invention are defined as follows.
(1) Gas Permeation Coefficient
A coefficient showing the permeation rate of gas for semipermeable membrane. The unit is expressed by the following equation (1).
Equation (1)
Barrer=10.sup.-10 cm.sup.3 (STP) cm/cm.sup.2 /sec/cmHg
where "cm 3 (STP)" shows a volume of gas that permeates at normal temperature (0° C.) and normal pressure (1 atm), "cm" shows a thickness of a film, "cm 2 " shows an area of a film, "sec" shows a time (second) and "cmHg" shows a pressure. The measurement data are values at 25° C. and 1 atm.
(2) Selectivity
A gas selectivity of a semipermeable membrane is expressed by the ratio of the permeability coefficients of individual gases which are measured when they permeate the same membrane. For example, CO 2 /N 2 =50 means that the membrane permeates CO 2 gas at the rate 50 times that of N 2 gas. The measurement data are values at 25° C. and 1 atm.
Hereinafter, the invention will be explained with reference to Examples and Comparative Examples, but is not limited to them alone.
Example 1
15.0 g (0.0754 mol) of diaminobenzylpyridine and 200 ml of N-methyl-2-pyrrolidone were placed in a 1000 ml three-neck flask and dissolved by stirring in an argon gas atmosphere. This flask was placed in a water bath of 10 to 15° C., followed by adding 33.4 g (0.0754 mol) of 4,4'-(hexafluoroisopropylidene) diphthalic acid dianhydride, dividing it into four parts over the course of 1 hour. After the addition, this flask is allowed to reach room temperature and stirred to react for 20 hours, and thus polyamic acid was obtained. 26.9 g (0.264 mol) of acetic anhydride and 26.7 g (0.264 mol) of triethylamine were added to this polymerization solution and reacted at room temperature for 20 hours. Then the reacted material was placed in the mixture solution of water and alcohol, and thus the deposition of polyimide resin was obtained. Moreover, this flask was washed with alcohol several times. The intrinsic viscosity of the polyimide resin was 0.72 (dL/g) (0.5 g/dL, NMP, 30° C.). The steps of the above mentioned chemical reaction are expressed by the following formula (19).
Chemical Formula 19 ##STR20##
The identification data of the polymer obtained in the above mentioned manner are shown in FIGS. 1 and 2. FIG. 1 is an analysis chart by nuclear magnetic resonance (NMR) of the polyimide according to Example 1 of the present invention. Each number of peaks shows each connection in the polymer structure formula shown in the upper left portion of this chart. As an analysis apparatus, FT--NMR: LA 400 (the product of JEOL LTD.) was used. The measurement was conducted under the following conditions: DMSO-d 6 was used as the solvent to make a solution having a concentration of 50 mg/0.5 ml; the number of times of integrating was 160 times; 1 H resonance frequency was 400 MHz; the pulse width was 6.4 μsec (45° pulse); the internal standard was DMSO-d 6 (2.5 ppm); observation center frequency was 399.78457419 MHz; and the observation range was 8 KHz.
Next, FIG. 2 is an analysis chart by infrared analysis (IR) of polyimide. As an analysis apparatus, microscope FT - IR:FTS - 40, UMA 300A (the product of Bio - Rad Laboratories) was used. As to the preparation of samples or the method of analysis: microscope FT - IR determination of the samples washed with hexane was conducted by using a compression cell. The observation conditions were as follows: the measurement mode was permeation; the separation performance was 8 cm -1 ; the number of times of integrating was 128 times; the measurement range was 4000 to 7000 cm 31 1.
The above obtained polyimide resin was dissolved in N-methyl-2 pyrrolidone at 9 wt. % concentration. And the solution was cast to the glass board and the solvent was removed by the use of a vacuum heating dryer, followed by conducting a heating procedure in N 2 gas atmosphere at 200 to 300° C. for 5 hours. At that time, the glass transition temperatures and gas permeation coefficients were measured. The results are shown in Table 1.
COMPARATIVE EXAMPLE 1
A polyimide having the intrinsic viscosity of 0.53 (dL/g) was obtained by the method of Example 1 except that 44.5 g (0.10 mol) of 4,4'-(hexafluoroisopropylidene) diphthalic dianhydride as a tetracarboxylic acid dianhydride and 12.5 g (0.100 mol) of 2,4-diamino toluene as the diamine were used. The glass transition temperature and gas permeation coefficients were measured and the results were shown in Table 1.
TABLE 1______________________________________Glasstransi-tiontemper- Gas permeation coefficients Selectivity (--)ature (Barrer*1) O.sub.2 CH.sub.4 CO.sub.2 /(° C.) O.sub.2 CH.sub.4 N.sub.2 CO.sub.2 /N.sub.2 /N.sub.2 N.sub.2______________________________________Example 303 7.22 1.67 1.34 54.9 5.38 1.25 40.9Comparative 342 7.12 0.86 1.23 20.5 5.79 0.70 16.7Example 1______________________________________ (remark *1) Barrer = × 10.sup.-10 cm.sup.3 (STP) cm/cm.sup.2 /sec/cmHg
As is apparent from Table 1, the gas separation membrane of the Example of the present invention was much higher in gas permeation performance and selectivity than that of the Comparative Example.
Finally, it is understood that the invention may be embodied in other specific forms without departing from the spirit or essential characteristics thereof. The embodiments disclosed in this application are to be considered in all respects as illustrative and not restrictive, so that the scope of the invention being indicated by the appended claims rather than by the foregoing description, and all changes which come within the meaning and range of equivalency of the claims are intended to be embraced therein. | A novel polyimide having a repeating structure unit expressed by the following general formula (1), a method for manufacturing the same, a gas separation membrane using the novel polyimide and the method for manufacturing the same. The gas separation membrane using this polyimide is excellent in gas permeable performance and separation selectivity for gas, for example, carbon dioxide, methane, etc.
General Formula (1) ##STR1## where R denotes a quadrivalent organic group. | 2 |
RELATED APPLICATIONS
This application claims priority under 35 U.S.C. §119 to Japanese Patent Application No. 2009-156257 filed on Jun. 30, 2009, the entire content of which is hereby incorporated by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a sample testing apparatus for testing a sample which is collected from a human subject.
2. Description of the Related Art Japanese Laid-open Patent Publication No. 2006-030100 discloses a dispensing apparatus in which, regarding operator identification information, three authority levels for a general operator, a manager and a serviceman are set in advance and which receives entry of an ID from an operator and permits the operator to execute functions of the authority level corresponding to the entered ID. In addition, Japanese Laid-open Patent Publication No. 2006-030100 contains a description that this technique can be applied not only to the dispensing apparatus but also to an analysis apparatus.
When an ID corresponding to the general operator is entered, the dispensing apparatus permits an operator to execute functions for the general operator, when an ID corresponding to the manager is entered, the dispensing apparatus permits an operator to execute functions for the general operator and the manager, and when an ID corresponding to the serviceman is entered, the dispensing apparatus permits an operator to execute functions for the general operator, the manager and the serviceman. An operator having an ID corresponding to the serviceman performs an operation test of the apparatus as maintenance work and confirms whether the apparatus is operating normally on the basis of the operation history of the apparatus. A general operator and a manager are operators on the facility side having the above-described dispensing apparatus delivered thereto and a serviceman is an operator on the trader side delivering the above-described dispensing apparatus to the facility.
When the technique described in Japanese Laid-open Patent Publication No. 2006-030100 is applied to an analysis apparatus, a serviceman performs an analysis operation as maintenance work by using a control sample and confirms an analysis result to confirm whether the analysis apparatus is operating normally. Since the analysis result which is generated with the maintenance work is not necessary for operators on the facility side, the serviceman is required to delete the analysis result when the maintenance work ends.
However, in the analysis apparatus to which the technique described in Japanese Laid-open Patent Publication No. 2006-030100 is applied, the serviceman is permitted to execute functions of a general operator and a manager. Accordingly, there is a concern that analysis results which are obtained by an operator on the facility side may be deleted by mistake when the serviceman deletes the analysis result of the control sample which is generated with the maintenance work.
SUMMARY OF THE INVENTION
The scope of the present invention is defined solely by the appended claims, and is not affected to any degree by the statements within this summary.
A first aspect of the present invention is a sample testing apparatus comprising: a first storing section for storing identification information of an operator in association with first or second attribute information showing the attribute of the operator; an identification information receiving section for receiving an input of the identification information of the operator; a testing section for obtaining a test result by testing a sample; a second storing section for storing the test result of the sample, which is obtained by the testing section, so as to be linked with the identification information which is received by the identification information receiving section; an operation end instruction receiving section for receiving an operation end instruction by the operator; and a deleting section for deleting from the second storing section the test result which is stored so as to be linked with the identification information received by the identification information receiving section in the case in which the identification information received by the identification information receiving section is associated with the second attribute information when the operation end instruction is received by the operation end instruction receiving section.
A second aspect of the present invention is a sample testing apparatus comprising: a first storing section for storing identification information of an operator in association with first or second attribute information showing the attribute of the operator; an identification information receiving section for receiving an input of the identification information of the operator; a testing section for obtaining a test result by testing a sample; a second storing section for storing the test result of the sample, which is obtained by the testing section, so as to be linked with the identification information which is received by the identification information receiving section; and an editing prohibition section for prohibiting a process of editing the test result which is linked with the identification information associated with the first attribute information when the identification information received by the identification information receiving section is associated with the second attribute information.
A third aspect of the present invention is a sample testing apparatus, comprising a memory storing an identification information of an operator in association with first or second attribute information showing the attributer of the operator; a testing section for obtaining a test result by testing a sample; and a controller, wherein the controller is configured to: receive an input of an identification information of an operator; store the test result in the memory which is obtained by the testing section so as to be linked with the received identification information; receive an operation end instruction; and delete from the memory the test result which is stored so as to be linked with the received identification information associated with the second attribute information in the case in which the received identification information is associated with the second attribute information when receiving the operation end instruction.
A fourth aspect of the present invention is A sample testing apparatus, comprising a memory storing an identification information of an operator in association with first or second attribute information showing the attributer of the operator; a testing section for obtaining a test result by testing a sample; and a controller, wherein the controller is configured to: receive an input of an identification information of an operator; store the test result in the memory which is obtained by the testing section so as to be linked with the received identification information; and prohibit a process of editing the test result which is linked with the identification information associated with the first attribute information when the received identification information is associated with the second attribute information.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view showing the external configuration of a sample testing apparatus according to a first embodiment;
FIG. 2 is a perspective view showing the external configurations of a rack which holds sample containers and the sample containers which are held in the rack;
FIG. 3 is a block diagram showing the configuration of a measuring unit according to the first embodiment;
FIG. 4 is a block diagram showing the configuration of a control apparatus according to the first embodiment;
FIG. 5 is a flowchart showing a sample testing process of the control apparatus according to the first embodiment;
FIG. 6 is a diagram showing an example of a login screen which is displayed on a display section according to the first embodiment;
FIG. 7 is a diagram showing an example of an error screen which is displayed on the display section according to the first embodiment;
FIG. 8 is a flowchart showing a process of a CPU in a user mode according to the first embodiment;
FIG. 9 is a diagram showing an example of an initial screen which is displayed on the display section in a user mode according to the first embodiment;
FIG. 10 is a flowchart showing a sample measurement process according to the first embodiment;
FIG. 11 is a diagram showing an example of a measurement result screen which is displayed on the display section in a user mode according to the first embodiment;
FIG. 12 is a flowchart showing sample measurement operations of the measuring unit according to the first embodiment;
FIG. 13 is a diagram showing an example of a test result list screen which is displayed on the display section in a user mode according to the first embodiment;
FIG. 14 is a flowchart showing a test result editing process in a user mode according to the first embodiment;
FIG. 15 is a diagram showing an example of an operation history screen which is displayed on the display section in a user mode according to the first embodiment;
FIG. 16 is a flowchart showing a process of the CPU in a service mode according to the first embodiment;
FIG. 17 is a diagram showing an example of an initial screen which is displayed on the display section in a service mode according to the first embodiment;
FIG. 18 is a diagram showing an example of a measurement result screen which is displayed on the display section in a service mode according to the first embodiment;
FIG. 19 is a diagram showing an example of a test result list screen which is displayed on the display section in a service mode according to the first embodiment;
FIG. 20 is a flowchart showing a test result editing process in a service mode according to the first embodiment;
FIG. 21 is a diagram showing an example of an error screen which is displayed on the display section in a service mode according to the first embodiment;
FIG. 22 is a diagram showing an example of an operation history screen which is displayed on the display section in a service mode according to the first embodiment;
FIG. 23 is a flowchart showing an operation history editing process according to the first embodiment;
FIG. 24 is a diagram showing an example of an error screen which is displayed on the display section in a service mode according to the first embodiment;
FIG. 25 is a schematic diagram showing an operator information database according to the first embodiment;
FIG. 26 is a schematic diagram showing a test result database according to the first embodiment;
FIG. 27 is a schematic diagram showing an operation history database according to the first embodiment;
FIG. 28 is a flowchart showing a process in a service mode according to a second embodiment;
FIG. 29 is a diagram showing an example of a logoff screen which is displayed on the display section in a service mode according to the second embodiment; and
FIG. 30 is a schematic diagram showing the configuration of a sample testing system according to a third embodiment.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
First Embodiment
A sample testing apparatus according to a first embodiment of the invention is a blood cell analysis apparatus which classifies and counts the number of blood cell components such as red blood cells, white blood cells and platelets which are included in a blood sample gathered from a human subject.
FIG. 1 is a perspective view showing the external configuration of a blood cell analysis apparatus 1 . As shown in FIG. 1 , the blood cell analysis apparatus 1 includes a measuring unit 3 , a transport apparatus 4 which is disposed in front of the measuring unit 3 (in a direction of the arrow Y 1 ) and a control apparatus 5 which is composed of a personal computer electrically connected to the measuring unit 3 and the transport apparatus 4 . The control apparatus 5 includes a display section 52 and an input device 53 . The display section 52 is provided to display analysis results and the like which are obtained by analyzing data of digital signals transmitted from the measuring unit 3 .
The transport apparatus 4 includes a before-analysis rack holding section 41 which can hold a plurality of racks 101 accommodating sample containers 100 each containing a sample not yet analyzed, an after-analysis rack holding section 42 which can hold a plurality of racks 101 accommodating sample containers 100 each containing a sample subjected to an analysis, a rack transporting section which transversely transports a rack 101 in directions of the arrows X 1 and X 2 , and a bar-code reading section which reads a bar-code 100 b of a sample container 100 and a bar-code 101 a adhered to a rack 101 .
FIG. 2 is a perspective view showing the external configurations of a rack which holds sample containers and the sample containers which are held in the rack. As shown in FIG. 2 , in a rack 101 , ten container accommodating sections 101 b are formed so that ten sample containers 100 are accommodated in a line. A bar-code 100 b of each sample container 100 is uniquely adhered to each sample and is used for management of a test result of each sample. In addition, in each container accommodating section 101 b , an opening section 101 c is provided so as to visually check the bar-code 100 b of the accommodated sample container 100 . A bar-code 101 a is uniquely adhered to each rack 101 and is used for management of test results of samples.
FIG. 3 is a block diagram showing the configuration of the measuring unit 3 of the blood cell analysis apparatus 1 ′. As shown in FIG. 3 , the measuring unit 3 includes a sample aspirating section 31 for aspirating blood which is a sample from a sample container 100 , a specimen preparing section 32 for preparing a detection specimen from the blood aspirated by the sample aspirating section 31 and a detecting section 33 for detecting blood cell components of the blood from the specimen prepared by the specimen preparing section 32 . In addition, the measuring unit 3 further includes a unit cover 34 for accommodating the sample aspirating section 31 , the specimen preparing section 32 and the like therein and a sample container transporting section 35 for introducing a sample container 100 into the unit cover 34 (see FIG. 1 ) to transport the sample container 100 to a position where the aspiration is carried out by the sample aspirating section 31 . Moreover, the measuring unit 3 further includes a CPU 36 for controlling the sections, a memory 37 for storing programs which are executed by the CPU 36 and data which are used in the execution of the programs and a communication interface 38 which is connected to the control apparatus 5 so as to communicate therewith.
The detecting section 33 is configured to carry out RBC detection (detection of red blood cells) and PLT detection (detection of platelets) by a sheath-flow DC detection method and to carry out HGB detection (detection of hemochromes in blood) by a SLS-hemoglobin method. In addition, the detecting section 33 is configured to carry out WBC detection (detection of white blood cells) by a flow cytometry method using a semiconductor laser. The detection result obtained by the detecting section 33 is transmitted as measurement data to the control apparatus 5 . This measurement data is the base of a final test result (the number of red blood cells, the number of platelets, quantity of hemoglobin, the number of white blood cells and the like) which is provided to a user.
The sample container transporting section 35 has a hand section (not shown) which can grasp a sample container 100 , a bar-code reading section (not shown) and a sample container moving section 355 for horizontally moving a sample container 100 in directions of the arrows Y 1 and Y 2 . The hand section is disposed above a transport path of a rack 101 which is transported by the transport apparatus 4 . The sample container moving section 355 has a sample setting section 355 a (see FIG. 1 ) and can allow the sample setting section 355 a to dispose an aspiration position (not shown)
FIG. 4 is a block diagram showing the configuration of the control apparatus 5 of the blood cell analysis apparatus 1 . As shown in FIG. 4 , the control apparatus 5 is composed of a computer 500 mainly including a control device 51 , the display section 52 and the input device 53 .
As shown in FIG. 4 , the control device 51 mainly includes a CPU 51 a , a ROM 51 b , a RAM 51 c , a hard disk 51 d , a reading device 51 e , an I/O interface 51 f , a communication interface 51 g and an image output interface 51 h . The CPU 51 a , ROM 51 b , RAM 51 c , hard disk 51 d , reading device 51 e , I/O interface 51 f , communication interface 51 g and image output interface 51 h are connected to each other by a bus 51 i.
The CPU 51 a can execute computer programs which are stored in the ROM 51 b and computer programs which are loaded to the RAM 51 c . The computer 500 functions as the control apparatus 5 by executing an application program 54 a to be described later with the CPU 51 a.
The ROM 51 b is composed of a mask ROM, a PROM, an EPROM, an EEPROM or the like, and computer programs which are executed by the CPU 51 a and data which are used in the execution of the programs are recorded therein.
The RAM 51 c is composed of a SRAM, a DRAM or the like. The RAM 51 c is used to read computer programs which are recorded in the ROM 51 b and the hard disk 51 d . In addition, the RAM is used as a work area of the CPU 51 a when these computer programs are executed.
In the hard disk 51 d , various computer programs for execution by the CPU 51 a , such as an operating system and an application program, and data which are used to execute the computer programs, are installed. The sample test program 54 a for the control apparatus 5 is also installed in the hard disk 51 d . In addition, the hard disk 51 d is provided with an operator information database 54 b , a test result database 54 c and an operation history database 54 d . Detailed descriptions of the databases will be described later.
The reading device 51 e is composed of a flexible disk drive, a CD-ROM drive, a DVD-ROM drive or the like and can read computer programs or data which are recorded in a portable recording medium 54 . In addition, the application program 54 a is stored in the portable recording medium 54 and the computer 500 can read the application program 54 a from the portable recording medium 54 and install the application program 54 a in the hard disk 51 d.
The above-described application program 54 a is provided by the portable recording medium 54 and can be also provided from an external device, which is connected to the computer 500 by an electric communication line (which may be wired or wireless) to communicate therewith, through the electric communication line. For example, the application program 54 a is stored in a hard disk of a server computer on the internet and the computer 500 accesses the server computer to download the application program 54 a and install the application program in the hard disk 51 d.
Further, in the hard disk 51 d , for example, an operating system for providing a graphic user interface environment, such as Windows (registered trade name) which is made and distributed by Microsoft Corporation in America, is installed. In the following description, the application program 54 a operates on the above-described operating system.
The I/O interface 51 f is composed of, for example, a serial interface such as USB, IEEE1394 or RS-232C, a parallel interface such as SCSI, IDE or IEEE1284, and an analog interface including a D/A converter and an A/D converter. The input device 53 is connected to the I/O interface 51 f and a user uses the input device 53 so as to input data to the computer 500 .
For example, the communication interface 51 g is an Ethernet (registered trade name) interface. The computer 500 uses a predetermined communication protocol by the communication interface 51 g so as to transmit and receive data to and from the measuring unit 3 and the transport apparatus 4 .
The image output interface 51 h is connected to the display section 52 composed of an LCD or a CRT so as to output to the display section 52 a picture signal corresponding to image data provided from the CPU 51 a . The display section 52 is configured to display an image (screen) in accordance with an input picture signal.
FIG. 5 is a flowchart showing a sample testing process of the control apparatus 5 of the blood cell analysis apparatus 1 . Hereinafter, the sample testing process of the control apparatus 5 (CPU 51 a ) according to this embodiment will be described with reference to FIG. 5 .
First, in Step S 1 , the CPU 51 a executes an initial setting process. Next, in Step S 2 , the CPU 51 a displays a login screen F (see FIG. 6 ) on the display section 52 .
FIG. 6 is a diagram showing an example of the login screen F which is displayed on the display section 52 . As shown in FIG. 6 , the login screen F includes an ID field F 2 , a password field F 3 and an OK button F 4 . An operator enters an ID and a password in the ID field F 2 and the password field F 3 by the input device 53 and selects the OK button F 4 to confirm the entry of ID and password. Herein, the ID is identification information for identifying the operator.
Returning to FIG. 5 , in Step S 3 , the CPU 51 a determines whether the entry of ID and password has been received. When it is determined that the entry of ID and password has been received (YES in Step S 3 ), the CPU 51 a determines in Step S 4 whether the received ID and the password corresponding to the ID are registered in the operator information database 54 b.
FIG. 25 is a schematic diagram showing the operator information database 54 b which is provided in the hard disk 51 d . The operator information database 54 b is a relational database and includes fields of ID, password and group as shown in FIG. 25 . The ID is information that is uniquely set for each operator and is used to specify an operator. The password is set by an operator. The group is information showing which of the three groups of general user, serviceman and manager an operator belongs to. In the blood cell analysis apparatus 1 according to this embodiment, executable functions vary depending on the group of an operator.
An operator belonging to the general user group (hereinafter, referred to as a general user) is an operator of the facility having the blood cell analysis apparatus 1 installed therein and carries out a test of a sample gathered from a human subject. The ID and password of the general user are registered in the operator information database 54 b in a general user registration screen (not shown) by an operator belonging to the manager group (hereinafter, referred to as a manager). The general user can execute various processes, such as measurement of samples in the blood cell analysis apparatus 1 , registration of measurements, changing and deletion of test results, validation (approval) of test results, external output of a display screen and changing of settings, in the range set by the manager.
The manager is an operator on the facility side having the blood cell analysis apparatus 1 installed therein and mainly performs the management of general users of the blood cell analysis apparatus 1 . The ID and password of the manager are registered in the operator information database 54 b by an operator belonging to the serviceman group (hereinafter, referred to as a serviceman). As described above, the manager can set which functions can be executed among the various functions of the blood cell analysis apparatus 1 for each general user. In addition, the manager can execute all the functions, which can be executed by a general user, of the blood cell analysis apparatus 1 .
The serviceman is an operator on the trader side delivering the blood cell analysis apparatus 1 to the facility and mainly performs maintenance work of the blood cell analysis apparatus 1 . The serviceman can execute functions such as changing of settings which cannot be changed by a general user or a manager. As functions relating to the maintenance of the blood cell analysis apparatus 1 , the serviceman can execute the setting of an error monitoring range by the apparatus, the setting of an error skip function and the like. In addition, the serviceman can execute all the functions, which can be executed by a general user, of the blood cell analysis apparatus 1 . However, the serviceman cannot change and delete test results and operation histories obtained by a general user. This will be described later.
Returning to FIG. 5 , when it is determined that the received ID and the password corresponding to the ID are not registered in the operator information database 54 b (NO in Step S 4 ), the CPU 51 a displays an error screen (see FIG. 7 ) J informing the operator of the determination on the display section 52 (Step S 5 ).
FIG. 7 is a diagram showing an example of the error screen J which is displayed on the display section 52 . As shown in FIG. 7 , the message “the entered ID and password have not been registered” is displayed in the error screen J. Further, the error screen J includes an OK button J 1 . The operator selects the OK button J 1 by the input device 53 so as to instruct the removal of the error screen.
Returning to FIG. 5 , in Step S 6 , the CPU 51 a determines whether the instruction of the removal of the error screen has been received. When it is determined that the instruction of the removal of the error screen has been received (YES in Step S 13 ), the CPU 51 a removes the error screen J displayed on the display section 52 by executing an error screen removing process. Then, the CPU 51 a executes a process of Step S 10 to be described later.
When it is determined that the received ID and the password corresponding to the ID are registered in the operator information database 54 b (YES in Step S 4 ), the CPU 51 a determines a group corresponding to the received ID by referring to the operator information database 54 b in Step S 7 . When the group corresponding to the received ID is a general user group or a manager group (general user or manager in Step S 7 ), the CPU 51 a performs a process of Step S 8 . In Step S 8 , the blood cell analysis apparatus 1 operates in the range of functions corresponding to the general user group or the manager group. Hereinafter, the process of the CPU 51 a in Step S 8 will be called a user mode. When the group corresponding to the received ID is a serviceman group (serviceman in Step S 7 ), the CPU 51 a performs a process of Step S 9 . In Step S 9 , the blood cell analysis apparatus 1 operates in the range of functions corresponding to the serviceman group. Hereinafter, the process of the CPU 51 a in Step S 9 will be called a service mode. Processes of the CPU 51 a in a user mode and in a service mode will be described later in detail.
Next, in Step S 10 , the CPU 51 a determines whether an instruction of shutdown from the operator has been received. When it is determined that the instruction of shutdown has been received (YES in Step S 10 ), the CPU 51 a executes a shutdown process in Step S 11 . When it is determined that the instruction of shutdown has not been received (NO in Step S 10 ), the CPU 51 a executes the process of Step S 2 .
FIG. 8 is a flowchart showing a process of the CPU 51 a in a user mode. Hereinafter, the process of the control apparatus 5 (CPU 51 a ) in a user mode will be described with reference to FIG. 8 . In the following description, a general user is set by a manager so as to execute at least the functions of changing and deletion of test results.
In Step S 101 , the CPU 51 a displays an initial screen 521 (see FIG. 9 ) on the display section 52 .
FIG. 9 is a diagram showing an example of the initial screen 521 which is displayed on the display section 52 in a user mode. As shown in FIG. 9 , the initial screen 521 includes various buttons for instructing the CPU 51 a so as to execute processes, such as measurement of samples, display of a setting screen, display of test results, display of operation histories and instructions of logoff and shutdown. An operator selects the above-described various buttons by the input device 53 so as to instruct the CPU 51 a of the various processes.
Next, in Step S 102 , the CPU 51 a determines whether an instruction of sample measurement from the operator has been received. When it is determined that the instruction of sample measurement has been received (YES in Step S 102 ), the CPU 51 a executes a sample measurement process in Step S 103 .
FIG. 10 is a flowchart showing a sample measurement process of the control apparatus 5 of the blood cell analysis apparatus 1 . Hereinafter, the sample measurement process of the control apparatus 5 (CPU 51 a ) will be described with reference to FIG. 10 .
First, in Step S 201 , the CPU 51 a transmits an instruction for starting the measurement of a sample to the measuring unit 3 . Sample measurement operations of the measuring unit 3 will be described later in detail. Next, in Step S 202 , the CPU 51 a determines whether measurement data transmitted from the measuring unit 3 has been received. When it is determined that the measurement data has been received (YES in Step S 202 ), the CPU 51 a executes a process of storing the received measurement data in the RAM 51 c in Step S 203 . Next, in Step S 204 , the CPU 51 a obtains a test result by analyzing the measurement data stored in the RAM 51 c . Next, in Step S 205 , the CPU 51 a stores the obtained test result together with the ID of the operator in the test result database 54 c provided in the hard disk 51 d.
FIG. 26 is a schematic diagram showing the test result database 54 c which is provided in the hard disk 51 d . The test result database 54 c is a relational database and includes fields of sample ID, WBC, RBC, . . . and ID as shown in FIG. 26 . The sample ID is identification information that is uniquely set for each sample contained in a sample container 100 . The WBC and the RBC are test items and indicate the number of white blood cells and the number of red blood cells in blood, respectively. The test items are not limited to the WBC and the RBC and may include the number of platelets and quantity of hemoglobin in blood. The ID indicates the ID of the operator of the apparatus when the test result is obtained.
Returning to FIG. 10 , in Step S 206 , the CPU 51 a executes a process of displaying on the display section 52 a test result display screen B (see FIG. 11 ) showing the test results stored in the test result database 54 c.
FIG. 11 is a diagram showing an example of the test result display screen B which is displayed on the display section 52 in a user mode. As shown in FIG. 11 , the test result display screen B includes a sample information field B 1 in which an ID of the sample and the like are displayed, an operator information field B 2 in which an ID of the operator executing the test and the like are displayed and a measurement result field B 3 in which test items of the sample are displayed. When a predetermined time elapses after the display of the test result display screen B on the display section 52 , the CPU 51 a executes the process of Step S 102 of the flowchart shown in FIG. 8 .
FIG. 12 is a flowchart showing sample measurement operations of the measuring unit 3 of the blood cell analysis apparatus 1 . Hereinafter, the sample measurement operations of the measuring unit 3 will be described with reference to FIG. 12 .
First, in Step S 301 , the CPU 36 executes an initial process and returns the sections in the measuring unit 3 to respective initial operation positions. Next, in Step S 302 , the CPU 36 determines whether a measurement start instruction transmitted from the control apparatus 5 has been received. When it is determined that the measurement start instruction has been received (YES in Step S 302 ), the CPU 36 controls the sample aspirating section 31 so as to aspirate a sample from a sample container 100 transported to the aspiration position in Step S 303 . Next, in Step S 304 , the CPU 36 controls the specimen preparing section 32 so as to prepare a detection specimen from the aspirated sample. Next, in Step S 305 , the CPU 36 controls the detecting section 33 so as to detect components of an analysis target from the detection specimen. Next, in Step S 306 , the CPU 36 transmits measurement data to the control apparatus 5 .
Next, in Step S 307 , the CPU 36 determines whether a shutdown instruction from the control apparatus 5 has been received. When it is determined that the shutdown instruction is not received (NO in Step S 307 ), the CPU 36 executes the process of Step S 302 . When it is determined that the shutdown instruction has been received (YES in Step S 307 ), the CPU 36 transmits an operation history to the control apparatus 5 and executes a shutdown process in Step S 308 .
The CPU 51 a receives the operation history transmitted from the measuring unit 3 and stores the received operation history together with the ID of the operator in the operation history database 54 d provided in the hard disk 51 d.
FIG. 27 is a schematic diagram showing the operation history database 54 d which is provided in the hard disk 51 d . The operation history database 54 d is a relational database and includes fields of date, time, contents and ID as shown in FIG. 27 . The date indicates a date at which the operation history is generated. The time indicates time at which the operation history is generated. The contents indicate the contents of the operation history (error or the like). The ID indicates an ID of the operator operating apparatus when the operation history is generated.
Returning to FIG. 8 , when it is determined that the instruction of sample measurement is not received (NO in Step S 102 ), the CPU 51 a determines in Step S 104 whether a test result list screen E (see FIG. 13 ) is displayed on the display section 52 . When the test result list screen E is not displayed on the display section 52 (NO in Step S 104 ), the CPU 51 a determines in Step S 105 whether an instruction for displaying the test result list screen E has been received. When it is determined that the instruction for displaying the test result list screen E has been received (YES in Step S 105 ), the CPU 51 a displays the test result list screen E on the display section 52 in Step S 106 .
FIG. 13 is a diagram showing an example of the test result list screen E which is displayed on the display section 52 in a user mode. As shown in FIG. 13 , the test result list screen E includes an outline display field E 1 in which outlines of test results are displayed and a detailed display field E 2 in which the test result selected in the outline display field E 1 is displayed in detail.
Returning to FIG. 8 , when the test result list screen E is displayed on the display section 52 (YES in Step S 104 ) and when the test result list screen E is caused to be displayed on the display section 52 , the CPU 51 a determines in Step S 107 whether a measurement result editing start instruction has been received. When it is determined that the measurement result editing start instruction is not received (NO in Step S 107 ), the CPU 51 a executes the process of Step S 102 . When it is determined that the measurement result editing start instruction has been received (YES in Step S 107 ), the CPU 51 a executes a test result editing process in Step S 108 .
FIG. 14 is a flowchart showing a test result editing process of the control apparatus 5 in a user mode. Hereinafter, the test result editing process of the control apparatus 5 (CPU 51 a ) in a user mode will be described with reference to FIG. 14 . Herein, the editing process is a process of executing the changing and deletion of the contents of test results.
In the outline display field E 1 of the test result list screen E which is displayed on the display section 52 , test results are displayed as a list in a tabular form. Herein, a row of the table corresponds to one test result registered in the test result database 54 c . By selecting a row by the input device 53 , an operator can select one corresponding test result. In Step S 501 , the CPU 51 a determines whether the selection of the test result in the outline display field E 1 has been received.
By selecting a test result by the input device, the operator can instruct the CPU 51 a to edit the selected test result. When it is determined that the selection of the test result has been received (YES in Step S 501 ), the CPU 51 a determines in Step S 502 whether an instruction for editing the selected test result has been received. By the input device 53 , the operator can instruct the CPU 51 a of an editing process of the selected test result. The operator can instruct a deletion process of the test result by, for example, pressing a Delete button (not shown) of the input device 53 .
When it is determined that the instruction of the editing of the test result has been received (YES in Step S 502 ), in Step S 503 , the CPU 51 a executes on the basis of the received instruction a process of editing the test result for which the editing instruction is issued.
When it is determined that the selection of the test result is not received (NO in Step S 501 ), when it is determined that the instruction of the editing of the test result is not received (NO in Step S 502 ), and when the editing process is executed, the CPU 51 a executes the process of Step S 102 of the flowchart shown in FIG. 8 .
Returning to FIG. 8 , when it is determined that the display instruction of the test result list screen E is not received (NO in Step S 105 ), the CPU 51 a determines in Step S 109 whether an operation history screen G (see FIG. 15 ) is displayed on the display section 52 . When the operation history screen G is not displayed on the display section 52 (NO in Step S 109 ), the CPU 51 a determines in Step S 110 whether a display instruction of an operation history screen has been received. When it is determined that the display instruction of an operation history screen has been received (YES in Step S 110 ), the CPU 51 a displays an operation history screen on the display section 52 in Step S 111 .
FIG. 15 shows the operation history screen G which is displayed on the display section 52 in a user mode. The operation history screen G includes an operation history list field G 1 in which an operation history list is displayed, as shown in FIG. 15 .
Returning to FIG. 8 , when the operation history screen G is displayed on the display section 52 (YES in Step S 109 ) and when the operation history screen G is caused to be displayed on the display section 52 , the CPU 51 a executes the process of Step S 102 .
When it is determined that the display instruction of the operation history screen G is not received (NO in Step S 110 ), the CPU 51 a determines in Step S 112 whether an instruction of logoff has been received. When it is determined that the instruction of logoff has been received (YES in Step S 112 ), the CPU 51 a executes a logoff process in Step S 113 . Then, the CPU 51 a executes the process of Step S 10 of the flowchart shown in FIG. 5 . When it is determined that the instruction of logoff is not received, the CPU 51 a executes the process of Step S 102 .
FIG. 16 is a flowchart showing a process of the CPU 51 a in a service mode.
Hereinafter, the process of the control apparatus 5 (CPU 51 a ) in a service mode will be described with reference to FIG. 16 .
In Step S 601 , the CPU 51 a displays an initial screen 521 (see FIG. 17 ) on the display section 52 .
FIG. 17 is a diagram showing an example of the initial screen 521 which is displayed on the display section 52 in a service mode. Herein, all the display screens in a service mode, that is, the initial screen 521 (see FIG. 17 ), a test result display screen B (see FIG. 18 ), a test result list screen E (see FIG. 19 ), an error screen K (see FIG. 21 ), an operation history screen G (see FIG. 22 ) and an error screen L (see FIG. 24 ) include a mode display bar A showing that a current operator is a serviceman. In addition, the mode display bar A is movable on the display section 52 . By the input device 53 , an operator can freely move the mode display bar A on the display section 52 .
Returning to FIG. 16 , in Step S 602 , the CPU 51 a determines whether a sample measurement instruction from an operator has been received. When it is determined that the sample measurement instruction has been received (YES in Step S 602 ), the CPU 51 a executes a sample measurement process in Step S 603 . In the related sample measurement, the serviceman performs a measurement operation on a control specimen and confirms a measurement result of the specimen and an operation history of the apparatus to confirm whether the blood cell analysis apparatus 1 is operating normally.
FIG. 18 is a diagram showing an example of the test result display screen B which is displayed on the display section 52 in a service mode. The process of Step S 603 is almost the same as the process of Step S 103 of the flowchart shown in FIG. 8 , except that the CPU 51 a displays on the display section 52 the test result display screen B shown in FIG. 18 .
Returning to FIG. 16 , when it is determined that the sample measurement instruction is not received (NO in Step S 602 ), the CPU 51 a determines in Step S 604 whether the test result list screen E (see FIG. 19 ) is displayed on the display section 52 . When the test result list screen E is not displayed on the display section 52 (NO in Step S 604 ), the CPU 51 a determines in Step S 605 whether a display instruction of the test result list screen E has been received.
When it is determined that the instruction for displaying the test result list screen E has been received (YES in Step S 605 ), the CPU 51 a displays the test result list screen E on the display section 52 in Step S 606 .
FIG. 19 is a diagram showing an example of the test result list screen E which is displayed on the display section 52 in a service mode. Herein, the CPU 51 a displays an S mark in a flag column of the test result corresponding to an ID of the serviceman by referring to the operator information database 54 b in an outline display field E 1 in which outlines of test results are displayed as a list. In this manner, the operator (serviceman) can identify whether each test result is obtained by the serviceman.
Returning to FIG. 16 , when the test result list screen E is displayed on the display section 52 (YES in Step S 604 ) and when a process of displaying the test result list screen E on the display section 52 is executed, the CPU 51 a determines in Step S 607 whether a test result editing start instruction has been received. When it is determined that the test result editing start instruction is not received (NO in Step S 607 ), the CPU 51 a executes the process of Step S 602 . When it is determined that the test result editing start instruction has been received (YES in Step S 607 ), the CPU 51 a executes a test result editing process in Step S 608 .
FIG. 20 is a flowchart showing a test result editing process of the control apparatus 5 in a service mode. Hereinafter, the test result editing process of the control apparatus 5 (CPU 51 a ) in a service mode will be described with reference to FIG. 20 . Herein, the editing process is a process of executing the changing and deletion of the contents of test results.
In the outline display field E 1 of the test result list screen E which is displayed on the display section 52 , test results are displayed as a list in a tabular form. Herein, a row of the table corresponds to one test result registered in the test result database 54 c . By selecting a row by the input device 53 , an operator can select one corresponding test result. In Step S 701 , the CPU 51 a determines whether the selection of the test result has been received.
By selecting a test result by the input device, the operator can instruct the CPU 51 a to edit the selected test result. When it is determined that the selection of the test result has been received (YES in Step S 701 ), the CPU 51 a determines in Step S 702 whether there is an instruction for editing the selected test result. By the input device 53 , the operator can instruct the CPU 51 a of an editing process of the selected test result. The operator can instruct the deletion of the test result by, for example, pressing the Delete button (not shown) of the input device 53 .
When it is determined that the instruction of the editing of the test result has been received (YES in Step S 702 ), the CPU 51 a determines in Step S 703 whether the test result for which the editing instruction is issued corresponds to the ID of the serviceman on the basis of whether an S mark is displayed in the flag column. When it is determined that the test result for which the editing instruction is issued does not correspond to the ID of the serviceman (when an S mark is not displayed in the flag column, NO in Step S 703 ), in Step S 704 , the CPU 51 a displays on the display section 52 the error screen K (see FIG. 21 ) for informing the operator (serviceman) that the target test result cannot be edited.
FIG. 21 is a diagram showing an example of an error screen which is displayed on the display section 52 . As shown in FIG. 21 , the message “this test result cannot be edited” is displayed in the error screen K. The operator selects an OK button K 1 by the input device 53 so as to instruct the removal of the error screen.
Returning to FIG. 20 , in Step S 705 , the CPU 51 a determines whether the instruction of the removal of the error screen has been received. When it is determined that the instruction of the removal of the error screen has been received (YES in Step S 705 ), the CPU 51 a removes the error screen K displayed on the display section 52 .
When it is determined that the test result for which the editing instruction is issued corresponds to the ID of the serviceman (when an S mark is displayed in the flag column, YES in Step S 703 ), the editing process is executed on the basis of the instruction in Step S 706 and the test result database 54 c is updated.
When it is determined that the selection of the test result is not received (NO in Step S 701 ), when it is determined that the instruction of the editing of the test result is not received (NO in Step S 702 ), when it is determined that the instruction of the removal of the error screen has been received, and when the test result database 54 c is updated, the CPU 51 a executes the process of Step S 602 of the flowchart shown in FIG. 16 .
Returning to FIG. 16 , when it is determined that the display instruction of the test result list screen E is not received (NO in Step S 605 ), the CPU 51 a determines in Step S 609 whether the operation history screen G (see FIG. 22 ) is displayed on the display section 52 . When the operation history screen G is not displayed on the display section 52 (NO in Step S 609 ), in Step S 610 , the CPU 51 a executes a process of determining whether a display instruction of the operation history screen G has been received. When it is determined that the display instruction of the operation history screen G has been received (YES in Step S 610 ), in Step S 611 , the CPU 51 a executes a process of displaying the operation history screen G on the display section 52 .
FIG. 22 is a diagram showing an example of the operation history screen G which is displayed on the display section 52 in a service mode. Herein, the CPU 51 a displays an S mark in a flag column of the operation history corresponding to the ID of the serviceman by referring to the operator information database 54 b in an operation history list field G 1 in which operation histories are displayed as a list. In this manner, the operator (serviceman) can identify whether each operation history is obtained by the serviceman.
Returning to FIG. 16 , when the operation history screen G is displayed on the display section 52 (YES in Step S 610 ) and when a process of displaying the operation history screen G on the display section 52 is executed, the CPU 51 a determines in Step S 612 whether an operation history editing start instruction has been received. When it is determined that the operation history editing start instruction is not received (NO in Step S 612 ), the CPU 51 a executes the process of Step S 602 . When it is determined that the operation history editing start instruction has been received (YES in Step S 612 ), the CPU 51 a executes an operation history editing process in Step S 613 . Herein, the editing process is a process of executing the changing and deletion of the contents of operation histories.
FIG. 23 is a flowchart showing an operation history editing process of the control apparatus 5 of the blood cell analysis apparatus 1 . Hereinafter, the operation history editing process of the control apparatus 5 (CPU 51 a ) will be described with reference to FIG. 23 .
In the operation history list field G 1 of the operation history screen G which is displayed on the display section 52 , operation histories are displayed as a list in a tabular form. Herein, a row of the table corresponds to one operation history. By selecting a row by the input device 53 , an operator can select one corresponding operation history. In Step S 801 , the CPU 51 a executes a process of determining whether the selection of an operation history has been received.
By selecting an operation history by the input device 53 , the operator can instruct the CPU 51 a to edit the selected operation history. When it is determined that the selection of the operation history has been received (YES in Step S 801 ), the CPU 51 a determines in Step S 802 whether an instruction for editing the selected operation history has been received. By the input device 53 , the operator can instruct the CPU 51 a of an editing process of the selected test results. The operator can instruct the deletion of the operation history by, for example, pressing the Delete button (not shown) of the input device 53 .
When it is determined that the instruction of the editing of the operation history has been received (YES in Step S 802 ), the CPU 51 a determines in Step S 803 whether the operation history for which the editing instruction is issued corresponds to the ID of the serviceman on the basis of whether an S mark is displayed in the flag column. When it is determined that the operation history for which the editing instruction is issued does not correspond to the ID of the serviceman (when an S mark is not displayed in the flag column, NO in Step S 803 ), in Step S 804 , the CPU 51 a displays on the display section 52 the error screen L (see FIG. 24 ) for informing the operator (serviceman) that the target operation history cannot be edited.
FIG. 24 is a diagram showing an example of the error screen L which is displayed on the display section 52 in a service mode. As shown in FIG. 24 , the message “this operation history cannot be edited” is displayed in the error screen L. The operator selects an OK button L 1 by the input device 53 so as to instruct the removal of the error screen.
Returning to FIG. 23 , in Step S 805 , the CPU 51 a determines whether the instruction of the removal of the error screen has been received. When the instruction of the removal of the error screen has been received (YES in Step S 804 a ), the CPU 51 a removes the error screen L displayed on the display section 52 .
When it is determined that the operation history for which the editing instruction is issued corresponds to the ID of the serviceman (when an S mark is displayed in the flag column, YES in Step S 803 ), the CPU 51 a executes the editing process in Step S 806 and updates the operation history database 54 d.
When it is determined that the selection of the operation history is not received (NO in Step S 801 ), when it is determined that the instruction of the editing of the operation history is not received (NO in Step S 802 ), when it is determined that the instruction of the removal of the error screen has been received, and when the operation history database 54 d is updated, the CPU 51 a executes the process of Step S 602 of the flowchart shown in FIG. 16 .
Returning to FIG. 16 , when it is determined that the display instruction of the operation history screen G is not received (NO in Step S 610 ), the CPU 51 a determines in Step S 614 whether an instruction of logoff has been received. When it is determined that the instruction of logoff has been received (YES in Step S 614 ), the CPU 51 a executes a logoff process in Step S 615 and then executes the process of Step S 10 of the flowchart shown in FIG. 5 . When it is determined that the instruction of logoff is not received, the CPU 51 a executes the process of Step S 602 .
As described above, the blood cell analysis apparatus 1 according to this embodiment is configured so that when a serviceman edits a test result and an operation history, it is determined whether the test result and the operation history correspond to an ID of the serviceman, and when it is determined that the test result and the operation history do not correspond to the ID of the serviceman, the test result and the operation history cannot be edited. Accordingly, in the blood cell analysis apparatus 1 according to this embodiment, there is no concern that test results and operation histories which are obtained by a general user will be deleted by mistake when the serviceman deletes a test result and an operation history which are generated with the maintenance work.
Second Embodiment
Hereinafter, a sample testing apparatus according to a second embodiment will be described. The sample testing apparatus according to the second embodiment is the same as the sample testing apparatus according to the first embodiment, except that when a logoff process is executed in a service mode, a test result and an operation history corresponding to an ID of a serviceman can be collectively deleted.
FIG. 28 is a flowchart showing a process in a service mode. Hereinafter, the process of the control apparatus 5 (CPU 51 a ) in a service mode will be described with reference to FIG. 28 .
Herein, since Steps S 1001 to S 1014 and Step S 1019 are the same as Steps S 601 to S 614 and Step S 615 of the flowchart shown in FIG. 16 , respectively, descriptions thereof will be omitted.
In Step S 1015 , the CPU 51 a displays a logoff screen H (see FIG. 29 ) on the display section 52 .
FIG. 29 is a diagram showing an example of the logoff screen H which is displayed on the display section 52 in a service mode. As shown in FIG. 29 , the message “the test result in the service mode will be deleted” is displayed in the logoff screen H. In addition, the logoff screen H includes a check box H 1 and an OK button H 2 .
Returning to FIG. 28 , in Step S 1016 , the CPU 51 a determines whether an operation history deletion instruction has been received. An operator selects the check box H 1 by the input device 53 and presses the OK button H 2 so as to instruct the CPU 51 a of the operation history deletion. Herein, when the operator does not select the check box H 1 but selects the OK button H 2 by the input device 53 , the operation history deletion instruction with respect to the CPU 51 a is not carried out. In this manner, in this embodiment, the deletion of the operation history in a service mode is selectable. Accordingly, a general user and a manager as operators on the facility side can confirm on the basis of the operation history which operation was executed in the maintenance work by the serviceman as an operator on the trader side.
When it is determined that the operation history deletion instruction has been received (YES in Step S 1016 ), in Step S 1017 , the CPU 51 a deletes all the test results and operation histories corresponding to the ID of the serviceman from the test result database 54 c and the operation history database 54 d . In addition, when it is determined that the operation history deletion instruction is not received (NO in Step S 1016 ), in Step S 1018 , the CPU 51 a deletes all the test results corresponding to the ID of the serviceman from the test result database 54 c.
As described above, the blood cell analysis apparatus 1 according to this embodiment is configured so that when a logoff process is executed in a service mode operation, a test result corresponding to an ID of a serviceman, or a test result and an operation history corresponding to the ID of the serviceman can be deleted from the test result database 54 c and the operation history database 54 d . Accordingly, in the sample testing apparatus according to this embodiment, it is possible to save for the serviceman the time to delete the test result and the operation history generated by maintenance work.
The blood cell analysis apparatus 1 according to this embodiment is not limited to the above-described configuration and may have a configuration so that when it is determined that a logoff instruction has been received in Step S 1014 , the CPU 51 a automatically and collectively deletes a test result and an operation history corresponding to the ID of the serviceman from the test result database 54 c and the operation history database 54 d and then executes a logoff process.
Third Embodiment
Hereinafter, a sample testing system according to a third embodiment will be described. In the sample testing system according to the third embodiment, a plurality of sample testing apparatuses according to the first or second embodiment, which are installed in facilities such as hospitals, and a server computer, which is installed in a support center, are connected to each other via a network. Herein, the support center is a facility in which servicemen are always resident as operators on the trader side delivering apparatuses to facilities such as hospitals.
FIG. 30 is a schematic diagram showing the configuration of a sample testing system 7 according to the third embodiment. As shown in FIG. 30 , in the sample testing system 7 , a plurality of blood cell analysis apparatuses 1 , which are installed in facilities such as hospitals, are connected to a server computer 2 , which is installed in a support center, via a network 6 . The server computer 2 manages operation histories in a user mode and test results and operation histories of control specimens in a service mode. In the server computer 2 , the test result database shown in FIG. 26 and the operation history database shown in FIG. 27 are provided for each blood cell analysis apparatus 1 .
The blood cell analysis apparatus 1 according to the first embodiment transmits operation histories in a user mode and test results and operation histories of control specimens in a service mode to the server computer 2 at predetermined timing. For example, in urgent situations, the apparatus promptly transmits the test results and operation histories, and in less urgent situations, the apparatus transmits the test results and operation histories at the time of logoff or shutdown. In addition, the blood cell analysis apparatus 1 according to the second embodiment transmits test results and operation histories of control specimens in a service mode to the server computer 2 when executing a logoff process in addition to the predetermined timing, and then deletes the transmitted test results and operation histories.
The server computer 2 receives the operation histories in a user mode and the test results and the operation histories of the control specimens in a service mode, which are transmitted from the blood cell analysis apparatus 1 , and stores the received test results and operation histories in the test result database and the operation history database corresponding to the blood cell analysis apparatus 1 transmitting them.
As described above, the sample testing system 7 according to this embodiment is configured so that operation histories in a user mode of the blood cell analysis apparatus 1 according to the first and second embodiments and test results and operation histories of control specimens in a service mode are managed by the server computer 2 installed in the support center. Accordingly, in the sample testing system 7 according to this embodiment, states of the blood cell analysis apparatuses 1 , each of which is installed in a facility, and situations of maintenance work of the apparatuses can be monitored in the support center.
Other Embodiments
It should be considered that the disclosed embodiments are examples in all aspects but do not restrict the invention. The scope of the invention is defined by the claims and not by the above description.
For example, in the above-described embodiments, the sample testing apparatus is a blood cell analysis apparatus, but the invention is not limited thereto. In the invention, the sample testing apparatus may be a blood coagulation measurement apparatus, a blood image analysis apparatus, an in-urine physical component analysis apparatus, a biochemical analysis apparatus or an immunoassay apparatus.
In addition, in the above-described embodiments, a sample container 100 held in a rack 101 is transported to the sample setting section 355 a by the transport apparatus 4 , but the invention is not limited thereto. In the invention, the sample container 100 may be directly disposed in the sample setting section 355 a by an operator.
In the above-described embodiments, test results and operation histories are stored in association with identification information (ID) of an operator in the test result database 54 c and the operation history database 54 d , but the invention is not limited thereto. For example, test results and operation histories may be stored in association with at least one of identification information (ID) of an operator and information indicating a group to which the operator belongs in the test result database 54 c and the operation history database 54 d.
In the above-described embodiments, a process in a user mode is executed when a group corresponding to a received ID is a general user group or a manager group, but the invention is not limited thereto. For example, when the group corresponding to the received ID is a manager group, a process in a manager mode may be executed. In the manager mode, for example, a process of setting a function which can be executed for each general user may be executed by a manager. | A sample testing apparatus comprising: a first storing section for storing identification information of an operator in association with first or second attribute information; an identification information receiving section for receiving an input of the identification information of the operator; a testing section for obtaining a test result by testing a sample; a second storing section for storing the test result of the sample so as to be linked with the received identification information; an operation end instruction receiving section for receiving an operation end instruction by the operator; and a deleting section for deleting from the second storing section the test result which is stored so as to be linked with the identification information received by the identification information receiving section in the case in which the received identification information is associated with the second attribute information when the operation end instruction is received. | 6 |
TECHNICAL FIELD
[0001] This invention relates to a method for producing a solar cell using a remote plasma-enhanced chemical vapor deposition (CVD) apparatus, and a solar cell produced by the method.
BACKGROUND ART
[0002] The solar cell is a semiconductor device for converting light energy to electricity and includes p-n junction type, pin type and Schottky type, with the p-n junction type being on widespread use. When classified in terms of substrate material, the solar cell is generally classified into three categories, crystalline silicon solar cells, amorphous silicon solar cells, and compound semiconductor solar cells. The crystalline silicon solar cells are sub-divided into monocrystalline and polycrystalline solar cells. Since crystalline silicon substrates for solar cells can be relatively easily manufactured, the crystalline silicon solar cells are currently manufactured at the largest scale and will find further widespread use in the future. See JP-A H08-073297 (Patent Document 1), for example.
[0003] In general, output characteristics of a solar cell are evaluated by measuring an output current-voltage curve by means of a solar simulator. On the curve, the point where the product of output current I max by output voltage V max , I max ×V max , becomes the maximum is designated maximum power point P max . The conversion efficiency η of the solar cell is defined as the maximum power point P max divided by the overall light energy (S×I) incident on the solar cell:
[0000] η={ P max /( S×I )}×100(%)
[0000] wherein S is a cell area and I is the intensity of irradiated light.
[0004] For increasing the conversion efficiency η, it is important to increase short-circuit current I sc (output current value at V=0 on the current-voltage curve) or V oc (output voltage value at I=0 on the current-voltage curve) and to make the profile of output current-voltage curve as close to squareness as possible. It is noted that the degree of squareness of an output current-voltage curve is generally evaluated by the fill factor (FF) which is defined as:
[0000] FF= P max /( I sc ×V oc ).
[0000] As the value of FF is closer to unity (1), the output current-voltage curve approaches ideal squareness, indicating an increase of conversion efficiency η.
[0005] For increasing the conversion efficiency η, it is important to reduce the surface recombination of carriers. In the crystalline silicon solar cell, minority carriers photo-generated by incidence of sunlight reach the p-n junction mainly via diffusion before they are externally extracted as majority carriers from electrodes attached to the light-receiving surface and back surface to provide electric energy.
[0006] At this point, those carriers which may be otherwise withdrawn as current flow can be lost by recombination via the interfacial level available on the substrate surface other than the electrode surface, leading to a lowering of conversion efficiency η.
[0007] Thus, in high-efficiency solar cells, an attempt to improve conversion efficiency η is by protecting the light-receiving and back surfaces of a silicon substrate with insulating films except for areas in contact with electrodes, for thereby restraining carrier recombination at the interface between the silicon substrate and the insulating film. As the insulating film, a silicon nitride film is useful and used in practice. This is because the silicon nitride film has the function of an antireflective film for crystalline silicon solar cells and is fully effective for the passivation of the surface and interior of the silicon substrate.
[0008] In the prior art, the silicon nitride film is formed by chemical vapor deposition (CVD) processes such as thermal CVD, plasma-enhanced CVD, and catalytic CVD. Of these, the plasma-enhanced CVD is the most widespread process. FIG. 1 schematically illustrates a parallel plate type plasma-enhanced CVD apparatus which is generally known as direct plasma CVD. The CVD apparatus 10 in FIG. 1 includes a vacuum chamber 10 c defining a deposition compartment 1 . Disposed in the deposition compartment 1 are a tray 3 for resting a semiconductor substrate 2 in place, a heater block 4 for maintaining the tray 3 at a predetermined temperature, and a temperature controller 5 for controlling the temperature of the heater block 4 . The deposition compartment 1 is also provided with a deposition gas inlet line 6 for introducing preselected deposition gas as reactant gas into the deposition compartment 1 , a radio-frequency power supply 7 for supplying energy to the introduced gas to generate a plasma, and a pumping unit 8 .
[0009] When an insulating film is deposited in the illustrated CVD apparatus, the preselected deposition gas is introduced into the deposition compartment 1 at the predetermined flow rate through the gas inlet line 6 , and the radio-frequency power supply 7 is operated to create a radio-frequency electric field. This operation generates a radio-frequency discharge to excite the deposition gas into a plasma, whereupon an insulating film is deposited on the surface of semiconductor substrate 2 via plasma-induced reaction. For example, when a silicon nitride film is deposited, a mixture of silane and ammonia gases is introduced as the deposition gas into the deposition compartment 1 through the gas inlet line 6 , whereupon a silicon nitride film is deposited utilizing decomposition reaction of silane in plasma.
[0010] The plasma-enhanced CVD process is often used in forming an insulating film for solar cells since a high deposition rate is achievable even when the process temperature is as low as about 400° C. However, since high-energy charged particles created in the plasma tend to cause damage to the film being deposited and the silicon substrate surface, the resulting silicon nitride film has a higher interfacial level density, failing to exert a satisfactory passivation effect. Thus, for improving the passivation effect, it is necessary to block a dangling bond with hydrogen or the like.
[0011] To address the above problem, for example, JP-A 2005-217220 (Patent Document 2) proposes a remote plasma-enhanced CVD process as the method capable of suppressing plasma damage. FIG. 2 schematically illustrates one exemplary apparatus. The remote plasma-enhanced CVD apparatus shown in FIG. 2 includes a cylindrical excitation compartment 93 for exciting a reactant gas introduced therein into plasma, and a reaction compartment (or treating compartment) 98 disposed below the excitation compartment 93 in fluid communication therewith. The excitation compartment 93 is provided at its top with an inlet port 93 a for a carrier gas 91 , and at its center with a radio-frequency introducing portion (or waveguide) 93 c which is connected to a microwave power source 95 via a matching unit 94 . A supply line for a reactant gas 97 for deposition is connected to the reaction compartment 98 , and a substrate holder 99 for holding a substrate 99 a is disposed in the reaction compartment 98 . With the apparatus of such construction, first microwave is introduced into the excitation compartment 93 from the microwave power source 95 to excite the carrier gas 91 , the excited carrier gas 91 is introduced into the reaction compartment 98 in accordance with a gas pumping stream, and the reactant gas 97 is introduced in the reaction compartment 98 where it is activated and contacted with the substrate 99 a , whereby a film is formed on the substrate 99 a . Using ammonia gas as the carrier gas 91 and silane gas as the reactant gas 97 , for example, a silicon nitride film can be formed on the substrate 99 a . Since the remote plasma-enhanced CVD apparatus is constructed such that the substrate is placed at a position remote from the plasma region 96 , the plasma damage to the substrate may be mitigated to some extent.
[0012] Also, JP-A 2009-117569 (Patent Document 3) reports that the passivation effect is improved when plasma treatment using ammonia gas is carried out as pretreatment, prior to the deposition of a silicon nitride film by surface wave plasma. JP-A 2009-130041 (Patent Document 4) reports that the passivation effect is improved when treatment with a plasma generated using a gas mixture of hydrogen gas and ammonia gas is carried out, prior to the deposition of a silicon nitride film.
[0013] However, since the above-cited methods need an extra process separate from the insulating film forming process, there arise the problems of an increased production cost and difficulty to improve productivity.
[0014] Further, if the composition of a silicon nitride film formed by the plasma-enhanced CVD is shifted from the stoichiometry to a silicon rich side so as to form a positive fixed charge, band bending occurs. Near the contact interface between silicon substrate and silicon nitride film, an inversion layer in which electrons are rich on the silicon substrate side is formed. Utilizing this, the passivation effect on the n-type region side can be enhanced.
[0015] JP-A 2002-270879 (Patent Document 5) reports that conversion efficiency is improved by a two-layer structure which is constructed by forming a silicon nitride layer having a high refractive index as a first dielectric film, and then forming a silicon nitride layer having a low refractive index thereon as a second dielectric film. This method, however, needs separate processes for forming high and low refractive index silicon nitride layers. For example, a silicon nitride layer having a high refractive index is first formed, after which the flow rate of deposition gas, after which a ratio of flow rates of ammonia gas and silane gas is adjusted, and then a silicon nitride layer having a low refractive index is formed. The method results in an increase of production cost and is difficult to improve productivity.
SUMMARY OF INVENTION
Technical Problem
[0016] An object of the invention, which is made under the above circumstances, is to provide a method for producing a solar cell in which an antireflective film of silicon nitride having an improved passivation effect is formed at high productivity, and a solar cell produced by the method.
Solution to Problem
[0017] Making extensive investigations to attain the above object, the inventors have found that when layers are successively deposited on a semiconductor substrate in a remote plasma-enhanced CVD apparatus, by using ammonia and silane gases as the deposition gas, providing a plasma flow from a first plasma compartment, and providing a plasma flow from a second plasma compartment having a different flow rate ratio of ammonia gas and silane gas than in the first plasma compartment, a silicon nitride film constructed of at least two layers of different compositions is completed, an inversion layer in which electrons are rich on the semiconductor substrate side is formed near the contact interface between the semiconductor substrate and the silicon nitride film, the plasma damage to the substrate is mitigated, and the passivation effect is improved. The invention is predicated on this finding.
[0018] Accordingly, the present invention provides a method for producing a solar cell and a solar cell, as defined below.
[0000] [1] A method for producing a solar cell comprising the step of forming an antireflective film composed of silicon nitride on a surface of a semiconductor substrate, using a remote plasma-enhanced CVD apparatus, characterized in that
[0019] said remote plasma-enhanced CVD apparatus includes a deposition compartment where the semiconductor substrate is conveyably placed, a plurality of plasma compartments disposed above the deposition compartment in fluid communication therewith, each adapted to generate a plasma flow of ammonia gas, to introduce silane gas into the plasma flow, and to inject the plasma flow toward the deposition compartment, and a flow controller coupled with the plasma compartments for controlling a flow rate ratio of ammonia gas to silane gas introduced into each plasma compartment,
[0020] a first silicon nitride layer is deposited on the semiconductor substrate from a plasma flow from a first plasma compartment, and as the substrate is conveyed to below a second plasma compartment, a second silicon nitride layer of a different composition than the first silicon nitride layer is deposited from a plasma flow having a different flow rate ratio of ammonia gas to silane gas than in the first plasma compartment.
[0000] [2] The solar cell production method of [1] wherein the flow rate ratio of ammonia gas to silane gas (ammonia gas flow rate/silane gas flow rate) in the first plasma compartment is 0.1 to 1.0.
[3] The solar cell production method of [2] wherein the flow rate ratio of ammonia gas to silane gas (ammonia gas flow rate/silane gas flow rate) in the second plasma compartment is 1.5 to 3.0.
[4] The solar cell production method of any one of [1] to [3] wherein the semiconductor substrate is a silicon substrate of one conductivity type having a diffusion layer of opposite conductivity type formed on a substrate surface that is assigned to a light-receiving surface, and the antireflective film is formed on the diffusion layer.
[5] The solar cell production method of any one of [1] to [4] wherein the semiconductor substrate is a silicon substrate of one conductivity type having a diffusion layer of one conductivity type formed on at least a portion of a substrate surface that is assigned to a surface remote from a light-receiving surface, and the antireflective film is formed on the diffusion layer-bearing surface.
[6] A solar cell produced by the method of any one of [1] to [5].
Advantageous Effects of Invention
[0021] Since a silicon nitride film of two-layer structure is formed by the remote plasma-enhanced CVD process according to the invention, an antireflective film having improved passivation effect is available. Since in each of two plasma compartments, a layer is continuously deposited at a fixed ratio of flow rates of ammonia gas and silane gas, a silicon nitride film of two-layer structure having the predetermined compositional ratio can be formed in a consistent manner while the productivity of solar cells is improved.
BRIEF DESCRIPTION OF DRAWINGS
[0022] FIG. 1 is a schematic view illustrating one exemplary parallel plate type plasma-enhanced CVD apparatus.
[0023] FIG. 2 is a schematic view illustrating one exemplary prior art remote plasma-enhanced CVD apparatus.
[0024] FIG. 3 is a schematic view illustrating a solar cell producing method in one embodiment of the invention; (A) showing a substrate, (B) showing an n-type diffusion layer formed on substrate back surface, (C) showing a p-type diffusion layer formed on substrate front surface, (D) showing antireflective films (silicon nitride films) formed on substrate front and back surfaces, (E) showing finger electrode and back electrode formed, and (F) showing bus bar electrode formed.
[0025] FIG. 4 is a schematic view illustrating a solar cell producing method in another embodiment of the invention; (A) showing a substrate, (B) showing an n-type diffusion layer formed on substrate front surface, (C) showing an antireflective film (silicon nitride film) formed on substrate front surface, and (E) showing finger electrode, back electrode, and bus bar electrode formed.
[0026] FIG. 5 is a schematic view illustrating one exemplary remote plasma-enhanced CVD apparatus used in the solar cell producing method of the invention.
DESCRIPTION OF EMBODIMENTS
[0027] Now the solar cell producing method of the invention is described with reference to the drawings although the invention is not limited thereto.
[0028] FIGS. 3 and 4 are schematic views illustrating the solar cell producing method in embodiments of the invention. The steps are described below in detail.
(1) Substrate
[0029] As shown in FIGS. 3 and 4 , a silicon substrate 11 used herein as the semiconductor substrate may be of n- or p-type. FIG. 3(A) shows an n-type silicon substrate, whereas FIG. 4(A) shows a p-type silicon substrate. A single crystal silicon substrate may have been prepared by either of the Czochralski (CZ) method and the floating zone melting (FZ) method. It is preferred for the manufacture of solar cells with better performance that the silicon substrate 11 have a resistivity of 0.1 to 20 Ω·cm, more preferably 0.5 to 2.0 Ω·cm. The preferred silicon substrate 11 is a phosphorus-doped n-type single crystal silicon substrate since a relatively long lifetime is obtainable. For phosphorus doping, the dopant concentration is preferably 1×10 15 to 5×10 16 cm −3 .
(2) Damage Etching/Texturing
[0030] For example, the silicon substrate 11 is immersed in sodium hydroxide aqueous solution to remove any slice-damaged layer via etching. For damage removal from the substrate, strong alkali aqueous solutions such as potassium hydroxide may be used. The same purpose may also be achieved with acid aqueous solutions such as fluoronitric acid.
[0031] After the etching for damage removal, the substrate 11 is provided with a random texture. Most often the solar cell substrate is preferably provided with an irregular shape or texture at its surface (light-receiving surface). This is because at least two reflections must occur on the light-receiving surface in order to reduce the reflectivity in the visible spectrum. While the texture shape consists of peaks and valleys, each peak may have a size of about 1 to 20 μm. Typical surface texture structures are V and U trenches, which may be formed by a grinding tool. The random texture structure may also be prepared by wet etching involving immersing in an aqueous solution of sodium hydroxide with isopropyl alcohol added, acid etching, or reactive ion etching (RIE). It is noted that the texture structures formed on opposite surfaces are not depicted in FIGS. 3 and 4 because they are of microscopic size.
[0000] (3) Formation of n-Type Diffusion Layer
[0032] Where the silicon substrate 11 is of n-type as shown in FIG. 3 , a coating agent containing a dopant is applied onto the back surface and heat treated to form an n-type diffusion layer 13 on at least a portion of the back surface, preferably on the entire back surface ( FIG. 3(B) ). Where the silicon substrate is of p-type as shown in FIG. 4 , a coating agent containing a dopant is applied onto the light-receiving surface and heat treated to form an n-type diffusion layer 13 on the light-receiving surface ( FIG. 4(B) ). The dopant is preferably phosphorus. The surface dopant concentration of n-type diffusion layer 13 is preferably 1×10 18 to 5×10 20 cm −3 , more preferably 5×10 18 to 1×10 20 cm −3 .
[0033] After the heat treatment, any glass deposits on the silicon substrate 11 are cleaned away by glass etching or the like.
[0000] (4) Formation of p-Type Diffusion Layer
[0034] As shown in FIG. 3(C) , treatment similar to the formation of n-type diffusion layer is carried out on the light-receiving surface to form a p-type diffusion layer 12 on the entire light-receiving surface. Alternatively, p-type diffusion layers 12 may be formed on the front surfaces by mating the n-type diffusion layer-bearing back surfaces together, and carrying out gas phase diffusion of BBr 3 . The dopant is preferably boron. The surface dopant concentration of p-type diffusion layer 12 is preferably 1×10 18 to 5×10 20 cm −3 , more preferably 5×10 18 to 1×10 20 cm −3 .
(5) p-n Junction Isolation
[0035] Using a plasma etcher, p-n junction isolation is carried out. In this junction isolation, samples are stacked so as to prevent the plasma and radicals from invading the light-receiving surface and back surface, and the edge is ground several microns in the stacked state. After the junction isolation, any glass deposits and silicon debris on the substrate are cleaned away by glass etching or the like.
(6) Formation of Antireflective Film
[0036] Subsequently, a silicon nitride film 14 serving as antireflective film is formed on each of the front and back surfaces of the silicon substrate ( FIG. 3(D) ) or the light-receiving surface of the silicon substrate ( FIG. 4(C) ) in order to effectively transmit sunlight into the silicon substrate. The silicon nitride film also functions as a passivation film for the surface and interior of the silicon substrate. The method of forming the silicon nitride film is a plasma-enhanced CVD process using a remote plasma-enhanced CVD apparatus 100 shown in FIG. 5 .
[0037] As shown in FIG. 5 , the remote plasma-enhanced CVD apparatus 100 used herein includes a vacuum chamber 100 c defining a deposition compartment 101 , two plasma diaphragms 100 a , 100 b defining two plasma compartments 111 , 112 disposed above the vacuum chamber 100 c in fluid communication with the deposition compartment 101 , a pumping unit 108 for vacuum pumping the interior of vacuum chamber 100 c , that is, deposition compartment 101 , and a flow controller 113 for independently adjusting the ratio of flow rates of carrier gas 116 and reactant gas 117 for each of the plasma compartments 111 , 112 . It is noted that the plasma diaphragms 100 a , 100 b have auxiliary vacuum pumping units (not shown).
[0038] Disposed in the deposition compartment 101 are a tray 103 for supporting the semiconductor substrate 102 such that the substrate having completed treatments until the p-n junction isolation may be conveyed through the compartment and a heater block 104 for heating the semiconductor substrate 102 via the tray 103 . The heater block 104 is connected to temperature control means 105 for controlling the heating temperature of the heater block 104 .
[0039] Each of the plasma compartments 111 , 112 is a cylindrical plasma-generating compartment consisting of an excitation section 111 a , 112 a for exciting a carrier gas 116 fed from upstream to plasma state to generate reactive species (or radicals), and an activation reaction section 111 b , 112 b disposed downstream of the excitation section 111 a , 112 a for introducing reactant gas 117 to the excited carrier gas 116 such that the reactive species may induce chemical reactions. The plasma compartments 111 , 112 are arranged above the deposition compartment 101 in the order of 111 to 112 in the convey direction of semiconductor substrate 102 , while the end opening of each plasma compartment is in fluid communication with the deposition compartment 101 . The end openings of plasma compartments 111 , 112 are positioned at such a close distance that material may be deposited on the semiconductor substrate 102 , but spaced apart from the semiconductor substrate 102 such that the semiconductor substrate 102 may not be directly exposed to the plasma flow injected from the end opening or damaged by the plasma.
[0040] The excitation sections 111 a , 112 a are provided at their top with carrier gas inlet ports 111 c , 112 c for introducing carrier gas 116 therein. The excitation sections 111 a , 112 a are also provided at their side with microwave power supplies 115 for applying microwave of 2.45 GHz to the carrier gas introduced therein to generate electric discharge.
[0041] The activation reaction sections 111 b , 112 b are provided with reactant gas inlet ports 111 d , 112 d for introducing reactant gas 117 therein.
[0042] After a ratio of flow rates of carrier gas 116 and reactant gas 117 is adjusted independently for each of the plasma compartments 111 , 112 by the flow controller 113 , the carrier gas 116 and reactant gas 117 are introduced into the plasma compartments 111 , 112 . In the excitation sections 11 a , 112 a , microwave is irradiated from the microwave power supplies 115 to excite the carrier gas 116 (to plasma state), to form plasma regions 110 . Then in the activation reaction sections 111 b , 112 b , the reactant gas 117 is introduced into the excited carrier gas 116 for activation. In the activation reaction sections 111 b , 112 b and transition zones from the activation reaction sections 111 b , 112 b to the deposition compartment 101 , chemical reactions take place between carrier gas components and reactant gas components. Plasma flows are injected from the end openings of the plasma compartments 111 or 112 toward the semiconductor substrates 102 placed immediately below the openings. When the semiconductor substrate 102 is placed below the end opening of the plasma compartment 111 , 112 in this state, a film corresponding to the composition of deposition gases, carrier gas 116 and reactant gas 117 is formed on the semiconductor substrate 102 .
[0043] In the practice of the invention, of the deposition gases, ammonia (NH 3 ) is used as the carrier gas 116 , and silane gas such as SiH 4 , or Si 2 H 6 is used as the reactant gas 117 . Then a silicon nitride film is formed.
[0044] In this step, film-forming treatment is carried out in the following procedure. In the deposition compartment 101 of the remote plasma-enhanced CVD apparatus 100 , the semiconductor substrate 102 is first rested on the tray 103 , and the compartment is evacuated to vacuum by the pumping unit 108 . Thereafter, the compartment is heated at the predetermined temperature, and ammonia gas as carrier gas 116 and silane gas as reactant gas 117 are introduced into each of the plasma compartments 111 , 112 after a ratio of flow rates of deposition gases is adjusted independently for each of the plasma compartments 111 , 112 by the flow controller 113 , for thereby forming the plasma regions 110 as mentioned above. Next, while the semiconductor substrates 102 on the tray 103 are conveyed forward, a first silicon nitride layer is deposited on the semiconductor substrate 102 below the end opening of the first plasma compartment 111 . Subsequently, the semiconductor substrate 102 is conveyed to below the end opening of the second plasma compartment 112 into which the carrier gas 116 (ammonia gas) and the reactant gas 117 (silane gas) are introduced in a different flow rate ratio than in the first plasma compartment 111 , where a second silicon nitride layer having a different composition than the first silicon nitride layer is deposited on the first silicon nitride layer, yielding a silicon nitride film of two-layer structure.
[0045] The overall thickness of the silicon nitride film may be selected as appropriate depending on the reflectivity of the film and the surface morphology of the semiconductor substrate although the thickness is typically in the range of about 60 to 100 nm, preferably about 70 to 90 nm. The thickness of the first silicon nitride layer is preferably in the range of about 30 to 70 nm, more preferably about 35 to 55 nm. The thickness of the second silicon nitride layer is preferably in the range of about 30 to 70 nm, more preferably about 35 to 55 nm.
[0046] The deposition gas conditions (gas flow rates) in the first plasma compartment 111 may be determined as appropriate depending on the shape and size of the deposition compartment 101 and the convey speed of the semiconductor substrate 102 . For example, provided that a silicon nitride film is deposited on the surface of a silicon substrate which is dimensioned 10 cm×10 cm to 15 cm×15 cm and continuously conveyed, it is preferred to feed 50 to 500 sccm of ammonia and 300 to 1,000 sccm of monosilane, more preferably 250 to 350 sccm of ammonia and 350 to 500 sccm of monosilane.
[0047] As for the deposition gas conditions (gas flow rates) in the second plasma compartment 112 , it is preferred to feed 300 to 1,000 sccm of ammonia and 10 to 500 sccm of monosilane, more preferably 450 to 500 sccm of ammonia and 250 to 300 sccm of monosilane.
[0048] In either of the first and second plasma compartments 111 and 112 , if the gas flow rates are lower than the ranges, a uniform silicon nitride layer may not be formed. If the gas flow rates are more than the ranges, the deposition gases may run to waste.
[0049] It is also preferred that a flow rate ratio of ammonia gas to silane gas (ammonia gas flow rate/silane gas flow rate) in the first plasma compartment 111 be lower than a flow rate ratio of ammonia gas to silane gas (ammonia gas flow rate/silane gas flow rate) in the second plasma compartment 112 . Specifically, the flow rate ratio of ammonia gas to silane gas (ammonia gas flow rate/silane gas flow rate) in the first plasma compartment 111 is preferably from 0.1 to 1.0, more preferably from 0.5 to 0.8. If this flow rate ratio is less than 0.1, the resulting film may be inadequate as the antireflective film. If the flow rate ratio is more than 1.0, the effect of enhancing passivation may not be obtained. Also, the flow rate ratio of ammonia gas to silane gas (ammonia gas flow rate/silane gas flow rate) in the second plasma compartment 112 is preferably from 1.5 to 3.0, more preferably from 1.5 to 2.0. If this flow rate ratio is less than 1.5 or more than 3.0, the resulting film may be inadequate as the antireflective film.
[0050] Of other deposition conditions in the above-described embodiment, preferably the pressure in the deposition compartment 101 is 10 to 100 Pa, the temperature of the semiconductor substrate 102 is 250 to 600° C., and the convey speed of the tray 103 , which varies with the flow rates and flow rate ratio of deposition gases, is 90 to 150 cm/min when the overall thickness of the silicon nitride film being deposited is 60 to 100 nm.
[0051] As described above, as long as a silicon nitride film of two-layer structure is formed under the above-specified deposition conditions using the remote plasma-enhanced CVD apparatus of FIG. 5 , a silicon nitride film having improved passivation effect may be formed in a consistent manner.
(7) Formation of Electrodes
[0052] Using a screen printing machine or the like, on the light-receiving surface and back surface sides, a paste containing silver, for example, is printed onto the p-type diffusion layer 12 and n-type diffusion layer 13 , i.e., coated in interdigital electrode patterns and dried to form a finger electrode 15 and a back electrode 16 ( FIG. 3(E) or FIG. 4(D) ). Particularly when the silicon substrate used is of p type, preferably a paste obtained by mixing aluminum (Al) powder in an organic binder is screen printed on the back surface side and dried to form a back electrode 16 . Next, on both the light-receiving surface and back surface ( FIG. 3(F) ) or on the light-receiving surface (FIG. 4 (D)), a bus bar electrode 17 is formed from a silver paste or the like by screen printing. Finally, firing is carried out at 500 to 900° C. for 1 to 30 minutes in a firing furnace, completing the finger electrode 15 , back electrode 16 and bus bar electrode 17 in electrical contact with the p-type diffusion layer 12 or n-type diffusion layer 13 . Although FIG. 3(F) is depicted as if the finger electrode 15 and back surface 16 are not in contact with the diffusion layers 12 , 13 , and FIG. 4(D) is depicted as if the finger electrode 15 is not in contact with the diffusion layer 13 , in fact, the electrodes are in electrical contact with the diffusion layers as a result of fire-through upon firing.
EXAMPLES
[0053] Examples and Comparative Examples are given below for further illustrating the invention although the invention is not limited thereto.
Example 1
[0054] As shown in FIG. 3 , a phosphor-doped n-type single crystal silicon substrate 11 of crystal face orientation ( 100 ), 15.65 cm squares, 200 μm thick, and as-sliced resistivity 2 Ω·cm (dopant concentration 7.2×10 15 cm −3 ) was immersed in sodium hydroxide aqueous solution where the damaged layer was removed by etching, then immersed in potassium hydroxide aqueous solution having isopropyl alcohol added thereto, where the substrate was textured by alkali etching ( FIG. 3(A) ).
[0055] A coating agent containing phosphorus dopant was coated onto the back surface of the silicon substrate 11 and heat treated at 900° C. for 1 hour to form an n-type diffusion layer 13 on the back surface ( FIG. 3(B) ). After the heat treatment, glass deposits on the substrate were removed in a conc. hydrofluoric acid solution or the like, and the substrate was cleaned.
[0056] Subsequently, two silicon substrates 11 having n-type diffusion layer 13 formed were stacked with their back surfaces mated, followed by gas phase diffusion of BBr 3 to form a p-type diffusion layer 12 on the entire light-receiving surface ( FIG. 3(C) ).
[0057] Next, p-n junction isolation was carried out using a plasma etcher. With the substrates kept stacked so as to prevent any plasma or radicals from invading the light-receiving surface and back surface, the end face was etched several microns. Thereafter, glass deposits on the substrate were removed in a conc. hydrofluoric acid solution or the like, and the substrate was cleaned.
[0058] Subsequently, by using a remote plasma-enhanced CVD apparatus (model SiNA1000 by Roth & Rau) constructed as shown in FIG. 5 , feeding ammonia as the carrier gas 116 and monosilane (SiH 4 ) as the reactant gas 117 , and setting a flow rate ratio of ammonia gas to monosilane gas (ammonia gas flow rate (sccm)/monosilane gas flow rate (sccm)) in the first plasma compartment 111 to be 0.5, and a flow rate ratio of ammonia gas to monosilane gas (ammonia gas flow rate (sccm)/monosilane gas flow rate (sccm)) in the second plasma compartment 112 to be 2.0, by means of the flow controller 113 , a silicon nitride film 14 of two-layer structure as a dielectric film was deposited on each of the p-type diffusion layer 12 on the light-receiving surface side and the n-type diffusion layer 13 on the back surface side ( FIG. 3(D) ). Each of the silicon nitride films had a thickness of 70 nm.
[0059] Finally, a silver paste was printed on the light-receiving surface and back surface sides, dried, and fired at 750° C. for 3 minutes, to form the finger electrode 15 , back electrode 16 and bus bar electrode 17 ( FIGS. 3(E) and (F)).
Example 2
[0060] As shown in FIG. 4 , a p-type single crystal silicon substrate as in Example 1 was used as the silicon substrate 11 and as in Example 1, immersed in sodium hydroxide aqueous solution where the damaged layer was removed by etching, then immersed in potassium hydroxide aqueous solution having isopropyl alcohol added thereto where the substrate was textured by alkali etching ( FIG. 4(A) ).
[0061] A coating agent containing phosphorus dopant was coated onto the light-receiving surface of the silicon substrate 11 and heat treated at 800° C. for 1 hour to form an n-type diffusion layer 13 on the surface ( FIG. 4(B) ). After the heat treatment, glass deposits on the substrate were removed in a conc. hydrofluoric acid solution or the like, and the substrate was cleaned.
[0062] Subsequently, by using a remote plasma-enhanced CVD apparatus (model SiNA1000 by Roth & Rau) constructed as shown in FIG. 5 , feeding ammonia as the carrier gas 116 and monosilane (SiH 4 ) as the reactant gas 117 , and setting a flow rate ratio of ammonia gas to monosilane gas (ammonia gas flow rate (sccm)/monosilane gas flow rate (sccm)) in the first plasma compartment 111 to be 0.5, and a flow rate ratio of ammonia gas to monosilane gas (ammonia gas flow rate (sccm)/monosilane gas flow rate (sccm)) in the second plasma compartment 112 to be 2.0, by means of the flow controller 113 , a silicon nitride film 14 of two-layer structure as a dielectric film was deposited on the n-type diffusion layer 13 on the light-receiving surface side ( FIG. 4(C) ). The film had a thickness of 80 nm.
[0063] Subsequently, silver paste and aluminum paste were printed on the light-receiving surface and back surface sides, respectively, dried, and fired at 750° C. for 3 minutes, to form the finger electrode 15 , back electrode 16 and bus bar electrode 17 ( FIG. 4(D) ).
Comparative Example 1
[0064] A solar cell was manufactured under the same conditions as in Example 1 except that using the direct plasma-enhanced CVD apparatus shown in FIG. 1 instead of the remote plasma-enhanced CVD apparatus 100 , silicon nitride films of 70 nm thick were formed on the p-type diffusion layer 12 on the light-receiving surface side and the n-type diffusion layer 13 on the back surface side.
Comparative Example 2
[0065] A solar cell was manufactured under the same conditions as in Example 2 except that using the direct plasma-enhanced CVD apparatus shown in FIG. 1 instead of the remote plasma-enhanced CVD apparatus 100 , a silicon nitride film of 80 nm thick was formed on the n-type diffusion layer 13 on the light-receiving surface side.
[0066] For the solar cells obtained in Examples 1, 2 and Comparative Examples 1, 2, current-voltage characteristics were measured using a solar simulator (light intensity 1 kW/m 2 , spectrum AM1.5 global). The results are shown in Table 1. It is noted that the value in Table 1 is an average of 10 cells manufactured in each of Examples 1, 2 and Comparative Examples 1, 2.
[0000]
TABLE 1
Open-circuit
Short-circuit
Fill
Conversion
voltage
current
factor
efficiency
(mV)
(mA/cm 2 )
(%)
(%)
Example 1
648
38.9
79.2
19.9
Comparative
645
38.3
79.0
19.5
Example 1
Example 2
637
36.6
79.0
18.4
Comparative
632
36.1
79.0
18.0
Example 2
[0067] In Examples 1 and 2, using the remote plasma-enhanced CVD apparatus of FIG. 5 , a film is continuously deposited in the state that the flow rate ratio of ammonia gas to silane gas is fixed in each of two plasma compartments. Thus a silicon nitride film rich in positive fixed charge is formed on the silicon substrate front surface side. Thus a silicon nitride film having improved passivation effect and increased productivity is formed in a consistent manner. The cells display higher conversion efficiency than Comparative Examples 1 and 2.
[0068] Although the invention is illustrated with reference to the embodiments shown in the drawings, the invention is not limited to the embodiments shown in the drawings. Other embodiments, addition, change, deletion or the like may occur to the skilled artisan. All such embodiments are included within the scope of the invention as long as the effects and results of the invention are achievable.
REFERENCE SIGNS LIST
[0000]
1 , 101 deposition compartment
2 , 102 semiconductor substrate
3 , 103 tray
4 , 104 heater block
5 , 105 temperature control means
6 deposition gas inlet line
7 radio-frequency power supply
8 , 108 pumping unit
10 CVD apparatus
10 c , 100 c vacuum chamber
11 silicon substrate (n- or p-type)
12 p-type diffusion layer
13 n-type diffusion layer
14 antireflective film (silicon nitride film)
15 finger electrode
16 back electrode
17 bus bar electrode
91 , 116 carrier gas
92 auxiliary pumping line
93 excitation compartment
93 a , 111 c , 112 c carrier gas inlet port
93 b auxiliary pumping port
93 c radio-frequency introducing means
94 matching unit
95 , 115 microwave power supply
96 , 110 plasma region
97 , 117 reactant gas
98 reaction compartment
98 a main pumping port
99 substrate holder
99 a substrate
100 remote plasma-enhanced CVD apparatus
100 a , 100 b plasma diaphragm
111 , 112 plasma compartment
111 a , 112 a excitation section
111 b , 112 b activation reaction section
111 d , 112 d reactant gas inlet port
113 flow controller | This solar cell production method involves productively forming an antireflection film comprising silicon nitride, said antireflection film having an excellent passivation effect. In an embodiment, a remote plasma CVD is used to form a first silicon nitride film on a semiconductor substrate ( 102 ) using the plasma flow from a first plasma chamber ( 111 ), then to form a second silicon nitride film, which has a different composition than the first silicon nitride film, using the plasma flow from a second plasma chamber ( 112 ), into which ammonia gas and silane gas have been introduced at a different flow ratio than that of the first plasma chamber ( 111 ). The plasma chambers ( 111, 112 ) have excitation parts ( 111 a, 112 a ) that excite the ammonia gas, and activation reaction parts ( 111 b, 112 b ) and a flow controller ( 113 ). | 8 |
[0001] This application is a continuation-in-part application of Serial No. 09/918,383, filed Jul. 30, 2001.
BACKGROUND OF THE INVENTION
[0002] The invention relates generally to the synthesis of salts of organic acids and, more specifically, to the solid phase synthesis of salts of organic acids, including butyric acid, in a dust-free form and particularly suited for use as animal feed additives.
[0003] Salts of organic acids are widely used in the animal feed industry as preservatives of the animal feed and as sources of acids in animal feed rations. The salts disassociate in the digestive tract of the animal and provide a number of advantageous effects, including the maintenance of a healthy gastric environment and a beneficial microbial balance. Monogastric animals, such as swine and poultry, must keep a low gastric pH to maintain a healthy gut. Low gastric pH is one of the major factors governing the performance of monogastric animals and the economics of livestock production. The pH of the gut may rise when the animals are young or under stress. The addition of salts of organic acids to the animal feed ration helps to maintain a low gastric pH and to improve the health of the animal.
[0004] Salts of butyric acid will have an acidifying effect, but because of its distinct alkyl chain, it will have a different activity and selectivity when compared to salts of other fatty acids, such as formic, acetic, and propionic acid. Salts of butyric acid also have an important function on the intestinal morphology of the gut. The addition of butyrates leads to an increased surface area of the gut wall due to an increase in size of the villi. The increased surface area aids the absorption of nutrients and promotes animal growth.
[0005] A satisfactory animal feed acidifier product must function as an acidifier, blend with the animal feed ration, be acceptable to the animal, and not grossly alter the physical characteristics of the animal feed. Problems have occurred in the production of animal feed acidifiers in the form of clumping of the acidifier during manufacture, requiring an additional processing step to comminute the acidifier to a size where it can be blended with the animal feed ration, be acceptable to the animal, and provide a bioavailable source of the organic acid upon ingestion. Comminution of clumps can result in the production of fines, i.e., finely divided particles that create dustiness, resulting in a loss of product during mixing into the animal feed ration and an unpleasant environment for persons conducting the mixing. Other methods of producing these products have required an additional energy-consuming step to remove excess water, such as distillation or spray drying. There is needed a method of producing salts of organic acids that results in a feed acidifier that has a small particle size without the presence of fines, which does not clump during formation and which does not require additional drying.
[0006] Animal feed acidifiers are commonly added to animal rations that also include mineral premixes. Many of the mineral premixes include either or both amino acids and copper sulfate. These ingredients react with the volatile acids of the animal feed acidifier to form clumps. There is a need for a method of producing salts of organic acids that does not cause clumping when combined with mineral premixes including either amino acids or copper sulfate. In addition, the lack of volatile acids in the animal feed acidifier of the present invention means it will not react with the butyrates.
SUMMARY OF THE INVENTION
[0007] The invention consists of a method of synthesizing salts of organic acids, including butyric acid, using solid phase synthesis. A mixture of butyric acid and at least one other liquid organic acid is added to an acceptable, inert carrier. A solid base is added during mixing. The acid is slowly released from the carrier preventing the fast reactions that lead to the formation of clumps. The exothermic reaction releases heat which assists in reducing the moisture content of the product. The process can be repeated to increase the loading of the salt on the carrier. The resulting product is comprised of free-flowing granules. The average particle size increases slightly with the number of repetitions of adding the acid and base to the carrier. A loading of between about 65% and 80% of the organic acid salt on the carrier can be easily achieved, depending in part on the characteristics of the organic acid being used, without undue clumping of the product.
[0008] When even small amounts of salts of butyric acid and an alkali metal are present, a synergistic effect is obtained over formulations not including the butyrate.
[0009] An object of the invention is to provide a method of synthesizing salts of an organic acid in form that is free-flowing and of a small particle size relatively free of dust, particularly suited for use as an animal feed acidifier.
[0010] Another object of the invention is to provide a method of synthesizing salts of an organic acid that is adaptable to adjust the loading of the organic salt on an inert carrier.
[0011] Still another object of the invention is to provide an animal feed acidifier including butyrates which has an improved effect on growth of the animal over a feed acidifier not including butyrates.
[0012] These and other objects of the invention will be made apparent to those skilled in the art upon a review of this specification and the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] [0013]FIG. 1 is a graphical representation of the laying percentage.
[0014] [0014]FIG. 2 is a graphical representation of the feed conversion ratio.
[0015] [0015]FIG. 3 is a graphical representation of eggshell thickness.
[0016] [0016]FIG. 4 is a graphical representation of the bacteriostatic effect of the feed additive of the present invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0017] The method generally comprises the addition of a liquid organic acid to an inert carrier in an amount sufficient to moisten the carrier. Of particular importance is the addition of at least a small amount of butyric acid. A dry base is slowly added to the moistened carrier during mixing. The base reacts with the acid as it is relatively slowly released from the carrier. The slow release of the acid prevents the fast reaction that can lead to clumping. Additionally, the heat released during the exothermic reaction between the acid and base assists in reducing the moisture content of the mixture. If desired, once the moisture content of the mixture has been reduced, additional liquid acid can be added to the mixture, followed by the adding of additional base, in order to increase the loading of the organic salt on the carrier.
[0018] Organic acids suitable for use in the present process are all liquid organic acids. Preferred organic acids include lactic acid, propionic acid, acetic acid, and formic acid and mixtures thereof. In addition, butyric acid is included as an organic acid used in the formulation. Bases suitable for use in the present process include alkali metal hydroxides and alkaline-earth metal bases, including calcium oxide, calcium hydroxide, sodium hydroxide and potassium hydroxide and mixtures thereof. Carbonates, such as calcium carbonate, sodium carbonate, and sodium bicarbonate, cannot be used as the sole bases in the reaction because of the formation of carbon dioxide during the reaction with the acids and because the reaction is not sufficiently exothermic to complete drying of the product. These bases may be used, however, in combination with the preferred bases.
[0019] During the first loading of the carrier with the liquid acid, it is preferable to avoid excess wetting of the carrier. A preferred range of the weight ratio of carrier to acid is between about 1:1 and 3:1, and more preferably, between about 1.5:1 and 2:1, giving consideration to the water content of the acid being used. For example, using lactic acid (80% feed grade), a ratio of 2:1 can be used, whereas when using propionic acid, a ratio of 1.5:1 is the preferred maximum.
[0020] The total loading of the carrier can be increased by repeated cycles of adding acid and base to the carrier. The maximum preferred loading that can be obtained is dependent on the acid. For lactic acid (80% feed grade), a preferred product is obtained until the product contains about 65% calcium lactate and 35% carrier. Further loading of the salt on the carrier makes the product more difficult to process as it becomes sticky. Also, the size profile of the granules of the product changes as the loading is increased above a certain level. Above about 65%, granules in the range of 0.5 to 1 cm appear, with a fraction even larger. For propionic acid, a preferred product is obtained until the product contains about 80% calcium propionate and 20% carrier. Further loading, while presenting no processing difficulties, begins to result in increased dustiness. This may be because the newly produced salt is no longer in contact with the carrier. Dustiness can be reduced, even at a loading above 80%, by the addition of a small amount of feed grade lactic acid.
[0021] Additional free acids in their solid form, such as fumaric or ascorbic acid, can be incorporated into the product after the last salt formation reaction. The free acids are preferably added when the temperature of the mixture is observed to start to drop. The acids are thus incorporated into the granules of the product during the drying process. In the same way, other powdered or granular materials can be incorporated into the product, such as mineral salts, minerals, antioxidants, or amino acids. A loading of up to about 50% of such additional ingredients can usually be obtained with the ingredient being incorporated into the product granules. Additional loading of the added ingredients can be made, but not all of the added ingredient may be incorporated into the granules.
[0022] In this process water and heat are produced. The reaction heat evaporates water to assist in obtaining a dry product. Care should be taken to respect the time that is needed to evaporate the water. The reaction time is controlled by the speed at which the organic acid mixture and the dry mixture are added. When the reagents are added to quickly the mixture doesn't have enough time to evaporate all the water that is being formed. Adding acids and bases step-wise is used to control the evaporation. After each addition, the blend is mixed for a short period of time until it has dried sufficiently. It is also possible to add acids and bases in a continuous process. In that case the rate of the addition is preferably lower in order to allow “in-process” drying. In that case the production of water and the evaporation are preferably adjusted to be in equilibrium.
Experiment 1
[0023] Solid Phase Synthesis of a Mixture of Salts
[0024] Small Batch: Twenty-one grams of lactic acid (food grade=80%) and 9 g propionic acid were combined and divided into three equal fractions. Calcium hydroxide, 10.256 g, and 0.862 g of calcium oxide are combined, mixed, and divided into three equal fractions. The first fraction of the acid combination is added to 20 g of almond shell meal while stirring. Then, the first fraction of the combined base mixture is slowly added while stirring. The temperature of the mixture is observed to increase and water starts evaporating. When the product appeared to be dry, the same procedure was repeated for the remaining fractions, adding the acid while stirring, adding the base while stirring and drying.
[0025] This method produced a non-dusty granulated product.
[0026] In an alternative experiment, a small amount (approx. 1 cm 3 ) of butyric acid was added to the acid mixture before dividing. A similar product resulted.
[0027] Large Batch: One hundred and thirty kilograms of lactic acid (food grade=80%), 110 kg propionic acid, and 8.9 kg of butyric acid were combined. Calcium hydroxide, 60 kg, and 38.4 kg of calcium oxide were combined and mixed. One hundred and sixty kilograms of almond shell meal and 103 kg of dry fumaric acid were added to the mixer (horizontal ribbon blender; 1000 liter; central outlet size of 200 mm; operated at 20 rpm). While stirring, the liquid acid mixture was added to the mixer at a rate of approximately 3.55 kg/min and the dry base mixture was added at a rate of approximately 3.59 kg/min. The total time for adding the liquid acid and dry base mixtures is typically about 70 minutes. After 70 minutes, the mixer is operated for an additional time of approximately 15 minutes to complete drying of the product. Of course, the addition rates and drying times will depend on the type and size of mixer employed. It is also possible to start with less almond shell meal and no fumaric acid and add the additional almond shell meal and fumaric acid after the liquid acid mixture and dry base have all been added. Of course, various other ingredients to be included in the final feed additive product can also be added after the addition of the liquid acids and dry base while the final stirring and drying stage is being completed in the mixer.
[0028] This method produced a non-dusty granulated product.
Experiment 2
[0029] Synergistic Effect of the Combination of Organic Acids and Sodium Butyrate on the Growth Prameters of Boilers.
[0030] In a broiler trial four different treatments were used in order to evaluate the possible synergistic effect between organic acids and sodium butyrate.
[0031] This pen trial included eight replicates of four treatments (Table 1). Each pen had 74 mixed sex commercial Ross broiler chicks. Birds were fed a wheat-based diet including enzymes. All birds were weighed on days 1, 5, 10 and 15 . The composition of the acid mixture is given in Table 2. The performance parameters at day 15 are given in Table 3. The results show the synergistic effect between organic acids and sodium butyrate. The feed conversion ratio based on weight gain of the treatment using only sodium butyrate or only a mixture of acids is not statistically different from the control group. On the other hand the combination of organic acids and sodium butyrate is significantly different from the other treatments (P<0.039).
TABLE 1 Treatments for Early Chick Growth Ingredient Group Acid mixture Na-butyrate(g/tonne) A None None B None 80 C 5000 None D 3000 40
[0032] [0032] TABLE 2 Composition of the acid mixture used in the broiler trial Ingredient Amount % Fumaric acid 45 Lactic acid 20 Formic acid 1 Propionic acid 1 Citric acid 1 Carrier (water, silica) 32
[0033] [0033] TABLE 3 Chick performances to 15 days Treatment 1 Performance parameter A B C D Feed consumed (g/bird) 437.4 441.3 451.1 459.9 Weight gain (g/bird) 349.1a 358.4a 367.4a 382.4b FCR based on wt gain 1.278a 1.279a 1.259a 1.239b
[0034] These trials show clearly that a combination of organic acids and sodium butyrate triggers a specific biochemical mechanism “in vivo” that leads to a synergistic effect of the combination of the ingredients. If there would be no new biochemical processes or interactions involved only an additive effect would be observed.
[0035] An important advantage of the synergism is the possibility to use lower concentrations of the acid mixture and the butyrate and still retain a significant improvement of the growth parameters, compared with the individual ingredients.
Experiment 3
[0036] Synergistic Effect of the Combination of Organic Acids, Calcium Salts of Organic Acids and Calcium Butyrate.
[0037] The objective of this trial was to study and compare two formulations (Table 4) with organic acids and calcium salts of organic acids. One of the formulations included calcium butyrate. Both formulations were compared with a positive and negative control in order to evaluate their possible growth promoting effect evaluated by broiler performance.
[0038] Twelve-hundred Ross broilers were divided over 40 floor pens. Each pen contained 15 male and 15 female Ross broilers, one tube feeder and one bell drinker. Feed and water were available ad libitum. All birds received a broiler starter feed from day 0 until day 11 and a broiler finisher meal from day 11 until day 39. The basic feeds did not contain any growth promoter or coccidiostat. Pens were assigned to one of four treatments (ten replicate pens for each treatment) using a block randomization. The in feed treatments consisted of: A. no treatment (negative control); B. Avilamycine 10 g/ton (positive control, dosed as Maxus G200 at 50 g/ton); C. Mixture 1, 5000 g/ton and D. mixture 2, 5000 g/ton. In the broiler house the temperature program started on day 0 at 31° C. decreasing 1° C. every two days until 21° C. was reached. The day-night cycle was 23 hours light and 1 hour dark. All birds were weighed at days 0, 11, 25, and 39. Feed usage was measured at days 11, 25 and 39. Live performance data were analyzed as a randomized block design with pen means as the statistical unit. Statistical analysis was performed with Figurepad Instat 2.0 and Microsoft Excel Analysis Toolpak software.
TABLE 4 Composition (%) of formulation 1 (without calcium butyrate) and formulation 2 (with calcium butyrate) Ingredient Formulation 1 Formulation 2 Inert carrier 25.4 25.4 Calcium lactate 26 26.0 Calcium propionate 28.6 26.8 Calcium butyrate 0 2.0 Fumaric Acid 16.6 16.6 Rapeseed oil 2.3 2.1 Sugars/water 1.1 1.1
[0039] The effect of different treatments on chick performance is shown in Table 5. On day 25 the positive control group receiving Avilamycine performed better than the negative control group concerning weight gain. This difference in weight gain was statistically significant (P<0.05). Only a treatment with formulation 2 resulted in a performance comparable with that of the positive control group. Formulation 1 did not perform any better than the negative control group. On day 39 the group receiving formulation 2 matched the positive control group concerning both weight gain and feed conversion ratio. Both these groups performed better than the negative control group. Weight gain differences were statistically significant. All treatments resulted in a feed conversion ratio (FCR) that was numerically better than that of the negative control group on day 39. The treatment with formulation 2 was the only one that resulted in an improved FCR with statistical significance (P<0.05). It also appears that the presence of the calcium butyrate leads to an extra gain of weight when the groups receiving formulation 1 and 2 are compared.
[0040] These results show that the combination of salts of organic acids and free organic acids leads to significant synergistic effects on the growth parameters when used in combination with calcium butyrate. Formulation 2 also had the same effect on the growth parameters as the antibiotic growth promoter.
TABLE 5 Average feed conversion ratio (FCR) and average weight gain (WG) of different treatment groups with their standard deviation; treatment means within the same row not sharing a same letter differ statistically significant (P < 0.05) Negative control Avilamycine 10 g/ton Formulation 1 Formulation 2 WG(g) Day 11 222 ± 13 a 227 ± 7 a 218 ± 9 a 221 ± 11 a Day 25 811 ± 40 a 853 ± 44 b 808 ± 30 a 830 ± 21 ab Day 39 1868 ± 62 a 1981 ± 58 b 1895 ± 70 a 1978 ± 57 b FCR day 11 1.316 ± 0.047 a 1.314 ± 0.034 a 1.333 ± 0.022 a 1.331 ± 0.043 a day 25 1.813 ± 0.085 a 1.775 ± 0.135 a 1.758 ± 0.066 a 1.737 ± 0.043 a day 39 1.877 ± 0.030 a 1.839 ± 0.061 ab 1.834 ± 0.038 ab 1.822 ± 0.042 b
Experiment 4
[0041] Synergistic Effect of Non-Volatile Organic Acids and Calcium Salts of Organic Acids in Combination with calcium Butyrate on the Performance Parameters of Laying Hens.
[0042] six undred one ear old laying hens of the breed Isa-Brown were divided in three groups and housed in cages of 5 hens per cage. Groups of eight cages were contiguous and formed a group of 40 hens that were allocated to a treatment.
[0043] The treatments were as follows: (a) Control group: receiving a commercial feed, without animal proteins and without AGP; (b) formulation 1 group: received 3 kg of formulation 1 on top of the commercial formula; (c) formulation 2 group: received 3 kg of formulation 2 on top of the commercial formula.
[0044] The trial design covered 3 treatments×5 repetitions×40 hens during a trial period of two times 4 weeks. All parameters were measured at the end of each 4-week period.
[0045] Tables 6 and 7 show the average performances of the laying hens over the 8 weeks period and Table 8 gives the average parameters on egg shell quality, measured on ⅓rd of the eggs.
TABLE 6 Effects on laying performances: average of 2 periods of 4 weeks Lay parameter Control Formulation 1 Formulation 2 Laying percentage, % 84.5 86.1 87.1 Mortality, % 0.7 1.2 0.5 Egg mass, g/hen/day 57.4 57.2 57.9
[0046] [0046] TABLE 7 Effects on feed intake and FCR: average of 2 periods of 4 weeks Treatment Growth Parameter Control Formulation 1 Formulation 2 Daily feed intake, g/hen 130.7 130.3 128.2 FCR 2.278 2.278 2.217
[0047] [0047] TABLE 8 Effects on egg quality: average of 2 periods of 4 weeks Treatment Eggshell quality parameter Control Formulation 1 Formulation 2 Broken eggs, % 0.62 0.60 0.61 Specific gravity index 1.087 1.088 1.087 Shell thickness, mm 0.299 0.322 0.314
[0048] Considering a normal decrease in laying percentage at that age of around 0.55% per week, the egg production is above standards. The use of formulation 2 improves the layer performance and feed conversion ratio numerically better than formulation 1. For the eggshell quality formulation 2 is equivalent to formulation 1. This phenomenon might be explained by the fact that the quality of the eggshell is mostly influenced by the calcium content of the formulations. Because of the limited difference in calcium content between formulation 1 and 2, no significant differences should be expected for the eggshell quality parameters. The evolution of the lay, growth and eggshell parameters in function of time is also clearly in favor of formulation 2, which includes the calcium butyrate. The differences of al the performance parameters between the treated groups and the control group become more important after a longer period of addition of the formulation to the feed. This is clearly demonstrated in FIGS. 1 - 3 . Considering a normal decrease in laying percentage at standards and seems to be in favor of formulation 2.
Experiment 5
[0049] The Effect of Non-Volatile Organic Acids and Calcium Salts of Organic Acids and their Combination with Calcium Butyrate on the in Vitro Eubiotic Effect Using a Cultured Inoculum.
[0050] An improvement of the condition of the gastro-intestinal tract in general may well be obtained by regulating the balance of the microbial flora (eubiosis) and has a beneficial effect on the health and growth of animals. The influence of formulation 1 and 2 on a mixture of two representative microorganisms was investigated in an in vitro assay (minimum inhibition concentration). The Gram-positive Lactobacillus fermentum was used as a reference organism for the beneficial lactic acid flora. A strain of the Gram-negative Salmonella enteritidis was used as a possibly harmful organism. In the assay the gastrointestinal conditions were simulated by mean of mixing an amount of ground feed raw material with buffer, a microbial cell suspension and the product. The tests were performed using a buffer of pH 4.25 to simulate the gastric conditions. A second buffer at pH 6.5 was used to simulate conditions further in the digestive tract. Both microorganisms were added together in the medium to test the influence of each other's presence on the response of their individual growth to the test products. Also in the animals' digestive tract both organisms are present.
[0051] It is very obvious that requirements for new antimicrobials/acidifiers are (1) that they do not inhibit beneficial organisms, as represented here by Lactobacillus fermentum and (2) that they inhibit or kill harmful organisms represented here by Salmonella enteritidis . The results of the in vitro tests are presented in FIGS. 4 and 5.
[0052] In summary, neither formulation inhibited L. fermentum in the presence of S. enteritidis . On the other hand, the S. enteritidis counts decreased after the addition of the formulations. Because there are no consistent differences between both formulations, the butyrate did not negatively influence the formulation, and that the existence of an eubiotic effect of a mixture of organic acids and calcium salts of organic acids in combination with calcium butyrate was confirmed by MIC tests.
Experiment 6
[0053] The Effect of Non-Volatile Organic Acids and Calcium Salts of Organic Acids and their Combination with Calcium Butyrate on the In Vitro Eubiotic Effect Using a Natural Inoculum
[0054] In this experiment 10 g of barley was added a flask together with buffer and an inoculum prepared from a faeces sample in a 10-1 dilution. An acid mixture (Table 2) and formulation 2 were added to the mixture in order to evaluate the eubiotic effect. The literature proves that freshly passed faeces collected under strictly anaerobic conditions could be considered as representative of the large-intestinal flora (Williams, B. A., Verstegen, M. W. A., and Tamminga, S.(2001) Fermentation in the large intestine of single-stomached animals and its relationship to animal health, Nutrition Research Reviews, 14, 207-227).
[0055] The Lactobacilli growth was determined after 0, 26 and 50 hours of incubation at 37° C. in a waterbath.
TABLE 9 Lactobacilli counts (cfu/g) Time (h) Control Acid mixture Formulation 2 0 2.44 10 6 26 7.90 10 10 3.24 10 10 1.89 10 10 50 5.76 10 7 9.34 10 7 1.07 10 9
[0056] The positive effect from formulation 2 compared with an acid mixture can be clearly observed from these data, and proves the eubiotic effect.
Experiment 7
[0057] The Effect of Non-Volatile Organic Acids and Calcium Salts of Organic Acids and their Combination with Calcium Butyrate on the In Vivo Eubiotic Effect.
[0058] At the end of a performance trial with 156 piglets (Piétrain×Hybride), 4 treatments×2 genders×2 replicates×9-11 piglets per pen), a sample of faeces was taken for every group. The obtained samples were subjected to microbial counts. The order of magnitude of enterobacteriaceae and lactic acid bacteria counts are presented in Table 10.
TABLE 10 Microbial counts of faeces (in cfu/g) Treatment Control Acid Formu- Formu- Microorganism (antibiotics) mixture lation 1 lation 2 Total enterobacteriaceae 10 3 10 4 10 3 <10 3 Lactic acid bacteria 3.38 10 7 1.5 10 6 2.06 10 7 2.20 10 7
[0059] The composition of the acid mixture is given in Table 2.
[0060] The composition of formulation 1 and 2 is given in Table 3.
[0061] These data demonstrate that formulation 2 brings about the best eubiotic effect of the series. One can also conclude that an acid mixture is less effective than a mixture of non-volatile organic acids and calcium salts of organic acids. The presence of a small amount of calcium butyrate in formulation 2 improves the eubiotic even further.
Experiment 8
[0062] Inclusion of Additional Compounds
[0063] The method also may be practiced wherein other ingredients or compounds are incorporated into the granulate. Examples of such ingredients are solid organic acids (e.g., citric acid, ascorbic acid, and fumaric acid), mineral salt solutions (e.g., copper sulfate), natural or synthetic surfactants, flavorings, colorants, and pigments. In a specific example, to 30 g of almond shell meal, 15 g or a diluted solution of one of the foregoing additional ingredients is added while stirring. Thereafter, 10 g or the organic acid is added, followed by and equivalent amount of the selected base, all while stirring. When the temperature of the mixture drops below 35° C. the procedure is repeated twice more.
[0064] The foregoing description comprise illustrative embodiments of the present inventions. The foregoing embodiments and the methods described herein may vary based on the ability, experience, and preference of those skilled in the art. Merely listing the steps of the method in a certain order does not necessarily constitute any limitation on the order of the steps of the method. The foregoing description and drawings merely explain and illustrate the invention, and the invention is not limited thereto, except insofar as the claims are so limited. Those skilled in the art who have the disclosure before them will be able to make modifications and variations therein without departing from the scope of the invention. | A process for the solid-phase synthesis of salts of organic acids in a granular, free-flowing, and dust-free form particularly suited for use as animal feed additives. A mixture of liquid organic acids, including butyric acid, is applied to an inert, absorbent carrier. A solid base is then added during stirring. The acid is slowly released from the carrier preventing the fast reactions that lead to the formation of clumps. The exothermic reaction releases heat which assists in reducing the moisture content of the product. The addition of butyric acid results in a product which has an improved effect on animal growth over the animal feed additive without the addition of butyric acid. | 2 |
TECHNICAL FIELD
[0001] The present invention describes the use of biopolymers, and method for the production of gels or creams that can be used in cosmetic, cosmeceutical, pharmaceutical and food applications. In order to obtain a gel or a cream, the biopolymers are combined with amphiphilic chemical entities.
BACKGROUND OF THE INVENTION
[0002] Polyhydroxyalkanoates (PHAs) are natural polyesters produced by a large variety of microorganisms such as bacteria and algae. They are biodegradable thermoplastics obtained from renewable sources that can be processed with conventional equipment, which makes them very attractive for the plastic industry. The potential worldwide market for biodegradable polymers is enormous due to the extreme variety of applications. For example, degradable polymers can be used as films, sheets, fibers, foams, molded articles and many other products.
[0003] PHAs produced by microorganisms are intracellular granules accumulated as energy storage resulting of adverse growth conditions, i.e., nutrient limitation. The biopolymer accumulation in bacteria increases when a deficiency in nitrogen occurs. This deficiency is generally expressed by an increase of the ratio C/N, where C is the source of carbon and N the source of nitrogen actually in the culture medium. Therefore, the feeding strategy becomes a critical step that will have a direct impact on the productivity of the biopolymer. The food source is also an important factor that will decide the nature of the produced biopolymer. In fact, different homo- or copolymers can be obtained by varying the food source provided to the microorganism during the fermentation. The most well-known representatives of the PHA family are poly(3-hydroxybutyrate) (PHB) as well as its copolymer poly(3-hydroxybutyrate-co-3-hydroxyvalerate) (PHBV).
[0004] PHAs are biopolymers that are characterized by other numerous interesting properties. Among them, they are biocompatible and bioresorbable, which makes PHAs potent candidates for food, cosmetic and biomedical applications. An increasing number of publications and patents over the last years provide the best illustration. Yalpani reported the use of poly(hydroxy alkanoates) as fat substitute for food in the U.S. Pat. No. 5,229,158. Marchessault et al. described the use of PHA for the entrapment or microencapsulation of hydrophilic or lipophilic drugs in the U.S. Pat. No. 6,146,665. In this case, PHA is synthesized in vitro by polymerization of a hydroxyalkanoate coenzyme A monomer. Other controlled applications were published on PHA from bacterial sources.
[0005] The potential of PHA in drug delivery systems is now known in the art. PHAs are also used as implants in orthopedic surgery because of their biodegradability and bioresorption. For this particular use, PHAs are often reinforced with hydroxyapatite (Biomaterials, 1991, 12:841-847; Biomaterials, 1992, 13:491-496; Polymer Testing, 2000, 19:485-492). Numerous other implant applications were developed such as heart valves, vascular grafts and tissue engineering. Cosmetic composition containing hydroxy alkanoate derivatives was reported by Browser et al. in the International Patent Pub No. WO 95/05153. In this patent application, oligomers (1 to 5 monomer domains) of 2-hydroxyalkanoate derivatives are incorporated in the composition.
[0006] The solubility of these biopolymers is very low. They are totally insoluble in water and in most common organic solvents, which appear to be poor-solvents, with the exception of some halogenated solvents such as chloroform, dichloromethane and 1,2-dichloroethane. Traditionally, PHB is extracted by adding a PHA non-solvent to an halogenated solution containing the biopolymer (U.S. Pat. No. 4,562,245), which is not cost efficient as far as a large scale production is concerned. Therefore, the major concern about the extraction and purification of the biopolymer from the microorganism was the production cost. As a result, a lot of efforts were put forth to resolve this problem and many patents were issued. For example, method using PHA-poor solvent at high temperature (International Patent Pub. No. WO 98/46783), using non-halogenated solvents (International Patent Pub. No. WO 98/46782) and using marginal non-solvents (International Patent Pub. No. WO 97/07229). An aspect of the use of organic solvents at high temperature was the discovery of PHA gels once the solutions were allowed to cool at room temperature. Other examples of the formation of physical gel were found in the literature, Fabri et al. studied dilute solution of PHB in N,N-dimethylformamide and N-methyl-2-pyrrolidone (Thermochimica Acta, 1998, 321:3-16) whereas Turchetto and Cesbro used dimethylformamide (Thermochemica Acta, 1995, 269/270:307-317). The lower degree of solubility of polymers like PHAs in organic solvents was exploited by Dunn and English for drug release applications (International Patent Pub. No. WO 01/35929). These authors used a floating component containing the polymer and a bioactive agent that is administered to human by syringe and needle. Once introduced in the body, the solvent is dispersed and the polymer which is non soluble in water forms a solid matrix where the bioactive agent is trapped and further release.
[0007] One aspect of the purification and extraction process is the use of a dispersing agent of PHA in water by the addition of a surfactant (Patent Pub. No. WO 97/21762), but it does not lead to the formation of a gel neither of a cream.
[0008] U.S. Pat. No. 5,229,158 describes the use of PHA in a latex solution, with particle sizes that can get from 0.1 to 10 microns, which is similar to our statements. However, the main aggregating agents are totally different, for example pectin, lecithin and xanthan gum. No indication is given regarding the physical aspect of the final product neither its stability in time. PHA is used to substitute fat entities because it has a fat-like texture.
[0009] Moreover, the above-described applications and inventions have a limited range of concentration of PHA when organic solvents are used. In fact, it is impossible to obtain over a 5%. PHA solution (weight/volume) in organic solvents.
[0010] The stabilization of PHA dispersion in water as been reported in International Patent Pub. No. WO 97/21762. This application describes the use of amphiphilic chemical entities that would improve the solubility of the PHA in water and simplify the process of dispersion in order to purify the biopolymer during the extraction/purification processes. Dispersants used are for example dioctyl sulphosuccinate, sodium dodecylsulphonate, sodium dodecylbenzenesulphonate, sodium lauryl sarcosinate or sodium dodecyldiphenyl oxide disulphonate.
[0011] Different biodegradable copolymers have been described until now, including aliphatic polyester, polyorthoester, polyanhydride, poly alpha-amino acid, polyphosphagen, and polyalkylcyanoacrylate. Among aliphatic polyesters, polylactide (PLA), polyglycolide (PGA) and polylactideglycolide (PLGA) were approved as copolymers nontoxic to humans by the FDA. These copolymers were employed as drug delivery devices to carry the drugs or biomedical devices.
[0012] Based on the above-listed patents and publications which are quite representative of the state of the art relating to biopolymers, there is still considerable amount of work to do in order to improve the process of producing gels and creams because of the lack for methods to obtain a gel and/or a cream using biopolymers, particularly PHAs, that would be suitable principally for cosmetic and pharmaceutical applications. Such a process would rather use biocompatible and bioresorbing species.
[0013] It would be very much desirable to be provided with a new method for producing new biocompatible gels and creams composed with biopolymers.
SUMMARY OF THE INVENTION
[0014] One object of the present invention is to provide a method for producing or modulating a physical characteristic of aqueous gel composition comprising a biopolymer linked to a binder agent, the method comprising the steps of:
a) providing at least one biopolymer selected from the group consisting of polyhydroxyalkanoate (PHA), polycaprolactone (PCL), adipic acid, aminocoproic acid, poly(butylenes succinate), polylactide (PLA), polyglycoside (PGA), and polylactideglycolide (PLGA), or a derivative thereof, brought to the state of particles in suspension in an aqueous medium to form a latex; b) combining the latex of step a) with at least one binder agent for a time and condition sufficient to form a soluble complex solution of biopolymer particles linked to the binder agent; and c) heating at between about 27° C. and 80° C. the soluble complex solution of step b), wherein at least one of the biopolymer of step a) or the binding agent of step b) are in determined concentration and the heating of step c) is long enough to obtain a desired physical characteristic of the gel composition.
[0018] The binder may be an amphiphilic molecules or a molecule comprising at least one hydrophilic domain such as, but not limited to, a polyethylene glycol (PEG), and at least one hydrophobic domain, such as for example a fatty acid, or a derivative thereof.
[0019] The gel composition of the invention may be a viscous liquid or a solid gel.
[0020] Another object of the present invention is to provide an aqueous gel composition comprised of at least one biopolymer selected from the group consisting of polyhydroxyalkanoate (PHA), polycaprolactone (PCL), adipic acid, aminocoproic acid, poly(butylenes succinate), polylactide (PLA), polylactideglycolide (PLGA) and polyglycoside (PGA), or a derivative or a mixture thereof, and at least one binder agent.
[0021] The binder may be an amphiphilic molecule or a molecule comprising at least one hydrophilic domain such as but not limited to, polyethylene glycol (PEG) and at least one hydrophobic domain, such as a fatty acid, or a derivative thereof.
[0022] For the purpose of the present invention, the following terms are defined below.
[0023] The term “amphiphilic” as used herein is intended to mean a chemical compound having a hydrophilic domain and at least one hydrophobic terminal domain.
[0024] The term “biopolymer” as used herein is intended to mean polymers obtained from natural and renewable sources and which mode of synthesis occurs naturally such as with plants or microorganisms.
[0025] The term “polymer” as used herein is intended to mean macromolecules synthesized by chemical reaction or obtained from petroleum sources, even if one of the components (monomer, precursor, etc.) is obtained from natural and renewable sources. PLA, PGA, PLGA, and PCL will be recognized as polymers to one skilled in the art.
[0026] The term “binder” as used herein is intended to mean amphiphilic chemical compound capable to associate with PHA granules, which are hydrophilic, and remain soluble in aqueous phase simultaneously. For example, but not limited to, a binder can be constituted of two hydrophobic domains separated by a hydrophilic domain.
[0027] The term “cream” as used herein is intended to mean a solution with enhanced viscosity properties which does not imply necessarily the formation of a three-dimensional network due to polymer chain entanglement.
[0028] The term “gel” as used herein is intended to mean a three-dimensional network organization swelling in a solvent. When water is the solvent, the gel may be defined as “hydrogel”. Further, the three-dimensional network is due to polymer chain entanglements for a physical gel, whereas it is due to chemical bonds for a chemical gel.
[0029] The terms “granule” and “particle” as used herein are intended to mean spheroids shaped biopolymer segments with particle size distribution from 0.1 to 10 μm, preferably form 0.2 to 5 μm.
[0030] The term “latex” as used herein is intended to mean a suspension of PHA granules and/or particles. A latex as defined herein may comprise an aqueous medium as diluent or solvent. The PHA granules can be either in their native state or re-suspended in water. The native PHA is defined as a granule of PHA, produced by bacterial fermentation, which was never precipitated, therefore its crystallization degree remains close to or slightly higher than what it was in the bacteria, i.e., very weak. The latex may have the aspect of milk in color and texture, while the viscosity may be similar to that of water.
[0031] The term “hardness” as used herein is intended to mean the force required to obtain a deformation of a body. The hardness measurement units are most of the time expressed in Newton. A Newton is a unit of force equal to the force that produces an acceleration of one meter per squared second of a mass of one kilogram.
[0032] The term “cohesiveness” as used herein is intended to mean the strength of the internal bonds making up the body of the cream or gel. It can be defined as the molecular force between particles within a body or substance that acts to unite them.
[0033] The term “viscosity” as used herein is intended to mean the rate of flow per unit of force (milli Pascal-seconds (mPa.s) or centiPoises (cPs)). The viscosity is the property of a fluid that resists the force tending to cause the fluid to flow. mPas is a milliPascal second. A pascal is the unit of pressure or stress, equal to one Newton per square meter.
[0034] Consistency can be defined as a quality of a gel or a cream which is perceptible to touch. The term ‘body’ can also be used to express consistency. A broader definition can be used when referring to consistency as a characteristic of a mixture of cream and gel substances, or as the touch feel characteristics of semi-solids or liquids. Hence, sensory concepts such as touch feel and body could be associated with consistency. Consistency could be empirically evaluated with apparatus such as the Adams consistometer or the Bostwick consistometer. The measure of consistency is usually presented as centimeters per 30 seconds when the Bostwick consistometer is used.
[0035] The term “elasticity” as used herein is intended to mean the rate at which deformed gels or creams go back to their original undeformed state after removal of the force. The measurement unit of elasticity is expressed in millimeters or in percentage. The elasticity is the property of a substance that enables it to change its length, volume, or shape in direct response to a force effecting such a change and to recover its original form upon the removal of the force.
[0036] The term “adhesion” as used herein is intended to mean the force necessary to overcome the attractive forces between the surface of a matter and the surface of an other material with which it is in contact. The adhesion is the attractive molecular force that tends to hold together unlike bodies where they are in contact. The measurement unit of the adhesion is expressed in Newton.
BRIEF DESCRIPTION OF THE DRAWING
[0037] FIG. 1 illustrates the evolution of the viscosity (Pa.s) versus the time (s) for a fixed strain and temperature for gel and cream solutions.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0038] In accordance with the present invention, a method of producing biocompatible gels and creams based on linking biopolymers, such as polyhydroxyalkanoate (PHA), polylactide (PLA), polyglycoside (PGA), polylactideglycolide (PLGA), and polycaprolactone (PCL) with a binder agent, preferably an amphiphilic chemical entity, in a aqueous medium in order to obtain a gel or a cream is provided.
[0039] The Applicant has discovered that by combining certain types of biopolymer to specific binding agents, such as amphiphilic agents, the resulting suspension may, depending of the processing conditions to prepare the mixture of these products, allows the aqueous dissolution of the biopolymer and induces the formation of gels or creams having different levels of density, firmness, and/or viscosity.
[0040] In one embodiment of the present invention, at least one binder is added to a biopolymer latex solution. The resulting product is a cream or a gel having improved or enhanced viscosity when compared to the viscosity of the latex or the binder itself in water, as well as an increase in the time of sedimentation of the PHA granules, which is almost infinite because the resulting product is extremely stable in time and temperature.
[0041] Applications where plastic products have a single use and/or short life are ideally suited in the case of PHAs, because at once used these products are entirely converted in compost sites or can be metabolized in biological conditions.
[0042] According to another embodiment of the present invention, the gels or creams issued from the method of the invention may comprise only one biopolymer or a mixture of different biopolymers configured into mono- or or multiblocks copolymers. These copolymers may be combinations of, polypropylene oxide, PHA, PLA, PLGA and PCL.
[0043] The invention is applicable to create a cream and/or a gel from any type of PHA biopolymer produced by plants or microbial organisms either naturally or through genetic engineering, as well as PHA polymers chemically synthesized.
[0044] According to one other embodiment of the invention, the PHA biopolymers used are polyesters composed of monomer units having the formula:
wherein n is an integer from 1 up to 9; R 1 is preferably an H, alkyl or alkenyl. Alkyl and alkenyl side chains are preferably from C 1 up to C 20 carbon long. PHA biopolymers can be homopolymers, with the same repeating monomer unit, and/or copolymers, with at least two different repeating monomer units.
[0045] Copolymers can be structured statistically, random-block, alternating or grafted. Molecular weights of the PHA biopolymers are generally in the range of 1,000 to 2,000,000 g/mol, preferably between 10,000 and 1,500,000 g/mol, and more preferably between 5,000 and 1,000,000 g/mol. The orientation of the monomers can be, for example, head to head, head to tail or tail to tail.
[0046] PHAs that can be used according to this invention may include poly(3-hydroxybutyrate), poly(3-hydroxyoctanoate), poly(4-hydroxybutyrate), poly(3-hydroxybutyrate-co-3-hydroxyvalerate), poly(3-hydroxybutyrate-co4-hydroxybutyrate) and poly(3-hydroxybutyrate-co-3-hydroxyoctanoate).
[0047] Copolymers of PHA, listed herein above, may be in the range of 40 to 100% of monomer 3-hydroxybutyrate and preferably between 60% and 95%.
[0048] According to this invention, the PHA concentration in the latex solution is from 0.01% to 50% and including, preferably from 1% to 45% and more preferably from 5% to 40%. Concentrations are expressed weight/volume. The latex can be obtained from a native biopolymer or dissolved from a dry powder. In the latter case, the high crystallinity of the biopolymer can affect the texture of the final cream and/or gel. This problem can be overcome by producing amorphous polymer suspension as described in International Patent Publication WO 99/64498 incorporated herein by reference.
[0049] According to the invention in its first aspect, the addition of a binder to biopolymer latex solutions is characterized by its transformation into a cream and/or a gel, which results in an increase in the viscosity or firmness and a better solution stability. Both phenomenon may be associated to the amphiphilic characteristic of the binder which contains a plurality of domains—at least 2 and to several 10, and typically 3 with opposite properties: hydrophilic and hydrophobic.
[0050] One structure of the binder may be a tri-block chemical compound, having two hydrophobic end domains and one core hydrophilic domain. It is assumed that the hydrophobic end domain is more easily associated with the hydrophobic PHA granules, for example, the hydrophilic core remains in the aqueous phase, thus creating a bridge between the granules and allowing interaction with water molecules. A physical gel is then obtained, i.e., reversible and with lower mechanical properties than a chemical gel. A similar phenomenon is assumed with two-domain amphiphilic compounds. The hydrophobic domain is associated with the biopolymer chains in suspension in water while the hydrophilic chains interact themselves in the aqueous phase. As a result, the cream or gel so obtained is less physically resistant to stress and strain.
[0051] Hydrophobic domain may be for example aliphatic chains C n H 2n+2 ranging from C 1 to C 40 , linear and/or branched out. Unsaturated alkyl chains ranging from C 2 to C 40 , with one or more insaturation, linear and/or branched out, chains including one or more aromatic moieties. In the case of a tri-block sample with hydrophobic domain at both ends, only one had to be long enough to associate with the PHA chain, the other can be shorter.
[0052] Hydrophobic domain may contain one or more heteroatoms (nitrogen, oxygen, sulfur, chlorine, fluorine, etc.), individually or mixed. For example, poly (propylene glycol) is an hydrophobic compound with an oxygen heteroatom in the main polymeric chain and an alkyl branched out, a methyl group.
[0053] Hydrophobic domain can be for example saturated fatty acids with an alkyl chain from C 10 to C 30 , preferably between C 14 and C 24 . For example, lauric, myristic, palmitic, stearic, arachidic, behenic, lignoceric acids. Hydrophobic domain can also be unsaturated fatty acids, having one or more insaturation, with alkyl chain from C 10 to C 30 , preferably between C 14 and C 24 . For example, palmitoleic, oleic, linoleic, α-linolenic, γ-linolenique, arachidonic, eicosapentaenoic, and nervonic acids. Binders can have one or two fatty acids at their ends, or derivatives thereof.
[0054] Molecular organization of the binder may be a two- or tri-block sample with one or two (similar or with groups from more than one chemical composition) hydrophobic domain mentioned above, respectively.
[0055] Hydrophilic domain may be for example non ionic chemical entities such as polyalkylene oxide, especially polyethyleneoxyde, glycoside, or polyglycerol or amine oxide. Hydrophilic domain may have ionic entities such as carboxylate, sulphate, sulphonate, phosphate, phosphanate or ammonium. Hydrophilic group of the binder may contain more than one chemical composition from the list above mentioned. The most suitable hydrophilic domain is the polyethylene glycol and derivatives of formula
HO—(CH 2 —CH 2 —O) n —H
where n is an integer varying from 1 to 2,500, preferably between 7 and 500. Hydrophilic domain may also be an hydrophilic polymer which is miscible with PHA, such as poly(vinyl alcohol), poly(vinyl acetate), poly(epichlorohydrin), polybutylacrylate, poly(methyl methacrylate), poly(ethyl methacrylate) and polysaccharides.
[0056] The quantity as well as the nature of the binder necessary to obtain a gel is closely linked to the concentration of PHA in the latex solution. If the latter is very diluted, the binder should contain a large molecule, the equivalent of an oligomer for example, and its concentration should be important. Moreover, the distribution between the hydrophobic and hydrophilic domains should allow a good interaction between the binder and the PHA granule. In other words, when the concentration in latex is low, the hydrophobic domain should be long enough to induce the interaction with the PHA granules. To the opposite, for higher latex concentration, the length of the hydrophobic domain does not need to be very long, but the length of the hydrophilic core domain needs to be long enough to maintain a cohesion with the aqueous medium. In brief, to form a gel with a dilute latex solution it is necessary to use a long binder with an elevated ratio of hydrophobic versus hydrophilic domains, while it is necessary to use a shorter binder with a lower ratio hydrophobic versus hydrophilic domains for a concentrated latex solution.
[0057] In one embodiment of the present invention, a short binder with a low ratio hydrophobic versus hydrophilic domains may be used with a thin latex solution to give a cream. The same result may be obtained when a concentrated latex solution is used with a long binder having an elevated ratio of hydrophobic versus hydrophilic domains.
[0058] According to the present invention, the concentration of the binder (added to the latex solution) in the final formulation is between 0.01% and 75%, preferably between 1% and 30% and rather between 2% and 20%. Concentrations are expressed weight/volume. The binder can be used alone or mixed at least 2 to several 10 or so with the either the same concentration or not. The nature of the binders added can also vary. For example, a binder with a short length and another with a long one. The ratio of the hydrophobic domains versus the hydrophilic domain can be similar or different, in the case of tri-block binders. One or several di-block binders can be added with one or several tri-block binders.
[0059] According to the present invention, another embodiment is the use of these creams and gels described above, for the delivery of chemical compounds and/or cells in food, cosmetic, cosmeceutical and pharmaceutical applications for humans as well as animals. In fact, all the components, the biopolymer as well as the binder agent, used in the preparation of the gels and creams are biocompatible and bioresorbing.
[0060] In one embodiment of the present invention, one step of the method invention comprises the modulation of at least one parameter of a gel or cream Theological profile in manner to allow the gel or cream composition at use to have a desired hardness, elasticity, cohesion, gumminess, consistency, viscosity and yield stress.
[0061] According to another embodiment of the invention, there is provided a method in which a quantitative and descriptive approach is used to adapted the gel or cream texture in, for example, alimentary, cosmetical, cosmeceutical or pharmaceutical applications. A description of textural characteristics of creams and gels is provided and prones to be an integral part of the alimentary, cosmetical, cosmeceutical or pharmaceutical applications. No publication has reported quantified gel or cream texture in relation to its importance in the health care of alimentary, cosmetical, cosmeceutical or pharmaceutical applications. Rheology is now offering a promising avenue in a more objective and optimized applications.
[0062] Rheology is the study of the deformation and flow of gel and cream compositions. It offers vocabulary and specific terminology to discuss these compositions and their textural characteristics. Gels and creams vary greatly in composition and show a vast array of textural characteristics. Liquids could be viscous and thick like molasses or fluid and thin like water. Solids also vary in texture. Solids could be adhesive. Rheology also offers several instruments such as viscometers and texturometers which permit quantification of these textural characteristics.
[0000] Rheology of Liquids
[0063] Viscosity is the internal friction of a fluid or its resistance to flow. It is a textural parameter that could be evaluated by fundamental testing which quantifies the flow of fluids. Instrumental devises such as capillary flow, Couette or Searle flow, parallel-plate or cone-and-plate viscometers could be used to determine viscosity. Isaac Newton was the first to express the law of ideal liquids can be described the flow behavior of ideal liquids as
η=σ/γ (Equation 1)
where η is the viscosity (Pa.s), a is the shear stress (Pa) and, γ is the shear rate (s −1 ).
[0064] Ever since, fluids are mainly classified as Newtonian or non-Newtonian. A linear relationship of the shear stress (σ) expressed in Pascal as a function of shear rate (γ) expressed in s −1 illustrates the flow behavior of ideal liquids. A Newtonian liquid will have a constant slope that will express viscosity (η). The Newtonian liquids present flow characteristics that are influenced only by temperature and gel or cream compositions. The Newtonian gel or cream compositions are not affected by shear rate and shear history.
[0065] Non-Newtonian liquids are affected by temperature, gel or cream compositions and shear rate. The apparent viscosity (η a ) is then used to express the viscosity and is specific to the shear rate at which the product is tested. Non-Newtonian gel or cream compositions could further be divided as time-independent or time-dependent. The latter, contrary to time-independent fluids, will show an apparent viscosity that will be affected by the length of time for which the shear is applied. Time-independent fluids could be either pseudoplastic (i.e. shear-thinning, losing viscosity with time at a varying shear rate) or dilatant (i.e. shear-thickening, gaining viscosity over time) which is rarely encountered. Shear-thinning could be explained by re-orientation, stretching, deformation or disaggregation of molecules, which compose the tested product, following shear. Therefore, important decrease in viscosity could be observed in products after the shearing.
[0066] Time-dependent flow characteristics are further divided into thixotropic and rheopectic liquids. The former displays a decrease in viscosity when a constant shear rate is applied for a certain period of time.
[0067] The latter presents an increase in viscosity over time when the shear rate is maintained constant.
[0068] One particular embodiment of the present invention is a method allowing the modulation of at least one of the physical characteristics described herein, as the viscosity, the consistency, the firmness or hardness, the yield stress, the elasticity, the cohesiveness, or the adhesion of a gel and/or a cream. For example, but without limiting it to, the consistency may have a value of between about 1 to 50 cm per 30 seconds, the viscosity between about 50 to 10 000 mPa, the yield stress between about 1 to 500, the elasticity between about 1 to 90%, the hardness between about 0,1 to 100 Newton, the cohesiveness between about 0.01 to 25, and the adhesion between about 0.01 to 100 Newton.
[0069] In performing the method of the present invention, one or more of the physical characteristics can be adjusted or modulated through different combination of biopolymers and binding agents.
[0070] The present invention will be more easily understood by referring to the following examples which are given to illustrate the invention rather than to limit its scope.
EXAMPLE I
Production of PHA Cream with PEG 900
[0071] The concentration of PHA in the latex obtained after fermentation, extraction and purification is 20% w/v. The binder used in this example is poly(ethylene glycol) distearate, PEG-distearate, of molecular weight 930 g/mol, which implies that the poly(ethylene glycol) part corresponds to 9 ethylene glycol repeating monomer units.
[0072] 0.8 gram of PEG-distearate is added to 20 mL of latex solution, and heated to 40° C. for 1 hour under moderated stirring and sealed to prevent water evaporation. The solution obtained is homogeneous and more viscous than the initial latex solution. Moreover, when PEG-distearate is dissolved in water to obtain a similar solution, 4% w/v, its viscosity is lower than the gel described above.
[0073] The cream remains stable in viscosity and does not settle down with variation in time and temperature. After 4 weeks, the gel still remains stable when kept sealed at room temperature. A similar result is observed with a sample kept sealed in a refrigerator at 4° C.
EXAMPLE II
Production of PHA Cream with PEG 6000
[0074] In this example, a similar product is developed with a PEG-distearate having a PEG part with a molecular weight of around 6,000 g/mol instead of 396 g/mol, which represents between 130 and 140 ethylene glycol repeating monomer units. The hydrophobic end parts of the binder in this example do not change, only the central hydrophilic part.
[0075] 0.8 gram of PEG-distearate is added to 20 mL of latex solution, and heated to 40° C. for 1 hour under moderated stirring and sealed to prevent water evaporation. The solution obtained is homogeneous and more viscous than the initial latex solution or the same PEG-distearate solution in water. However, this solution is less viscous than the previous solution obtained with a shorter PEG domain. The stability in time and temperature is not affected and is similar to the previous one.
EXAMPLE III
PHA Latex and Mono Fatty Acid-co-PEG
[0076] In this example, a cream is developed with a PEG having a single fatty acid. The hydrophobic end part of the binder is an oleic acid, i.e., insaturated fatty acid with the same length as stearic acid. The hydrophilic part is also slightly shorter than in the first example, total molecular weight of PEG is 860, which gives about 5 repeating ethylene glycol monomer units.
[0077] 3.57 mL of PEG-monooleate is added to 20 mL of latex solution, and heated to 40° C. for 1 hour under moderated stirring and sealed to prevent water evaporation. The PHA concentration in the latex is 30%. The solution obtained has a cream like structure, i.e., homogeneous and more viscous than the initial solutions. This cream remain relatively stable in time like the previous ones, but do not show the same extend of temperature stability. Further, it is less viscous than the ones described in the two first examples.
EXAMPLE IV
PHA Latex and PPO-PEO-PPO
[0078] In this example, a gel is made with a different triblock sample based on poly(propylene glycol) and PEG. Such samples are commonly called poloxamer.
[0079] 4 mL of poloxamer P181 was added to a latex solution in order to obtain a 20 mL solution. The PHA concentration in the latex is 40%. After few minutes an gel like composition is obtained which is homogenous and stable. If the mixture is headed to 40° C., a more firm and consistent gel like composition is obtained. In addition, water is expelled from the gel, providing a clear and distinct phase.
EXAMPLE V
Rheological Measurements
[0080] Five solutions were tested using a rheometer AR 2000 (Advance Rheometer). Solution A is a latex of a copolymer (PHB-HV 95-5), with a specific concentration of 20% w/v. Solution B 1 and B 2 are made of poly(ethylene glycol) distearate of molecular weights 930 and 6000, respectively, with concentration of 4% w/v. Solutions G 1 and G 2 result of the mixture of a latex solution with solution B. or B 2 as previously described in Examples I and II.
[0081] All experiments were realized at 37° C. and constant shear stress of 1 Pa excepted for sample B 1 (10 Pa) because its consistency is much more harder than the other samples. As shown on FIG. 1 , the viscosity of the gels (G 1 and G 2 ) are much more higher than the viscosity of each constituent (A+B 1 and A+B 2 respectively). The increase in viscosity for samples G 1 and G 2 is a clear evidence of the interaction between the constituents that it the core of the invention and was described in details previously.
[0082] While the invention has been described in connection with specific embodiments thereof, it will be understood that it is subject to further modifications and this application is intended to cover any variations, uses, or adaptations of the invention following, in general, the principles of the invention and including such departures from the present disclosure as come within known or customary practice within the art to which the invention pertains and as may be applied to the essential features set forth hereinbefore, and as follows in the scope of the appended claims. | The formation of a cream and gel is described using a biopolymer, such as a polyhydroxyalkanoate (PHA), a polylactide (PLA), a polylactideglycolide (PLGA) and a polyglycoside (PGA), or a derivative thereof, in a latex form with the addition of a binder, which is generally an amphiphilic chemical entity. An hydrophobic domain of the amphiphilic chemical entity interacts with at least one biopolymer forming a water soluble complex, while the hydrophilic domain of the amphiphilic chemical entity maintains the soluble complex in suspension in an aqueous solution, which after proper heating becomes a gel or a cream. As a result, a versatile gel or cream is created with different compositions and textures that are obtained based on the nature of the binder used and the ratio of biopolymers and binder(s). | 2 |
FIELD OF THE INVENTION
This application claims the benefit of U.S. Provisional Application No. 60/252,056 filed Nov. 20, 2000.
The present invention relates to a system for facilitating the use of several appliances, machines, tools from a single work position and without the necessity of removing and replacing a desired sewing machine or tool implement. More particularly, the invention relates to a system comprising a turntable apparatus adapted to the top of any cabinet/workbench/table wherein several appliances, machines, tools are mounted or placed and can be rotated into the work position. Rotating the turntable can be manually or electric motor driven.
SUMMARY OF THE INVENTION
It is noted that the features of the present invention have application in many fields as noted above. However, the features have particular application to sewing systems.
In accordance with the present invention, there is provided a sewing system comprising a unique rotating turntable for mounting several sewing implements and a cabinet with drop leaves, drawers and shelves. For space utilization efficiency, equal amounts of the front and back of the turntable rotating mounting platform can be removed so as to form a straight edge on the front and back of the cabinet top. All drawers use all the depth available, some with the use of full extension drawer slides. The remaining available space has adjustable shelves.
The present invention provides a space-saver model for use in areas where space is at a premium are provided. This sewing system is designed to utilize the cabinet top for mounting several types of machines, such as a sewing machine, and provide adequate storage space in the form of up to five drawers and eight shelves. A minimum of four surge protected outlets are provided with an on/off switch and a heavy-duty electric cord out the back of the table that can be plugged into any household outlet.
The turntable assembly comprises a turntable attached to the upper plate of a ball bearing metal raceway. The lower plate of the ball bearing race is bolted to the cabinet top. The upper plate and the attached turntable, therefore, are free to rotate on the ball bearing lower plate race. A circular groove in the cabinet top forms a track way for a spring-loaded locking pin that protrudes through the turntable into the circular track way. Locking holes in the circular groove allow the spring-loaded locking pin to drop into the locking holes thereby providing means for locking the turntable in a desired position. A knob-like handle on the spring-loaded locking pin provides the means for manually rotating the turntable.
A second embodiment provides a motor and gear arrangement to rotate the turntable. The mounting platform, in this embodiment, is attached to a large circular gear whose teeth engage a smaller drive gear attached to the drive shaft of an electric motor. The electric motor is switch activated to rotate the turntable. Stops on the large driven gear engage a switch arrangement to reverse motor current thereby reversing the direction of the turntable and preventing the turntable from continuing to rotate beyond 355°.
With the above in mind, an object of the present invention is to provide a system for rotating multiple implements into a work position which is characterized by novel features of construction and arrangement including means for plugging in the appliances, machines, tool, etc., incorporating a surge protection.
Another object of the present invention is to provide a system for rotating multiple implements into a work position incorporating a turntable which can only be rotated 355° and in this matter preclude any of the cord extensions from becoming entangled.
Still another object of the present invention is to provide a system of the type disclosed wherein a wire race keeps the cores from interfering with a drawer directly under the turntable.
Still a further object of the present invention is to provide a system for rotating multiple implements into a work position, incorporating a knee switch for revolving and changing direction of the turn table.
A still further object of the present invention is to provide a system wherein the stops at the end of the 355° rotation reverses rotation of the switch as well as being able to change direction with turning the switch off and then back on.
Still another object of the present invention is to provide a system wherein the manual turntable locks into aposition with a spring-loaded locking pin at a predetermined location which the electric turntable locks into position wherever it stops and is held by a gearing system.
BRIEF DESCRIPTION OF THE FIGURES
These and other objects of the present invention and various features and details of the operation and construction thereof are hereinafter more fully set forth with reference to the accompanying drawings, wherein:
FIG. 1 is a perspective view of a typical configuration of the present invention with two sewing machines mounted on a rotating table that is integral with a sewing cabinet.
FIG. 2 is a top view of the turntable with a sewing machine in the work position and a power cord leading from the sewing machine to a center opening in the turntable and wherein the groove within the rotating turntable is shown in phantom. Only one sewing implement is shown although several machines can be mounted on the turntable.
FIG. 3 is a top view similar to FIGS. 1 and 2 and illustrates the process of rotating the sewing machine to another position.
FIG. 4 is a top view similar to FIGS. 2 and 3 with a sewing machine rotated 180° from its original position.
FIG. 5 is a partial front view of the turntable system with the turntable elevated showing the turntable, locking pin, and groove.
FIG. 6 is an enlarged exploded view of the locking pin and track.
FIG. 7 is an enlarged, fragment sectional view taken on line 7 — 7 of FIG. 2 with locking pin engaged in a stop position in the track.
FIG. 7A is a further enlarged view of FIG. 7 showing details of the locking pin.
FIG. 7B is a view similar to FIG. 7A with the locking pin disengaged from its stop position.
FIG. 8 is an exploded view of turntable construction elements and assembly.
FIG. 8A is a partial section elevation view of the turntable support illustrating the power cord cutout and cutout cap.
FIG. 8B is a view taken along line 8 B— 8 B of FIG. 8A showing the power cord cutout and cutout cap.
FIG. 9 is a top view of the turntable assembly with the mounting plate removed to show the motorized gear mechanism for rotating the turntable.
FIG. 10 is a fragmentary view of the gear mechanism with the drive gear rotating in a counter clockwise direction. The stop projection on the driven gear is approaching the fixed reversing switch.
FIG. 11 is a fragmentary view of the drive gear mechanism showing the stop projection depressing the plunger of the reversing switch.
FIG. 12 is a fragmentary view with the motor turning the drive gear in a clockwise direction, the stop projection on the driven gear has rotated approximately 355° and is approaching the reversing switch in the opposite direction.
FIG. 13 is a sectional front view of the turntable assembly and motor taken along line 13 — 13 of FIG. 9 .
FIG. 14 is an enlarged view of circled view 14 of FIG. 13 illustrating details of the attachment of ball bearing supported turntable assembly.
FIG. 15 is an enlarged view of circled view 15 of FIG. 13 illustrating details of the drive and driven gears of the motorized turntable assembly.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
It will be appreciated by those skilled in the art that the turntable system described hereinafter has application to many different kinds of appliances, machines, and tools. For example, the turntable system of the present invention may find application in a motorized turntable wherein several kitchen appliances are mounted such as a mixer, electric can opener, blender and the like. To illustrate the principles of the present invention, a sewing machine application is described.
Referring now to FIG. 1, there is shown a sewing system 10 of the present invention comprising a generally rectangular shaped sewing cabinet 11 , turntable 20 , and sewing machines S 1 and S 2 . Sewing cabinet 11 is illustrative of one of several sewing cabinet models having a cabinet top 12 , drop leaf 13 on one side of sewing cabinet 11 , drawers 14 for storing sewing accessories and file folders, adjustable shelves 15 , a center kneehole drawer 16 , and a knee activated switch 17 . Shelves (not shown) may also be provided at the form and potion of knee hole. Sewing system 10 is illustrated in a typical configuration with drop leaf 13 in a down position, sewing machine S 1 on turntable 20 is in the work position and sewing machine S 2 in an idle position. Electrical power cords C 1 and C 2 extending from S 1 and S 2 are routed through spindle opening 19 (see FIG. 2) on turntable 20 to a power receptacle (not shown) attached within kneehole of sewing cabinet 11 . Turntable 20 is positioned in a recessed circular cut out 18 (FIG. 5) on cabinet top 12 of sewing cabinet 11 such that cabinet top 12 and turntable 20 are coplanar with no height discontinuities. Equal amounts of the front and back of turntable 20 are removed so as to form straight edges 27 and 28 on the front and back so as to conform to cabinet 11 width dimension.
Top views of turntable 20 on cabinet top 12 of cabinet 11 shown in FIGS. 2, 3 , and 4 with sewing machine S 2 removed for clarity purposes, illustrate positional accommodation of sewing system 10 . A 355° channel cut into cabinet top 12 of cabinet 11 constitutes a circular track 21 that guides turntable 20 to user desired positions. In FIGS. 5, 6 and 7 rotation handle 31 and locking pin 23 ride on a circular metallic insert 32 embedded in circular track 21 providing means for manually rotating sewing machines S 1 and S 2 from one position to another. Locking holes are formed by drilling through metallic insert 32 and partially into cabinet top l 2 within the channel of circular track 21 . Locking holes 24 , 25 , and 26 are typical examples of pre-positioned stops on circular track 21 although stops may be positioned anywhere along circular track 21 at the discretion of the user. Spring 30 is compressed when locking pin 23 is riding on metallic insert 32 . When a locking hole is encountered, spring 30 forces locking pin 23 into a locking hole thus preventing further rotation until locking pin 23 is manually lifted out of the locking hole. In FIG. 2, locking pin 23 is engaged in locking hole 24 . Likewise, in FIG. 3, turntable 20 has been rotated 90° and locking pin 23 is engaged in locking hole 25 . In FIG. 4, sewing machine S 1 is shown rotated approximately 180° from its original position with locking pin 23 inserted in locking hole 26 . Electrical power cords C 1 and C 2 are fed through spindle opening 19 in the center of turntable 20 and routed through cutout 40 shown in FIGS. 8A and 8B to electrical receptacle (not shown) on the underside of cabinet top 12 . Closure 41 retains electrical cord C 1 in cutout 40 and prevents electrical cord C 1 from sagging and becoming entangled. This arrangement allows electric power cords C 1 and C 2 to move with sewing machine S 1 an S 2 without constraining rotational motion.
Details of the manual version of sewing system 10 are illustrated in FIGS. 5, 6 , and 7 and is comprised of turntable 20 , spindle shaft 22 , locking pin 23 , circular track 21 , spring 30 , rotation handle 31 , and metallic insert 32 in circular track 21 . FIG. 7 is an enlarged assembly view of locking pin 23 and rotation handle 31 . Spring 30 is compression biased between upper and lower spring retainers 33 and 33 a respectively so that a downward force is continually exerted on locking pin 23 . Cotter pin 34 maintains lower spring retainer 33 a on locking pin 23 while shoulder 20 a in inverted T shaped circumferential groove 20 b in turntable 20 retains upper spring retainer 33 on locking pin 23 . FIGS. 7A and 7B are expanded detail views showing the operation of locking pin 23 . The flanged upper end 23 a of locking pin 23 is retained within an internal slot 31 a of rotation handle 31 such that when rotating turntable 20 , handle 31 is free to rotate on locking pin 23 thereby allowing locking pin 23 to remain in a fixed orientation. In FIG. 7A, it can be seen that locking pin 23 through the action of compression biased spring 30 has been inserted in locking hole 24 while in FIG. 7B a manual upward force has released locking pin 23 from locking hole 24 allowing turntable 20 to be rotated.
When assembled turntable 20 is secured to cabinet top 12 by ball bearing raceway 42 as shown in FIGS. 13 and 14. To rotate turntable 20 , on ball bearing raceway 42 , locking pin 23 is released from its locking hole 24 with an upward pull on rotation handle 31 compressing spring 30 . Turntable 20 can then be rotated in circular track 21 to a new position. When the new position is reached rotation handle 31 is released forcing locking pin 23 into a new locking hole as shown in FIGS. 3 and 4.
A motorized embodiment of sewing system 10 is shown in an exploded view in FIG. 8 and is comprised of turntable 20 , spindle shaft 22 , drive gear 35 , drive shaft 35 a , driven gear 36 , ball bearing raceway 42 , reversing switch 38 , and electric motor 39 . Motorized turntable 20 is positioned in a recessed circular cut out 18 on cabinet top 12 such that cabinet top 12 and turntable 20 are coplanar with no height discontinuities. Equal amounts of the front and back of turntable 20 are removed so as to form straight edges 27 and 28 conforming to sewing cabinet 11 width dimension. Electrical Cord C 1 from sewing machine S 1 to electrical outlet (not shown) is routed through cutout 40 on the under surface of cabinet top 12 . Electrical cord C 1 is supported in cutout 40 by closure 41 which snaps into cutout 40 thereby constraining electrical cord C 1 and preventing entanglement as shown in FIGS. 8A and 8B. Referring again to FIG. 8, drive shaft 35 a is connected to electric motor 39 . Driven gear 36 has internal gear teeth 36 a and is attached to the underside of turntable 20 . Referring now to FIG. 9 in conjunction with FIGS. 13, 14 , and 15 , top plate 43 of ball bearing raceway 42 and driven gear 36 are bolted to turntable 20 . Bottom plate 44 of ball bearing raceway 42 is bolted to recess 18 of cabinet top 12 . Top plate 43 is free to rotate on ball bearings 45 while bottom plate 44 remains stationary. When power is applied to electric motor 39 , it rotates drive gear 35 whose teeth 35 b are in meshed contact with gear teeth 36 a of driven gear 36 causing driven gear 36 , turntable 20 , and top plate 43 to rotate. Turntable 20 may be stopped at any position within its 355° travel by simply removing power to electric motor 39 . When turntable 20 has reached its travel limit in one direction, means are provided to reverse motor 39 polarities to rotate turntable 20 in the opposite direction. Referring now to FIGS. 10, 11 , and 12 , pin 36 b on the outer perimeter of driven gear 36 rides in channel 37 and when in contact with reversing switch 38 , power to motor 39 is reversed turning drive gear 35 in the opposite direction and counter rotating driven gear 36 . In this motorized embodiment, switch 45 prevents rotation beyond 355°. When pin 36 b on the outer perimeter of driven gear 43 as shown in FIGS. 10 and 11, contacts switch 38 , power to motor 39 is reversed turning drive gear 35 in the opposite direction and counter rotating driven gear 36 as shown in FIG. 12 .
Even though particular embodiments of the present invention have been illustrated and described herein, it is not intended to limit the invention and changes and modifications may be made therein within the scope of the following claims. | A system facilitating the use of multiple sewing machines mounted on a sewing cabinet is disclosed. A circular turntable on which multiple sewing machines are mounted can be activated either manually or with an electric motor to rotate a desired sewing implement to the working position. The cabinet is designed for maximum storage space in a minimum of wall space. Different models provide up to five drawers and eight shelve as well as a drop leaf for increased table area. The system has surge protected outlets with an on/off switch and an electric cord that can be plugged into any household outlet. | 3 |
BACKGROUND
1. Field of the Invention
Embodiments of the present invention relate to techniques for performing reliability testing in computer systems. More specifically, embodiments of the present invention relate to a method and an apparatus for performing swept-sine testing within a computer system to assure vibrational integrity.
2. Related Art
Some computer systems and storage arrays are adversely affected by vibration of system components. These vibrational problems are becoming increasingly more common because of the following trends: (1) cooling fans are becoming powerful; (2) chassis and support structures are becoming weaker because of design modifications to reduce cost and weight; and (3) internal disk drives, power supplies, and other system components are becoming more sensitive to vibration-induced degradation. For example, hard disk drives (HDDs) are becoming more sensitive to vibration because the storage density for HDDs has increased to the point where a write head has to align with a track which is less than 20 nanometers wide. Moreover, the write head floats only 7 nanometers above the disk surface. These extremely small dimensions make the read and write performance of the HDDs very sensitive to vibrations.
Complicating this issue, some computer systems and storage arrays do not lock fan speeds at fixed number of revolutions per minute (RPM). Instead, the fan speeds can vary. For example, at higher altitudes, where the air is thinner, fan blades turn faster. In fact, between sea level and 10,000 ft, fan speeds can vary by 10% or more.
These fan speed variations can cause vibrational resonances inside the chassis of a computer system. When the fan speed intersects an internal vibrational resonance, there can be a significant resonance-related amplification of the vibrations which can cause components such as disk drives and power supplies to fail.
Because fan speeds can vary with altitude, a system that is tested and qualified in a lab at one altitude may get distributed in the field at another altitude where the fan speed intersects a vibrational resonance, which can cause failures. A related problem is that new systems tend to have very low rotational friction for fan motors. With age, ball bearings lose roundness, lubrication dries out, and shaft axes gain eccentricity. Consequently, rotational friction increases and fan speeds can drop with age due to the increase in rotational friction. These effects mean that even if a system is qualified to have good vibrational integrity when the system is manufactured, if there are any structural resonances in the vicinity of the rotational frequency of the fans, the system may subsequently fail in the field.
In order to avoid the damage that can be caused by vibration, some system designers test prototypes of computer systems and storage arrays with a technique called “swept-sine” testing. Swept-sine testing is common for safety-critical mechanical systems such as aircraft and nuclear power plants, where the presence of structural resonances can have catastrophic consequences. To examine computer systems or storage arrays for the presence of structural resonances, system designers typically bolt a system under test onto a large programmable “shake table” that inputs a vibrational stimulus at a fixed frequency. The system designer then “sweeps” this frequency from a starting frequency (e.g. 1 kHz or 10 kHz) down to a very low frequency. By monitoring one or more vibration sensors (accelerometers) placed on or inside the system under test, the system designer can “map” the frequencies corresponding to vibrational resonances inside the system.
When the frequencies of the resonances are known, the system designer can adjust the fan speeds (and the speeds of other devices such as disk drives, tape drives, etc.) to avoid vibrations in the vicinity of the resonances. Alternatively, the system designer can mitigate the resonances. For example, the system designer can place a small mass, a dampener, or a stiffener at a specific location in the system.
The difficulty with the above-described approaches is that a customer may reconfigure their computer system, by adding and/or removing one or more system components. This changes the mass distribution of the system, which can create new structural resonances that can cause drive failures and can accelerate degradation of other system components.
For many computing systems, especially midrange and high-end systems, it is impossible to anticipate all the potential combinations of vendor and 3rd-party components that customers may install over the life of their computer system. Consequently, in order to accurately determine if new vibrational resonances are introduced in the system when a customer makes a configuration change, the system needs to be shipped to a facility with a shake table and retested.
Hence, what is needed is a method and apparatus for performing vibrational testing without the above-described problems.
SUMMARY
Embodiments of the present invention provide a system that performs vibration testing in a computer system. The system starts by generating a vibration at a predetermined frequency in a computer system. The system then determines if the computer system has a resonance at the predetermined frequency. If so, the system adjusts an operating parameter of at least one computer system component to prevent the computer system component from vibrating at or near a resonance frequency.
In some embodiments, when adjusting the operating parameter of the computer system component, the system adjusts the speed of a fan or an operating speed of a disk drive or a tape drive.
In some embodiments, the system generates vibrations across a range of frequencies in the computer system. The system then determines if the computer system has one or more resonances in the range of frequencies. If so, the system adjusts an operating parameter of at least one computer system component to prevent the computer system component from vibrating at or near the one or more resonances.
In some embodiments, the system outputs a representation of the resonances to a user, which enables the user to adjust an operating parameter of the system component to prevent the system component from vibrating at or near the resonance.
In some embodiments, the system generates the vibration at a predetermined time, wherein the predetermined time can include: (1) when the computer system is initially configured; (2) when the computer system's configuration is changed; or (3) when the computer system has been running for a pre-specified time.
BRIEF DESCRIPTION OF THE FIGURES
FIG. 1 illustrates a server in accordance with embodiments of the present invention.
FIG. 2 presents a flowchart illustrating the process of performing a swept-sine test in a computer system in accordance with embodiments of the present invention.
FIG. 3 presents a graph of resonances in accordance with embodiments of the present invention.
DETAILED DESCRIPTION
The following description is presented to enable any person skilled in the art to make and use the invention, and is provided in the context of a particular application and its requirements. Various modifications to the disclosed embodiments will be readily apparent to those skilled in the art, and the general principles defined herein may be applied to other embodiments and applications without departing from the spirit and scope of the present invention. Thus, the present invention is not limited to the embodiments shown, but is to be accorded the widest scope consistent with the claims.
Computer System
FIG. 1 illustrates a server 100 in accordance with embodiments of the present invention. Server 100 includes vibration-generation device 102 and accelerometer 104 . Note that although server 100 is used for the purposes of illustration, embodiments of the present invention can be applied to other computer systems, such as desktop computers, workstations, embedded computer systems, automated manufacturing systems, and other computer systems where vibrations can affect the life-span of system components.
In some embodiments of the present invention, vibration-generation device 102 is a transducer that accepts an input signal and outputs mechanical vibrations. The frequency of the mechanical vibrations vary according to the magnitude of an input voltage.
Accelerometer 104 measures the responding vibrations of the server while vibration-generation device 102 is outputting mechanical vibrations at a given frequency. Note that although server 100 is illustrated with one accelerometer 104 , in some embodiments of the present invention, other components in server 100 that are to be protected from destructively amplified resonance vibrations also include accelerometers. For example, disk drives, peripheral boards, system board components, tape drives, ASICs, mounting brackets, and other components in the system may include one or more accelerometers. (Some commercial off-the-shelf (COTS) HDDs are already being manufactured with one or two internal accelerometers which can be used to measure the vibration experienced by the HDDs.)
When performing a swept-sine test (e.g., following a configuration change), the voltage input into vibration-generation device 102 can be swept through a range of voltages to produce a vibrational frequency range known to encompass the rotational frequencies for all components (fans, disk drives, tape drives, etc.) in the system. During the sweep, vibration-generation device 102 can also be configured to simulate vibrational frequencies that arise from “beat” phenomena (which can occur if 2 devices have close rotational frequencies).
In some embodiments of the present invention, vibration-generation device 102 is a COTS vibrator, such as the vibrators used in cell phones (although vibration-generation device 102 is modified to output vibrations at differing frequencies according to variations in an input voltage). The amplitude of vibration for these COTS vibrators is even sufficient for resonance mapping applications in high end servers because resonances can be identified at small vibrational amplitudes.
In some embodiments of the present invention, firmware included in server 100 performs swept-sine test when a configuration change has occurred (or at other predetermined times). Hence, internal resonance mapping can be performed in the factory, in Ongoing Reliability Testing (ORT), or in the customers' datacenter. In other words, systems no longer need to be shipped to a facility containing programmable shake tables in order to perform swept-sine testing. Moreover, computer systems can be tested in the actual “vibrational environment” in which they operate. For example, a swept-sine test can be performed on a computer system on a factory floor where the computer system picks up vibrations from nearby machines. In alternative embodiments, software such as the operating system triggers the swept-sine test when a configuration change has occurred (or at other predetermined times).
Note that in these embodiments, the swept-sine testing mechanism can be built in to the computer system or storage device (meaning that accelerometer 104 , vibration-generation device 102 , and other components that perform the swept-sine test are permanently coupled to the computer system).
In alternative embodiments, the mechanism for performing the swept-sine test is a separate device, which is coupled to the computer system to perform the swept-sine test. For these embodiments, accelerometer 104 , vibration-generation device 102 , and other components used during the swept-sine test are temporarily attached to server 100 .
Swept-Sine Testing Process
FIG. 2 presents a flowchart illustrating the process of performing a swept-sine test in a server 100 (see FIG. 1 ) in accordance with embodiments of the present invention. At a predetermined time, a vibration-testing mechanism runs a swept-sine test on server 100 and maps the resonant frequencies (step 200 ). This predetermined time can occur: (1) when the server 100 is initially set up; (2) when a hardware configuration change occurs; or (3) when server 100 has been operating for a sufficient length of time (e.g., 6 months, 1 year, or 2 years).
While running the swept-sine test, the vibration-testing mechanism sweeps the voltage input to vibration-generation device 102 across a range of voltages. In response, vibration-generation device 102 outputs mechanical vibrations across a corresponding range of frequencies. While vibrational testing mechanism sweeps the vibration-generation device 102 through the range of frequencies, a data-acquisition mechanism collects a sequence of vibration samples from accelerometer 104 .
The vibration-testing mechanism then analyzes the resonances (step 202 ). In other words, the vibration-testing mechanism examines the sequence of vibration samples collected by the data-acquisition mechanism to determine if there are any frequencies (resonances) at which the vibration detected by accelerometer 104 surpasses a given threshold.
The system then adjusts system parameters to avoid creating resonances within the server during operation (step 204 ). In some embodiments of the present invention, the system uses administrative controls to limit the speeds of fans in server 100 to avoid the resonances. For example, if a fan typically runs at 240 Hz and a customer memory upgrade creates a resonance at about 238 Hz, the system could set an administrative fan control speed at 250 Hz. In this case, if the nominal fan speed is moved to be higher than the new structural resonance and adequate cooling is still obtained, but destructive amplification of internally excited vibrations is now avoided. In some embodiments, the system uses the administrative controls to limit the rotational velocity of tape drives, optical drives, or hard drives, and to limit the activities of other system components to avoid vibrational resonances.
FIG. 3 presents a graph of resonances in accordance with embodiments of the present invention. The presence of spectral “ridges” at certain frequencies in FIG. 3 indicates the structural resonances in the system.
In some embodiments, the vibration-testing mechanism creates an output such as the graph in FIG. 3 . Using such a graph, a user can visually interpret server 100 's response to vibrations and can use administrative controls to accordingly limit vibrations in server 100 . For example, given a resonance at 380 Hz (as shown in FIG. 3 ), the user can adjust fan speeds, drive speeds and can limit the activities of other system components in order to avoid the 380 Hz resonance.
The foregoing descriptions of embodiments of the present invention have been presented only for purposes of illustration and description. They are not intended to be exhaustive or to limit the present invention to the forms disclosed. Accordingly, many modifications and variations will be apparent to practitioners skilled in the art. Additionally, the above disclosure is not intended to limit the present invention. The scope of the present invention is defined by the appended claims. | Embodiments of the present invention provide a system that performs vibration testing in a computer system. The system starts by generating a vibration at a predetermined frequency in a computer system. The system then determines if the computer system has a resonance at the predetermined frequency. If so, the system adjusts an operating parameter of at least one computer system component to prevent the computer system component from vibrating at or near a resonance frequency. | 6 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of International Application No. PCT/FI2005/000007 filed Jan. 5, 2005, designating the United States and claiming priority from application Ser. No. FI20040157 filed in Finland on Feb. 2, 2004, the disclosures of both foregoing applications being incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] The present invention relates to an arrangement for coupling pallets of a travelator or equivalent.
[0003] Like escalators, travelators are conveying devices used to move people and goods. They differ from escalators e.g. in that they often work in a substantially horizontal position or in a position slightly inclined relative to their direction of motion, so that successive steps, i.e. pallets, form a substantially even and rectilinear transport track instead of stair-like steps as in escalators. Travelators are also referred to as moving sidewalks and autowalks.
[0004] In known travelators, autoramps and escalators, the pallets or steps are typically connected to an endless chain, belt or equivalent serving as a drive element by means of a separate coupling element. In known solutions, the coupling arrangements are complicated and often also require the use of special tools for the coupling to be successfully performed in the desired manner. Long travelators contain a large number of pallets, each one of which has to be coupled to the drive element either by one end or by both ends. These known coupling solutions and the associated adjustments are slow and complicated to implement, which is why the installation times are very long, especially when long travelators are to be installed. This is expensive and otherwise undesirable. In addition, maintenance and repair operations take a longer time because the release and re-mounting of known coupling elements is a slow process. Coupling elements of a larger size, which take up space around their path of motion and add to the weight of the structures present further problems. An additional problem in known coupling elements is the chain serving as a drive element, which has to be of a special construction due to the coupling. Such a chain, which is specific only to a given application, is generally expensive and may be difficult to obtain in urgent cases of repair.
SUMMARY OF THE INVENTION
[0005] An object of the present invention is to overcome the above-mentioned drawbacks and to achieve an arrangement for coupling pallets of a travelator, moving ramp or escalator or an equivalent apparatus, an arrangement that is of economical cost and allows easy coupling, and wherein the pallet is coupled especially to a chain functioning as a drive element moving the pallets.
[0006] The above and other objects are achieved according to the invention by the provision of an arrangement for coupling a pallet in a conveying device which in one exemplary embodiment includes: a pallet having wheels and forming a part of a transport track of the conveying device; a drive element; a coupling piece adapted to be connected to the pallet; and a fastening part connecting the drive element to the coupling piece.
[0007] The advantages provided by the pallet coupling arrangement of the invention include easy and fast installation, which means that the installation, maintenance and repair times are short and consequently the downtimes are also short. In addition, the coupling solution is simple and reliable, so the coupling is safe and requires no special tools in order to be successfully carried out. A further advantage is that the drive elements used may consist of standard chains, which are economical and quickly available when needed. Yet another advantage is that the coupling element is of small size and light weight, so the coupling solution does not take up much space around its path and the coupling pieces do not strain the travelator structures by their weight. A significant advantage is that the pallet can be connected to the chain from above. Thus, the pallet can be easily fastened to the chain during installation, and during maintenance or repair the pallet can be easily released from the chain and secured to it again. In the further exemplary embodiments of the invention, the pallet can be lowered to its position relative to the chain and the pallet track and connected to the chain without lateral movement of the chain or the pallet lowered into position. As the connection is easy to make and release, installation and maintenance work requires less time.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] In the following, the invention will be described in detail with reference to an exemplary embodiment and the accompanying drawings, wherein:
[0009] FIG. 1 shows an oblique top view of a typical pallet in which the coupling arrangement of the invention can be used;
[0010] FIG. 2 shows a more detailed view of the pallet of FIG. 1 as seen from the end of the pallet;
[0011] FIG. 3 shows an oblique top view of the main components of the pallet coupling arrangement according to an exemplary embodiment of the invention;
[0012] FIG. 4 shows a detail of a pallet coupling arrangement according to according to another exemplary embodiment of the invention in oblique top view;
[0013] FIG. 5 shows an oblique top view of the main components of the pallet coupling arrangement of an exemplary embodiment of the invention in an assembled state; and
[0014] FIG. 6 shows a top view of a pallet provided with a pallet coupling arrangement according to a further exemplary embodiment of the invention.
DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS
[0015] Referring to FIG. 1 , there is shown a pallet structure 1 comprising a pallet body 3 , which has preferably been produced by extruding a suitable profile from aluminum or some other appropriate metal or metal alloy. During manufacture of the profile, a given profile is extruded in bars of a length suited for manufacture, transport or other purposes. Later during manufacture of the pallet, parts of a length exactly suited for the purpose are cut from these profiled bars. Thus, the same profile can easily be used for pallets of different lengths, which makes it easy to vary the width of the conveyor track of the travelator. Secured to the pallet body 3 are wheels 4 at each end of the pallet and likewise at least at one end a fastening element 20 (see for example FIGS. 3 and 5 ), by which the pallet 1 is coupled to an endless chain, toothed belt, rope or equivalent actuating element serving to move the pallets. The fastening element 20 is secured e.g. to a mounting hole 5 ( FIGS. 1 and 2 ) provided at the end of the body 3 . The holes and other shapes provided in the body 3 for mounting the fastening elements and wheels may be profile shapes or separately made in the profile.
[0016] As shown in FIG. 2 , a surface part extruded from plastic or equivalent material is fastened onto the body 3 of the pallet 1 e.g. by snap-on couplings or corresponding shape-locked couplings. The surface part preferably consists of one or more surface plates 2 a - 2 c ( FIG. 1 ) of suitable width, which are also provided with the necessary corrugations in the direction of the pallet track. Each surface plate 2 a - 2 c is provided with snap-on coupling elements or corresponding coupling elements 6 , preferably in the lower part or on the lower surface of the surface plates, placed at suitable points, for example at the ends and in the middle part of the surface plates. The surface plates are thus firmly held in position on the pallet body 3 and can be easily pressed into position and also easily released from the body using a tool suited to the purpose. Correspondingly, placed at suitable points in the upper part of the pallet body 3 are counterparts 7 corresponding to the aforesaid coupling elements, so that the coupling elements 6 can be fastened to the counterparts in a shape-locked manner.
[0017] The width of the surface plates 2 a - 2 c is so defined that, using a suitable number of surface plates of the same width, it is possible to cover pallet bodies of different lengths, so the same parts can be used to assemble pallets of different lengths.
[0018] FIGS. 1 and 2 show a pallet 1 provided with differently colored surface plates 2 a and 2 b and also transparent or translucent surface plates 2 c. A notice, advertisement or other element varying the appearance, printed on paper, plastic or equivalent material may be placed under the transparent or translucent surface plates 2 c, between the body 3 and the surface plate 2 c. By illuminating such an element from below or from the side, various visual effects can be produced. The transparent or translucent surface plates 2 c are preferably placed in the middle part of the pallet 1 . By disposing surface plates of different colors in different places in the longitudinal direction of the pallet 1 , the appearance of successive pallets may be varied. Thus, the appearance of the conveyor track of the travelator may be easily to changed.
[0019] The body 3 of the pallet 1 consists of one or more profiled parts placed side by side. The body 3 is preferably composed of two body halves consisting of identical, mutually upside-down oriented profiled parts, which are also horizontally conversely arranged. Thus, the two halves of the body can be easily cut off the same profiled bar and turned into mutually opposite positions and joined together during assembly of the body.
[0020] FIGS. 3-5 present a fastening element 20 used in the coupling arrangement of the invention, designed to connect the pallet to the chain 12 that moves the pallets. The fastening element 20 comprises at least a coupling piece 8 , a cylindrical shaft 9 fixedly secured to the coupling piece 8 and a locking element 13 , such as a spring. Two downwards-opening slots 10 are provided in the lower surface of the coupling piece 8 . The distance between the slots 10 corresponds to the distance between holes in the chain 12 . The slots 10 extend in the same direction as the shaft 9 which is transversely, i.e. perpendicularly, to the direction of motion of the pallets 1 . The width, height and radius of curvature at the upper edge of the slots 10 are designed so that two fastening pins 11 of a diameter corresponding to that of a normal chain pin can be inserted into the slots 10 , yet without making the slot-and-pin coupling too loose. Since there are chains of many widths, the fastening pins 11 used may be normal longer chain pins of a wider chain instead of separate fastening pins. In this case, the longer chain pins function as fastening pins 11 . Hereinafter, ‘fastening pins’ 11 refers to both longer chain pins and fastening pins specially made for this purpose.
[0021] The spring used as a locking element 13 is of a size and shape such that it can be locked onto the coupling piece 8 by spring force. The locking element 13 is a roughly U-shaped piece made from thin sheet metal, and it has in its bottom part two protrusions 14 whose size, orientation and mutual distance correspond to the size, orientation and mutual distance of the slots 10 . Moreover, the locking element 13 has at each upper edge an inward elbow 21 , which is fitted to meet the upper surface of the coupling piece 8 when the pallet is coupled to the chain.
[0022] FIG. 4 presents a more detailed view of the counter-structure in the body part of the pallet 1 for coupling the fastening element 20 to the pallet 1 . The body 3 may be provided with a separate coupling piece 15 as shown in the figure, with a mounting hole 16 for the shaft 9 of the fastening element, or the body may be provided with a mounting hole 5 corresponding to hole 16 as mentioned above. In this case, no coupling piece 15 is needed. From the point of view of the invention, either solution will serve the same purpose. The mounting hole 5 , 16 , which is located at the end of the pallet in the area between the wheels 4 , is provided with bushes 17 functioning as slide bearings so that, when mounted in the mounting hole 5 , 16 through the bushes 17 , the outer end of the shaft 9 extends over the innermost bush 17 . This protruding outer end of the shaft is provided with a groove 22 whereby the shaft is locked in position in the axial direction by means of a circlip 18 . A further feature characteristic of the shaft 9 is that the shaft 9 extends in the same direction as the fastening pins 11 and substantially in the same plane with the axes of the fastening pins, preferably at an equal distance from the axes of the fastening pins.
[0023] If the shaft 9 is locked directly to the mounting hole 5 going through the entire pallet, then the lower surface of the pallet body has to be provided with recesses 19 as shown in FIG. 6 to allow the outermost bush 17 and the circlip 18 to be mounted in place. On the other hand, if a separate coupling piece 15 is used, then the pallet body has to be provided with a suitable space for this purpose.
[0024] FIG. 5 presents the pallet coupling arrangement in an assembled state. The coupling piece 15 may represent a separate piece or also a part of the pallet body. At the coupling point, instead of normal chain pins, the chain 12 may be provided with longer fastening pins 11 , the other ends of which are inserted into the slots 10 in the lower surface of the coupling piece 8 so that the front surface of the coupling piece 8 is as close to the chain 12 as possible or in contact with the chain. With the fastening pins 11 in the slots 10 , the locking element 13 is set from below onto the coupling piece 8 so that the protrusions 14 in the bottom of the locking element 13 press the fastening pins 11 against the upper surface of the slots 10 and that the elbow 21 extending inwards at each upper edge of the locking element 13 meets the upper surface of the coupling piece 8 , pressing the locking element 13 tightly into position.
[0025] The structure of the fastening element 20 may differ from that described above. For example the coupling piece 8 and the locking element 13 may be of some other type than in the above description. The fastening element 20 may be, for example, so constructed that the shaft 9 is not a fixed part of the coupling piece 8 , but instead the coupling piece 8 is provided with a hole which is used to fasten the coupling piece onto a locking shaft locking the two halves of the body 3 together. The end of the locking shaft extends far enough out of the central hole of the body 3 to allow the coupling piece to be locked onto the locking shaft, for example, by a circlip.
[0026] The locking element corresponding to locking element 13 may also be a structure like that presented in FIGS. 7 and 8 . In FIG. 7 , the locking element is a plate 23 which is provided with a central hole substantially corresponding to the cross-sectional shape of the coupling piece 8 and which is placed on the shaft 9 at the mounting stage. After the fastening pins 11 have been mounted into the slots 10 from below, the fastening pins are locked in place by pulling the plate 23 onto the coupling piece, thus preventing them from falling out of the slots. The plate 23 may additionally have at the lower edge of its central hole small upwards acting spring-like parts (not shown) pressing the fastening pins 11 to the slots 10 . Such a structure provides the advantage of easy locking and release. In addition, for example, in connection with maintenance, the plate 23 will not be easily lost as it can be left on the shaft for the time of maintenance.
[0027] In FIG. 8 , the locking element is a spring 24 corresponding to locking element 13 . It has a construction that allows it to be pressed into position from above the coupling piece 8 in the direction of the arrow 25 to lock the fastening pins in the slots 10 . In FIG. 8 , the spring 24 depicted with a broken line represents the position of the spring before the spring 24 is locked in position on the coupling piece. The size of the spring 24 is so designed in relation to the coupling piece 8 that, when mounted in the locking position, the free ends of the spring will press the fastening pins into the slots 10 while the spring is simultaneously pressed against the upper surface of the coupling piece 8 . The advantage of this embodiment is that it permits an easy and quick installation. A correctly designed spring 24 is easy to press onto the coupling piece 8 . Likewise, the spring can be easily removed by means of a suitable tool.
[0028] Similarly, it is obvious that, instead of the use of locking elements 13 , 23 , 24 , the slots 10 may be holes and the ends of the fastening pins 11 projecting from the chain can be locked on the back surface of the coupling piece 8 by means of circlips. In this case, the lower surface of the back part of the coupling piece may be provided with recesses or equivalent to allow the circlips to be mounted from the below. The recesses allow the surface of the locking piece to be evenly set against the pallet body. Instead of circlips, the fastening pins 11 may have bolt-like heads with a diameter larger than the shank part of the pin. In this case, the fastening pins can be inserted into the holes of the coupling piece 8 from the side of the pallet, whereupon the chain 12 is fastened by its holes to the fastening pins. The holes of the coupling piece are in this case provided with countersinks on the back surface for the heads of the fastening pins.
[0029] It is additionally possible that the coupling piece 8 has only one slot 10 or hole, in which is mounted only one fastening pin 11 or equivalent of a design such as a longer chain pin. This may be possible, for example, in light structures or if the chain 12 has thick pins in any case.
[0030] Instead of a fastening pin/fastening pins 11 , the chain may also have another type of fastening part, for example, a chain link shaped to permit fastening or some other detent for engaging the coupling piece 8 . In the case of another type of fastening part, the coupling piece is correspondingly specifically designed as required by such a detent. For example, a tooth-like peg provided with a hole and jutting out laterally from the side plate of a chain link could be coupled in the fastening element by means of a bolt or a suitable cotter pin arrangement.
[0031] It is likewise obvious that the shafts 9 may also function as locking shafts that lock the body structure composed of two separate profiled pieces together as a single assembly.
[0032] It is further obvious that, instead of a chain as described above, it is possible to use different types of chain structures or equivalent as a drive element.
[0033] It is further obvious to the person skilled in the art that the coupling piece 8 may be rigidly fastened relative to the link of the chain 12 , or that the fastening to the pallet is implemented between the joints/pins of the chain 12 at the link whereby the fastening to the chain 12 takes place.
[0034] It will be understood that the above description of the present invention is susceptible to various modifications, changes and adaptations, and the same are intended to be comprehended within the meaning and range of equivalents of the appended claims. | An arrangement for coupling a pallet in a conveying device includes a pallet having wheels and forming a part of a transport track of the conveying device, and a drive element. A coupling piece is adapted to be connected to the pallet and a fastening parties connects the drive element to the coupling piece. | 1 |
BACKGROUND OF THE INVENTION
The present invention relates to a novel shield for a syringe mounted hypodermic needle.
Syringes and hypodermic needles are used very extensively in the medical field to introduce or remove material from the body parenterally. Although hypodermic needles and syringes are quite useful they must be carefully handled by medical practitioners since there is a danger that serious diseases may be spread by an accidental jab from a contaminated hypodermic needle.
In the past, hypodermic needles and syringes have been shipped with a cup which snugly fit over the hub portion of the syringe and extends beyond the end of the hypodermic needle to protect the same. This cap is separable from the needle and syringe combination, and is often lost after initial removal. Also, such cap must be placed on the syringe by exerting force toward the point of the needle. In the past, users have been accidentally pricked by the hypodermic needle when such cap failed to encompass the needle and engage the hub portion of the syringe. Moreover, syringe and needle devices are generally disposable after usage on a single patient. Unfortunately, such discarded syringe and needles have found their way into public areas such as streets, sidewalks, vacant lots, beaches, and the like, causing accidental contact with passersby.
A shield device for a syringe mounted hypodermic needle which overcomes the problems encountered in the prior art would be a great advance in the medical field.
SUMMARY OF THE INVENTION
In accordance with the present invention a novel and useful shield device for a syringe mounted hypodermic needle is herein provided.
The shield of the present invention employs a translucent sheath which extends over the barrel of the hypodermic needle. The sheath is movable relative to the barrel and extendable between the flange end of the syringe barrel and the tip of the syringe. Such, the sheath may be described as extending to a first position adjacent the flange end of the barrel of the syringe and to a second position beyond the point of the hypodermic needle.
Stop means may be provided for limiting movement of the sheath between the flange end of the syringe and the tip end of the syringe. Such stop means may take the form of an obstruction placed at either end of the syringe barrel to engage a portion of the shield.
Means may also be provided in the present invention for holding the sheath in a first extended position adjacent the flange end of the barrel or a second extended position beyond the point of the hypodermic needle. Of course, the latter position would protect the user from being jabbed by the end of the hypodermic needle while handling the needle and syringe. Such holding means may be accomplished by the provision of including a tapered inner wall of the translucent sheath which is engageable with the outer surface of the barrel of the syringe. Such a structure is particularly auspicious when the sheath is extended the point of the tip of the needle i.e. in the second extended position. In this regard, the syringe may be fitted with a collar which permits engagement between the tapered inner wall of the sheath and the syringe body. Further, a groove and cooperating protuberance may be fitted onto the syringe or the sheath. Thus, the syringe may include either a groove or a protuberance respectively engageable by a protuberance or groove on the sheath. In certain cases, a plurality of grooves may be placed on either the sheath or syringe to engage a protuberance on the cooperating body, as the case may be.
It may be apparent that a novel and useful shield device for a needle and syringe has been described.
It is therefore an object of the present invention to provide a shield device for a syringe mounted hypodermic needle which protects the user of the syringe and needle from accidental jabbing or pricking by the hypodermic needle tip.
It is another object of the present invention to provide a shield device for a syringe mounted hypodermic needle which includes a sheath movable along the exterior of the syringe barrel to multiple positions and is not separable from the syringe and hypodermic needle unit.
Another object of the present is to provide a shield device for a syringe mounted hypodermic needle which is easily retrofitted on existing needle and syringe units and on machines for manufacturing for such needle and syringe units.
Yet another object of the present invention is to provide a shield device for a syringe mounted hypodermic needle which is simple and inexpensive to manufacture, permitting disposal with a disposable needle and syringe unit.
A further object of the present invention is to provide a shield device for a syringe mounted hypodermic needle which is safely usable by a medical practitioner requiring a force exerted away from the needle point in order to protect the same.
Another object of the present invention is to provide a shield device for a syringe mounted hypodermic needle which protects the point of a hypodermic needle after disposal of the same.
A further object of the present invention is to provide a shield device for a syringe mounted hypodermic needle which does not interfere with the visual acquiring of measurement data and indicia appearing on the external surface of a syringe barrel.
Yet another object of the present invention is to provide a shield device for a syringe mounted hypodermic needle which prevents the spread of diseases.
The invention possesses other objects and advantages especially as concerns particular character characteristics and features thereof which will become apparent as the specification continues.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a front elevational view showing an embodiment of the present on a needle and syringe unit, as well as a prior art cap, shown in phantom.
FIG. 1A is broken, sectional, enlarged view of the needle and syringe unit depicted in FIG. 1.
FIG. 2 is a side elevational view depicting the partial operation of the embodiment depicted in FIG. 1 with the prior art cap removed and shown in phantom.
FIG. 3 is a side view of the needle and syringe unit depicted in FIGS. 1 and 2 with the shield device depicted in section.
FIG. 3A is a broken, sectional, enlarged view of the needle and syringe unit depicted in FIG. 3.
FIG. 4 is a side elevational view of a needle and syringe unit depicting another embodiment of the present invention in section.
FIG. 5 is a side elevational view of the embodiment of the present invention depicted in FIG. 4 showing the sheath member in one of its extended positions.
FIG. 6 is a top partial isometric view of a portion of the sheath depicting an embodiment of a protuberance on its inner surface.
For a better understanding of the invention reference is made to the following detailed description of the preferred embodiments thereof which should be referenced to the hereinabove described drawings.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The embodiment of the invention as a whole depicted in the drawings by reference characters 10 and 10A. FIGS. 1-3 illustrate shield device 10 which is usable with syringe 12 and hypodermic needle 14, forming a unit 16.
Hypodermic needle 14 includes a hollow cannula 18 with a ground point 20. A hub 22 connects to cannula 18 opposite to points 20 of cannula 18. Hub 22 may or may not detachably fit to the tip 24 of syringe 12. Tip 24 lies at one end of syringe barrel 26, best shown in FIG. 3. A flange 28 lies at the other end of barrel 28 from tip 24. A piston or plunger 30 closely fits the interior of barrel 26 to draw liquids therein and to force liquids out of the interior of barrel 26. It should be noted that the end of piston 30 includes an elastomeric seal 31. Indicia 32 depict the volumetric level of the liquid which may be found in barrel 26 of syringe 12.
Also shown on FIGS. 1 and 2 is a cap 34 which is intended to friction fit to the exterior of hub 22 in order to protect the integrity of point 20 and to prevent jabbing or pricking by point 20 during handling of unit 16. As depicted in FIG. 2, cap 20 has been removed from unit 16. To replace cap 34 over point 20 of cannula 18 would require a motion toward point 20. In the past, this motion has resulted in accidental jabbings by point 20 to someone handling unit 16. In addition, it should be apparent that cap 34 is completely separable from unit 16 and may easily be lost or damaged to the extent that it is not reusable to cover point 20 of cannula 18.
Shield device 10 is depicted in one embodiment, FIGS. 1-3 as including a translucent sheath 36 in the form of a cylindrical body which lies over syringe barrel 26. Translucent sheath 36 may be formed of plastic, glass, or any suitable material compatible with the medical use for unit 16. Sheath 36 includes a flange end 38 which closely fits over the exterior surface 40 of barrel 26. The interior surface 37 of sheath 36 slightly tapers from a large transverse dimension end 42 to a smaller transverse dimension end 44, adjacent flange FIGS. 1A and 3A 38.
Shield device 10 also includes a collar 46 which is friction fitted or formed intergrally with hub 22 of needle 14 or with the tip end of syringe 12. Thus, sheath 36 is extendable to a first position over barrel 26 adjacent flange 28 of syringe 12 and to a second position beyond the point 20 of hypodermic needle 14, FIG. 1 and 3, respectively. The small diameter end 44 of shield 36 frictionally engages the exterior surface 53 of collar 46 in the extended position depicted in FIG. 3. Thus, stop means 48 is provided for limiting the movement of sheath 36 between the flange 28 of syringe 12 and the tip 24 of syringe 12. Such stop means 48 may take the form of contact between the inner transverse surface 46 of flange 38 and collar 46, as well as contact between the outer transverse surface 51 of flange 38 and flange 28 of syringe 12. It should also be observed, that the outer surface 40 of syringe barrel 26 slightly tapers to a large transverse dimension to adjacent flange 28 of barrel 26 and to a smaller transverse dimension adjacent tip 22. Thus, the interaction of the outer surface 53 of collar 46 with the interior surface 37 of the small end 44 of sheath 36, FIG. 3 and 3A, and the interaction of flange 38 with the exterior surface 40 of barrel 26, FIG. 1 and 1A serve as holding means 50 to maintain sheath in either of the extended positions depicted, therein. In addition, such interactions may also serve as stop means 48 hereinabove described.
Turning to FIGS. 4-6, a syringe 12A is depicted having piston 30 (partially illustrated) which fits within a barrel 26A. The outer surface 40A of barrel 26A includes a pair of circumferential grooves 52 and 54.
Sheath 56 is formed with a flange 58 at end portion 60. A plurality of protuberances 62 extend inwardly at flange 58 and are capable of stopping and holding sheath 56 along its travel, shown by directional arrow 64, at grooves 52 and 54, FIGS. 4 and 5, respectively. As may be apparent from FIGS. 4 and 5, the holding of sheath 56 in such positions either exposes hypodermic needle 14 for use or covers the same when hypodermic needle 14 is not in use or to be disposed. Stepped down portion 66 of sheath 56 includes a shoulder 68 which may ride against end surface 70 of barrel 26A. Since sheath 56 is translucent, indicia 32A are clearly visible when covering barrel 26A.
In operation, the user of shield device 10 would retract sheath 36 to the position shown in FIG. 1. The interaction of flange 38 of sheath 36 and the exterior surface 40 of barrel 26 would stop any further movement of sheath 36 toward flange 28 of syringe 12. Needle and syringe unit 16 may be used in the conventional manner at this point by the movement of plunger 30 depicted in FIG. 2. After use or before reuse, in certain cases, sheath 36 would be extended into the position depicted in FIG. 3. The interaction of flange 38 of sheath 36 and collar 46 would stop and hold sheath 36 in the position shown in FIG. 3. It should be noted that the movement required of sheath 36 to achieve this position is opposite the direction which would normally permit point 20 of hypodermic needle 18 to jab or prick the user. The application or force on sheath 36 back toward flange 28 of syringe 12 would free sheath 36 for such travel for holding and stopping sheath 36, again, in the position shown in FIG. 1. With reference to the embodiment 10A depicted in FIGS. 4-6, the user would simply move sheath 56 from the position depicted in FIG. 4 to the position depicted in FIG. 5. The interaction of protuberances 62 and grooves 52 and 54 would stop and hold sheath 56 in the positions shown. It should be noted, that in either embodiment the stopping and holding of sheaths 36 and 56 is a temporary condition. The application of force along directional arrows 64 or 72 would easily free sheaths 36 and 56 from any of the extended position shown in FIGS. 1-5.
While in the foregoing embodiments of the present invention have been set forth in considerable detail for the purposes of making a complete disclosure of the invention, it may be apparent to those of skill in the art that numerous changes may be made in such detail without departing from the spirit and principles of the invention. | A shield for a syringe mounted hypodermic needle which utilizes a translucent sheath. The sheath extends over the barrel to one position adjacent the barrel flange and to another position or beyond the needle point. The sheath may be distinctly stopped at these positions. | 0 |
This application is a divisional of prior application Ser. No. 12/872,495, filed Aug. 31, 2010, now U.S. Pat. No. 8,324,922, issued Dec. 4, 2012;
Which was a divisional of prior application Ser. No. 11/850,436, filed Sep. 5, 2007, now U.S. Pat. No. 7,808,264, granted Oct. 5, 2010;
Which was a divisional of prior application Ser. No. 11/621,621, filed Jan. 10, 2007, now U.S. Pat. No. 7,362,120, granted Apr. 22, 2008;
which was a divisional of prior application Ser. No. 11/214,088, filed Aug. 29, 2005, now U.S. Pat. No. 7,180,319, granted Feb. 20, 2007;
which was a divisional of prior application Ser. No. 10/832,919, filed Apr. 26, 2004; now U.S. Pat. No. 6,954,080, granted Oct. 11, 2005;
which was a divisional of prior application Ser. No. 09/835,802, filed Apr. 16, 2001, now U.S. Pat. No. 6,727,722, granted Apr. 27, 2004;
which was a divisional of prior application Ser. No. 09/325,487, filed Jun. 3, 1999, now U.S. Pat. No. 6,262,587, granted Jul. 17, 2001;
which was a divisional of prior application Ser. No. 08/742,189, filed Oct. 31, 1996, now U.S. Pat. No. 5,969,538, granted Oct. 19, 1999;
which claims priority from Provisional application No. 60/008,186, filed Oct. 31, 1995.
FIELD OF THE DISCLOSURE
The disclosure relates generally to integrated circuit manufacturing and, more particularly, to testing die on wafer.
BACKGROUND OF THE DISCLOSURE
Integrated circuit (ICs) manufacturers produce die on typically circular substrates referred to as wafers. A wafer may contain hundreds of individual rectangular or square die. Die on wafer, or unsingulated die, must be tested to determine good from bad before the dies are singulated. Unsingulated die testing traditionally occurs by physically probing each die at the die pads, which allows a tester connected to the probe to determine good or bad die. This type of probing is relatively slow and requires expensive mechanical mechanisms to accurately step and position the probe at each die location on the wafer. The probing step can damage the die pads which may interfere with the bonding process during IC packaging or assembly of bare die on MCM substrates. Also, as die sizes shrink, pads are positioned closer and closer together and it becomes more difficult and costly to design precision probing instruments to access them.
Alternate conventional methods for testing unsingulated die on wafers include: (1) designing each die to test itself using built-in-self-test (BIST) circuitry on each die and providing a way to enable each die BIST circuitry to test the die, (2) widening the scribe lanes between the die to allow for: (a) test probe points, (b) test access conductors, and/or (c) test circuitry, and (3) processing an overlying layer of semiconductor material with test circuitry over the die on wafers and providing via connections, from the overlying layer, to the pads of each die on the wafer. Method 1 disadvantageously requires BIST circuitry on the die which takes up area, and the BIST circuitry may not be able to adequately test the I/O of the die. Method 2 disadvantageously reduces the number of die that can be produced on a wafer since the widening of the scribe lanes takes up wafer area which could be used for additional die. Method 3 disadvantageously requires additional wafer processing steps to form the overlying test connectivity layer on top of the die on wafers, and also the overlying layer needs to be removed from the wafer after testing is complete. This overlying layer removal step is additive in the process and the underlying die could be damaged during the removal step.
Ideally, only good die are singulated and packaged into ICs. The cost of packaging die is expensive and therefore the packaging of bad die into ICs increases the manufacturing cost of the IC vendor and results in a higher cost to the consumer.
FIG. 1 illustrates a schematic of a die containing functional core logic (FCL) and input and output buffering to pad locations. The variety of pad buffering shown includes: inputs (I), 2-state outputs (2SO), 3-state outputs (3SO), open drain outputs (ODO), input and 3SO bidirectionals (I/O 1 ), and input and ODO bidirectionals (I/O 2 ). The FCL could be a custom or semicustom (ASIC) implementation comprising: microprocessors, combinational logic, sequential logic, analog, mixed signal, programmable logic, RAMs, ROMs, Caches, Arrays, DSPs, or combinations of these and/or other functions. The die is shown having a top side A, right side B, bottom side C, and left side D for convenience of description in regard to its position on the wafer. The die also has at least one voltage supply (V) pad and at least one ground (G) pad for supplying power to the die. Side A has pad locations 1 - 7 , B has pad locations 1 - 8 , C has pad locations 1 - 8 , and D has pad locations 1 - 9 . The arrangement of the buffer/pad combinations on each side (A, B, C, D) corresponds to the desired pinout of the package that the die will be assembled into, or to signal terminals on a multi-chip module (MCM) substrate onto which the die will be connected. FIG. 2 is a cutaway side view of the die showing an input pad at D 2 and an output pad at B 2 both connected to the FCL.
FIG. 3A shows an example wafer containing 64 of the die of FIG. 1 . FIG. 3B shows the position of each die on the wafer with respect to sides A, D, C, and D. The phantom die in dotted line shows how the wafer would be packed to yield more die per wafer. Notice that even when the die is tightly packed on the wafer (i.e. the phantom die locations utilized), there is still area at the periphery of the wafer where die cannot be placed. This is due to the circular shape of the wafer versus the square/rectangular shape of the die. This unusable peripheral area of the wafer can be used to place test points (pads), test circuitry, and conductors for routing test signals and power and ground to die.
FIG. 4 shows how conventional die testing is performed using a tester and pad probe assembly. The probe assembly is positioned over a selected die and lowered to make contact with the die pads. Once contact is made the tester applies power and checks for high current. If current is high a short exists on the die and test is aborted and the die is marked (usually by an ink color) as bad. If current is normal, then testing proceeds by applying test patterns to the die and receiving test response from the die. If the test fails the die is marked as bad. If the test passes the die is good and not marked, or if marked, marked with a different ink color. During testing the die current can be monitored to see if it stays within a specified range during the test. An out of range current may be marked as a high current functional failure.
Such conventional wafer testing has several disadvantages. The act of probing the die scars the metal die pads. Thus, using physical probing, it is essential that dies be tested only once, since re-probing a die to repeat a test may further damage the pads. Even a single probing of a die may cause enough pad damage to adversely affect subsequent assembly of the die in IC packages or on MCM substrates. With the extremely small target provided by a die pad, the equipment used for positioning the probe on a die pad must be designed with great care and is therefore very expensive to purchase/build and maintain and calibrate. Also the stepping of the probe to each die location on the wafer takes time due to the three dimensional motions the probe must be moved through to access and test each die on the wafer.
It is therefore desirable to test die on wafers without the disadvantages described above.
The present disclosure provides: a die framework comprising die resident circuitry and connections to selectively provide either a bypass mode wherein the die has direct pad-to-pad connectivity or a functional mode wherein the die has die pad to functional core logic connectivity; a fault tolerant circuit and method to select a die on a wafer to be placed in functional mode while other die remain in bypass mode; a method and apparatus for (1) electronically selecting one die on a wafer to be placed in functional mode for testing while other die on the wafer are in bypass mode, (2) testing that selected die, and (3) repeating the electronic selection and testing steps on other die; and a method and apparatus for (1) electronically selecting a plurality of diagonally positioned die on the wafer to be placed in functional mode for testing while other die on the wafer are in bypass mode, (2) testing the selected group of diagonally positioned die in parallel, and (3) repeating the electronic selection and testing steps on other groups of diagonally positioned die.
The present disclosure provides improved testing of unsingulated die on wafer. The disclosure provides the following exemplary improvements: (1) electronic selection and testing of unsingulated die on wafer, (2) faster testing of dies on wafer, (3) elimination of expensive, finely designed mechanical wafer probes, (4) the ability to at-speed test unsingulated die on wafer. (5) the ability to test a plurality of unsingulated die in parallel, and (6) the ability to simplify the burn-in testing of unsingulated die.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 diagramatically illustrates the functional core logic, input and output pads and pad buffering structures of a conventional integrated circuit die.
FIG. 2 is a cutaway side view of a portion of the conventional die of FIG. 1 .
FIGS. 3A-3B illustrate the placement and orientation of a plurality of die on a conventional wafer.
FIG. 4 illustrates a conventional arrangement for testing die on a wafer.
FIG. 5 diagramatically illustrates the functional core logic, input and output pads and pad buffering of an exemplary integrated circuit die according to the present disclosure.
FIG. 6 schematically illustrates pad-to-pad connections that exist in the die of FIG. 5 when in a bypass mode.
FIGS. 7A-11B are cutaway side views of various portions of the FIG. 5 die in both functional and bypass modes.
FIG. 12A illustrates an exemplary embodiment of the input state holder of FIG. 7A .
FIG. 12B illustrates an alternative to the input state holder of FIG. 12A .
FIGS. 13A-14B are further cutaway side views similar to FIGS. 7A-11B .
FIGS. 15A-15B illustrate an exemplary arrangement for bussing power and ground to each die on a wafer.
FIGS. 16A-16B illustrate an exemplary die selection scheme according to the present disclosure.
FIGS. 17A-17B illustrate the operation of the die selectors of FIG. 16A .
FIGS. 18A-18C illustrate the structure and operation of the die selection scheme of FIG. 16A .
FIGS. 19A-19C illustrate a fault tolerant feature of the die selection scheme of FIG. 16A .
FIG. 19D illustrates the die selection scheme of FIG. 16A applied to a plurality of die on a plurality of wafers.
FIGS. 20A-20B illustrate another exemplary die selection scheme according to the present disclosure.
FIGS. 21A-21B illustrate the operation of the die selectors of FIG. 20A .
FIGS. 22A-23B illustrate the structure and operation of the die selection scheme of FIG. 20A .
FIGS. 24A-24C illustrate a fault tolerant feature of the die selection scheme of FIG. 20A .
FIGS. 24D and 24E diagramatically illustrate an exemplary implementation of the die selector defined in FIGS. 21A-23B .
FIGS. 24F and 24G diagrammatically illustrate an exemplary implementation of the die selector defined in FIGS. 17A-18C .
FIGS. 25A-25E illustrate an exemplary arrangement according to the present disclosure for testing die on wafer.
FIG. 26 illustrates a portion of FIG. 25A in greater detail.
FIG. 27 illustrates an exemplary arrangement according to the present disclosure for testing a plurality of die on wafer in parallel.
FIG. 28 illustrates an exemplary power and ground bussing arrangement for use with the testing arrangement of FIG. 27 .
FIG. 29 illustrates an exemplary die selection scheme for use with the testing arrangement of FIG. 27 .
FIG. 30 illustrates a portion of FIG. 27 in greater detail.
FIGS. 31A-31O illustrate a sequence of testing steps supported by the arrangement of FIG. 27 , wherein groups of diagonally positioned die are tested in parallel fashion.
FIGS. 32A-32H illustrate a sequence of testing steps supported by the arrangement of FIG. 27 , wherein groups of diagonally positioned die are tested in parallel fashion.
DETAILED DESCRIPTION
In FIG. 5 a die schematic similar to that of FIG. 1 is shown. Like FIG. 1 , the die is a substrate of semiconductor material having a rectangular shape with two sets of opposed sides A, B, C, and D and corresponding pad sites arranged at the margins of each side for input, output, input/output, V and G. FIG. 5 includes additional pad sites A 8 and B 9 referred to as bypass, and an additional pad site C 9 referred to as mode. The mode pad is buffered like a data input. When mode is at a predetermined logic level, say high, the die schematic appears as shown in FIG. 5 , and the die is in its functional mode which is exactly the equivalent of the die in FIG. 1 . In functional mode, the FCL, input, output, and input/output pads are enabled and the die performs its intended function. In functional mode, the bypass pads are not used.
In exemplary FIG. 6 , the die of FIG. 5 is schematically shown as it would operate in the bypass mode of the present disclosure. The die is placed in bypass mode by taking the mode pad to a logic state opposite that of the functional mode logic state, in this case a logic low. In bypass mode, the die's FCL, input, output, and input/output buffers are disabled to isolate the FCL from the pad sites and pad sites of corresponding position between sides A and C and between sides D and B are electrically connected. In bypass mode the die is transformed into a simple interconnect structure between sides A and C and between sides D and B, unconnected from the FCL. The interconnect structure includes a plurality of conductors extending parallel to one another between sides A and C, and a further plurality of conductors extending parallel to one another between sides D and B. While in bypass mode, signals from a tester apparatus can flow through the interconnects between A and C and between D and B to access and test a selected die on a wafer.
While most bypass connections can be made between existing functionally required pad sites, the number of functional pad sites on one side may not equal the number of functional pad sites on the opposite side. Thus the bypass pads of FIG. 5 provide pad-to-pad connectivity when the number of pads on opposite sides are not equal. For example, in FIGS. 5 and 6 , bypass pads A 8 and B 9 provide connecting pads for functional pads C 8 and D 9 respectively, on opposite sides of the substrate that have one less pad site. The bypass connections between opposite side die pads form a low impedance, bidirectional signaling path through the die from pad to pad. The bypass connections between two sides are preferably designed to have an equal propagation delay between opposite side pads to avoid skewing of test signals passed through bypassed die.
Assuming for example the die positioning shown on the wafer of FIG. 3A , the sides of a die selected for testing need to be driven by signals from the adjacent sides of top, right, bottom, and left neighboring die which are in bypass mode ( FIG. 6 ). In order for the neighboring die to be tested, it is placed in functional mode, and: (1) all signals required at its A side are provided at the C side of the top neighboring bypassed die, (2) all signals required at its B side are provided at the D side of the right neighboring bypassed die, (3) all signals required at its C side are provided at the A side of the bottom neighboring bypassed die, and (4) all signals required at its D side are provided at the B side of the left neighboring bypassed die.
FIGS. 7 through 14 depict cross section views of example circuitry and connections which can achieve the framework for selective die functional and bypass modes.
Exemplary FIGS. 7A and 7B illustrate side views of the D 1 input pad and the B 1 3-state output pad of the die in FIGS. 5 and 6 . A switch 71 is provided between the input pad and input buffer to allow isolating the input pad from the input buffer during bypass mode, and an input state holder (ISH) circuit is provided between the switch and input buffer to allow holding a predetermined input state to the input buffer (which drives the FCL) while the switch is open during bypass mode. Gating circuitry, such as an AND gate (A), is provided in the control path between the FCL and 3-state output buffer to allow the 3-state output buffer to be disabled during bypass mode. A selectable connection path 73 between the input and output pad includes a conductor 75 connected between a switch 77 associated with the input pad and a switch 79 associated with the output pad, which switches are operable to connect conductor 75 to G or to the input and output pads. The mode pad is connected to the switches. ISH and gate A as shown such that when the mode pad is in one logic state the die is in functional mode and when in the opposite logic state the die is in bypass mode. The mode pad can be connected to FCL as shown to permit disabling of clocks or other operations in FCL during bypass mode.
As shown in exemplary FIG. 12A , ISH can be realized with a 3-state data buffer having a data input connected to a desired logic level (logic “1” in this example) and a data output connected to the input of the input buffer and a 3-state control input connected to the mode pad. The desired logic level for a given FCL input could be, for example, a logic level which minimizes current flow in the FCL during bypass mode. The 3-state buffer is enabled during bypass mode and 3-stated during functional mode. If the desired logic level is a don't care condition, then the bus holder BH of exemplary FIG. 12B can be used to hold the last input logic level during bypass mode.
When in functional mode ( FIG. 7A ), the switches 77 and 79 connect the conductor 75 to G which provides a ground plane on the conductor and prevents AC coupling between the input and output pads. When in bypass mode ( FIG. 7B ), the switches 77 and 79 and the conductor 75 provide a low impedance, bidirectional signaling path connection between the input and output pads. In bypass mode, switch 71 is open to isolate FCL from the input pad, and the 3-state output buffer is disabled (3-stated) via AND gate A to isolate FCL from the output pad.
The examples of FIGS. 8-11 show the use of the bypass circuitry with other types of pad buffers. FIGS. 13 and 14 show the use of the bypass circuitry between functional input (D 9 ) and bypass (B 9 ) pads, and functional output (C 8 ) and bypass (A 8 ) pads.
In FIGS. 8A and 8B , a further switch 81 is used to isolate the 2-state output buffer from output pad B 2 during bypass mode. FIGS. 8C and 8D are similar to FIGS. 8 A and 8 B except a 3-state output buffer is used instead of a 2-state output buffer and switch 81 , in order to eliminate the impedance of switch 81 during functional mode.
The input pads in FIGS. 9A and 9B and the 3-state output pads in FIGS. 10A and 10B are arranged in the manner described above with respect to FIGS. 7A and 7B . The bypass pad B- 9 in FIGS. 13A and 13B is unconnected with the FCL. The bypass pad A- 8 in FIGS. 14A and 14B is unconnected with the FCL.
FIGS. 11A and 11B illustrate I/O pads with 3-state (I/O 1 ) and open drain (I/O 2 ) outputs. The input buffers and the 3-state output buffer of FIGS. 11A and 11B are arranged as described above with respect to FIGS. 7A and 7B . The open drain output buffer of FIGS. 11A and 11B has its input connected to an output of an OR gate (O) which has one input driven by FCL and another input driven by the logical inverse of the mode signal, whereby the open drain output will float high during bypass mode assuming that the mode signal selects bypass mode when low.
The input pad in FIGS. 13A and 13B , and the 3-state output pad in FIGS. 14A and 14B are arranged in the manner described above with respect to FIGS. 7A and 7B .
FIG. 15A illustrates an example of how wafer voltage (WV) and wafer ground (WG) bussing can be distributed to the V and G pads of each die on the wafer. The WV bussing is shown originating from areas of the wafer designated as probe area PA 1 and probe area PA 2 . The WG bussing is shown originating from probe area PA 3 and probe area PA 4 . Probe areas PA 1 - 4 are positioned at the periphery of the wafer and in areas where die cannot be placed, as mentioned in regard to FIG. 3A . FIG. 15B illustrates how WV and WG are coupled to the V and G die pads (see FIGS. 1 and 5 ) through diodes. By placing diodes between WG and G and WV and V, conventional localized probing and power up of an individual die can occur without powering up neighboring dies.
FIG. 16A illustrates an exemplary scheme for performing fault tolerant selection of unsingulated die on wafer. The scheme involves the placement of a small circuit, referred to as a die selector 161 , in the scribe lane adjacent each die on the wafer. The die selector 161 shown in FIG. 16B includes an I/O terminal S 1 , an I/O terminal S 2 , a mode output terminal, and connections to WV and WG for power. The die selector's mode output is connected to the mode pad of an associated die. The die selectors are connected in series via their S 1 and S 2 terminals. In the example of FIG. 16A , S 1 of the first die selector in the series (at die 1 ) is connected to PA 4 , and S 2 of the last die selector in the series (at die 64 ) is connected to PA 3 . Because the die selector is placed in the scribe lane instead of on the die, the mode pad of the die can be physically probed if required, to override the die selector mode output. This feature permits any die to be tested using the conventional probe testing technique. Because the mode output of the die selector drives only the mode pad of a single die, it can be designed with a relatively weak output drive so that the conventional probe tester can easily override the mode output without any damage to the mode output.
Power is applied to WV and WG by probing PA 1 -PA 4 . When power is first applied, all the die selectors get reset to a state that forces their mode outputs low, which causes all die to be placed in bypass mode. If excess current is detected at power up (indicating perhaps a short between WV and WG), the wafer can be powered down and tested using the traditional mechanical probing technique (note that the diodes of FIG. 15B allow for this). If normal current is detected (meaning that all die have successfully powered up in bypass mode) further testing according to the present disclosure may be performed.
Before testing die, the integrity of the serially connected die selectors 161 can be tested. Testing of the die selectors can occur by injecting clock pulses from PA 4 to S 1 of the upper left die selector (adjacent die 1 ) and monitoring S 2 of the lower left die selector (adjacent die 64 ) at PA 3 . If the serial path between the die selectors is intact, a clock pulse output will occur on lower left S 2 after 65 clock pulses have been applied to upper left S 1 . On the falling edge of the first injected clock pulse, die 1 is switched from bypass mode to functional mode by the mode output of the associated die selector going high. All other die are forced to remain in bypass mode by their die selectors' mode outputs being low. Also on the falling edge of the first injected clock pulse, the upper left die selector connects its S 1 and S 2 terminals so that subsequent S 1 clocks are output on S 2 . On the rising edge of the second injected clock pulse, die 1 is placed back into bypass mode by its die selector's mode output going low. This second clock pulse is transferred through the upper left die selector to the next die selector via the S 1 to S 2 connection. On the falling edge of the second clock pulse, the die 2 selector connects its S 1 and S 2 terminals and switches die 2 from bypass to functional mode by driving the mode output high. This process continues on to die 64 and its die selector. On the rising edge of the 65th injected clock pulse, die 64 is placed back into the bypass mode by its die selector's mode output going low, and the 65th clock pulse is output from S 2 to PA 3 .
Also, during the die selector test the current flow to and/or from the wafer via WV and WG can be monitored during each rising and falling clock edge to see if the expected current increase and decrease occurs as each die transfers in sequence between bypass and functional modes. By sensing the wafer current fluctuations, it is possible to detect when a die that should be selected (i.e. in functional mode) is not selected, which could indicate a defect in the die selector arrangement as discussed further below.
The above description illustrates how to test and operate the die selector path from PA 4 to PA 3 . The same test and operation mode is possible by clocking S 2 of the lower left die selector from PA 3 and monitoring S 1 of the upper left die selector at PA 4 . The die selector model of exemplary FIG. 17A and state diagram of exemplary FIG. 17B illustrate die selector operation modes in detail. From FIG. 17B it is seen that the die selector responds to a first received S 1 or S 2 clock pulse to output mode control (on the falling edge) to place the connected die in functional mode so that it can be tested. After the die is tested, a rising edge on the same signal (say S 1 ) causes the tested die to be placed back into bypass mode and also drives the S 1 input of the next die selector. On the next successive falling edge the die associated with the next die selector is switched into functional mode for testing. And so on.
Exemplary FIGS. 18A-18C illustrate in detail the die selector operation described above. PS 1 and PS 2 in FIG. 18 are externally accessible terminals (like PA 3 and PA 4 ) for injecting and receiving clock pulses. Note that the die selectors operate bidirectionally as mentioned above. The reason for the bidirectional operation is for fault tolerance, i.e. a broken connection between two die selectors can be tolerated. An example of the fault tolerant operation of the die selector is shown in FIGS. 19A-19C . In FIG. 19A an open circuit fault exists between the 2nd and 3rd die selectors. PS 1 clock activations can only select die 1 and 2 ( FIG. 19B ). However, PS 2 clock activations can select die 5 , 4 , and 3 ( FIG. 19C ). Thus even with an open circuit the die selector arrangement is able to select and place a given die in functional mode for testing.
Wafers such as shown in FIG. 16A may also be connected in series via the S 1 /S 2 signals to allow selection of die on many wafers as shown in FIG. 19D . S 2 of the lower left die of wafer 191 is connected, via PA 3 of wafer 191 and external conductor 193 and PA 4 of wafer 195 , to S 1 of the upper left die of wafer 195 . An analogous connection also exists between wafers 195 and 197 . External probe connections at PA 4 of wafer 191 and PA 3 of wafer 197 permit the die selection scheme described above with respect to FIGS. 16A-18C to be applied to die on plural wafers.
Exemplary FIGS. 20 and 21 illustrate how to further improve die selector fault tolerance by the addition of a second pair of I/O terminals S 3 and S 4 in die selector 201 . In FIG. 20A , the S 3 and S 4 serial connection path is shown routed between PA 1 and PA 2 in the vertical scribe lanes. Separating the S 1 /S 2 (horizontal scribe lanes) and S 3 /S 4 (vertical scribe lanes) routing is not required, and both routings could be in the same horizontal or vertical lanes if desired. It is clear in the example of FIG. 20A that routing S 1 and S 2 in the horizontal lanes and routing S 3 and S 4 in the vertical lanes will result in different die selection orders, i.e. S 1 and S 2 select die order 1 , 2 , 3 . . . 64 or die order 64 , 63 , 62 . . . 1 , whereas S 3 and S 4 select die order 1 , 16 , 17 , . . . 64 . . . 8 or die order 8 , 9 , 24 . . . 1 .
Exemplary FIGS. 21A and 21B illustrate the model and state diagram of the improved fault tolerant die selector 201 of FIGS. 20A and 20B . The operation of the die selector 201 of FIG. 21A is similar to that of the die selector 161 of FIG. 17A except that the die selector 201 has redundant bidirectional selection paths. Redundant selection paths allow the die selector 201 to maintain operation even when one of its selection paths is rendered inoperable by gross defects that defeat the fault tolerance features provided in the single path die selector 161 of FIG. 17A .
In FIGS. 22A-24C operational examples using dual selection path die selectors 201 are shown. For clarity, the examples show both paths (S 1 and S 2 , and S 3 and S 4 ) routed together (in same scribe lanes) to the same sequence of die 1 through 5 . This differs from the example routing of FIG. 20A where S 1 and S 2 are routed in horizontal lanes and S 3 and S 4 are routed in vertical lanes, and thus each path has a different sequence of die selection. FIG. 22B shows PS 1 selecting die in the order 1 , 2 , 3 , 4 & 5 . FIG. 22C shows PS 2 selecting die in the order 5 , 4 , 3 , 2 & 1 . FIG. 23A shows PS 3 of FIG. 22A redundantly selecting die in the same order as PS 1 ( FIG. 22B ). FIG. 23B shows PS 4 of FIG. 22A redundantly selecting die in the same order as PS 2 ( FIG. 22C ). Both paths can tolerate a single defect (open circuit) as shown in FIGS. 19A-19C .
However, FIG. 24A shows a multiple defect example (two open circuits) on the S 1 and S 2 path that would disable access to intermediate die 2 , 3 & 4 if only the S 1 and S 2 path were provided. FIGS. 24B-24C illustrate that PS 1 can only select die 1 , and PS 2 can only select die 5 with the defects shown in FIG. 24A . However, since redundant selection paths are provided in the die selectors 201 of FIG. 24A , the S 3 and S 4 path can be used to select die 2 , 3 & 4 as illustrated in FIGS. 23A-23B . Thus an advantage of die selector 201 is that it can maintain access to die even if one of the paths is critically disabled by multiple defects.
FIGS. 24F and 24G illustrate an exemplary implementation of the die selector 161 defined in FIGS. 17A-18C . In FIG. 24F , input terminals S 1 and S 2 are respectively connected to inputs S 1 IN and S 2 IN of a die selector state machine 241 via respective input data buffers 243 and 245 . The die selector state machine 241 outputs the mode signal and enable signals S 1 ENA and S 2 ENA. Enable signals S 1 ENA and S 2 ENA respectively control output data buffers 247 and 249 . The output of input data buffer 243 is connected to the input of output data buffer 249 to permit signals received at terminal S 1 to be output on terminal S 2 when enable signal S 2 ENA enables output data buffer 249 . Similarly, the output of input data buffer 245 is connected to the input of output data buffer 247 to permit signals received at terminal S 2 to be output on terminal S 1 when enable signal SIENA enables output data buffer 247 .
Exemplary FIG. 24G illustrates the die selector state machine 241 of FIG. 24F in greater detail. A conventional power-up reset circuit initially clears D flip-flops 251 , 253 and 255 when the die selector is initially powered up. The pass signal output from flip-flop 255 is inverted at one input of AND gate 259 . The other input of AND gate 259 , which is driven by the output of OR gate 257 , is thus qualified at gate 259 by the pass signal upon initial power up. Because flip-flop outputs QS 1 and QS 2 are low after initial power-up, the mode signal is therefore low after power-up. Noting that QS 1 is connected to S 2 ENA and QS 2 is connected to SIENA, it is seen from FIG. 24F that output data buffers 247 and 249 are initially disabled after power-up. Because signal QS 1 is initially low, signal S 2 IN is initially qualified at AND gate 261 , and because signal QS 2 is initially low, signal S 1 IN is also initially qualified at AND gate 263 . The low levels of QS 1 and QS 2 also drive the D input of flip-flop 255 low via OR gate 265 . The outputs of AND gates 261 and 263 are connected to respective inputs of OR gate 271 whose output drives the clock inputs of flip-flops 251 , 253 and 255 . The output of AND gate 261 is connected to the D input of flip-flop 253 via delay element 267 , and the output of AND gate 263 is connected to the D input of flip-flop 251 via delay element 269 . Delay elements 267 and 269 are designed to have a propagation delay which is greater than the propagation delay of OR gate 271 .
A rising edge of a first clock pulse on S 1 IN causes a logic zero to be clocked through flip-flop 255 , thereby maintaining the pass signal at its initial low state. When the falling edge of the clock pulse occurs and propagates through OR gate 271 to clock flip-flop 251 , the D input of flip-flop 251 will still be high due to the delay element 269 , thus causing flip-flop output QS 1 to go high. With QS 1 high, the mode signal is driven high via OR gate 257 and AND gate 259 . Also with QS 1 high, the output data buffer 249 of FIG. 24F is enabled via signal S 2 ENA, the input S 2 IN is disqualified at AND gate 261 , and the D input of flip-flop 255 is driven high via OR gate 265 . Thus, the rising edge of the second clock pulse on terminal S 1 of FIG. 24F passes directly to terminal S 2 via output data buffer 249 , and also passes through AND gate 263 and OR gate 271 of FIG. 24G to clock flip-flop 255 and take the pass output thereof high, thereby driving the mode signal low. The next falling edge on terminal S 1 will pass through data output buffer 249 to terminal S 2 , and will maintain the QS 1 output of flip-flop 251 in the high logic state. The positive edge of the third clock pulse received on terminal S 1 will pass through data output buffer 249 to terminal S 2 , and will also clock a logic one through flip-flop 255 so that the pass signal will maintain the mode output low via AND gate 259 . The negative edge of the third clock pulse will maintain the logic one at the QS 1 output of flip-flop 255 . Each successive clock pulse after the third clock pulse on terminal S 1 will achieve the same results as described with respect to the third clock pulse.
The bidirectional feature of die selector 161 should be apparent from FIGS. 24F and 24G . That is, if a succession of clock pulses had occurred on terminal S 2 rather than on terminal S 1 , then output QS 2 of flip-flop 253 would have been driven high to enable data output buffer 247 and disable the S 1 IN signal via AND gate 263 . The mode signal behaves exactly the same in response to a succession of clock pulses on terminal S 2 as described above with respect to the succession of clock pulses on terminal S 1 , and the terminal S 1 will receive the second and all successive clock pulses input on terminal S 2 .
Exemplary FIGS. 24D and 24E show an implementation of die selector 201 which is similar to the implementation of die selector 161 illustrated in FIGS. 24F and 24G . Referencing FIG. 24D , the output of data input buffer 243 is connected to the input of data output buffer 249 as in FIG. 24F , and the output of data input buffer 245 is connected to the input of data output buffer 247 as in. FIG. 24F . Similarly, the output of data input buffer 275 is connected to the input of data output buffer 277 , and the output of data input buffer 281 is connected to the input of data output buffer 279 .
The die selector state machine 273 of FIG. 24D is shown in greater detail in FIG. 24E . As seen from FIG. 24E , the die selector state machine 273 of FIG. 24D represents an extension of the die selector state machine of 241 of FIG. 24G . An additional AND gate 287 , delay element 293 , and flip-flop 283 have been added for terminal S 3 , and an additional AND gate 289 , delay element 291 and flip-flop 285 have been added for terminal S 4 . The operation of these additional elements is identical to the operation described above with respect to the corresponding elements in FIG. 24G . Similarly to the operation described above with reference to FIG. 24G , a first falling clock pulse edge on terminal S 3 will result in the QS 3 output of flip-flop 283 going high to drive the mode signal high and to enable the data output buffer 277 to connect terminal S 3 to terminal S 4 . The rising edge of the second clock pulse on terminal S 3 will clock a logic one through flip-flop 255 so that the pass signal will drive the mode signal low again via AND gate 259 . Similarly, the falling edge of a first clock pulse on terminal S 4 will drive high the QS 4 output of flip-flop 285 , which drives the mode signal high and enables data output buffer 279 to connect terminal S 4 to terminal S 3 . The decoder circuit 291 receives QS 1 -QS 4 as inputs and provides DS 1 -DS 4 as outputs. When QS 1 is active high, the decoder circuit 291 drives DS 2 -DS 4 active high, which disables signals S 2 IN, S 3 IN and S 4 IN at AND gates 261 , 287 and 289 . Similarly, when signal QS 2 is active high, the decoder circuit drives signals DS 1 , DS 3 and DS 4 active high, when signal QS 3 , is active high, the decoder circuit drives signals DS 1 , DS 2 and DS 4 active high, and when QS 4 is active high, the decoder circuit drives signals DS 1 -DS 3 active high.
Referencing exemplary FIGS. 25A and 25D , probe test pads in PA 1 are bussed (via A-Bus) to one side of eight top column switch groups (TC 1 - 8 ), representative switch group TC 8 being shown in FIG. 25D . Each top column switch group also receives a select top column signal (such as STC 8 ) from PA 1 that opens or closes the switches. The other side of each top column switch group is bussed to the A side (recall FIG. 5 ) pads of die 1 , 2 , 3 , 4 , 5 , 6 , 7 , and 8 .
Also referencing FIG. 25C , probe test pads in PA 2 are bussed (via B-Bus) to one side of eight right row switch groups (RR 1 - 8 ), representative switch group RR 8 being shown in FIG. 25C . Each right row switch group also receives a select right row signal (such as SRR 8 ) from PA 2 that opens or closes the switches. The other side of each right row switch group is bussed to the B side pads of die 8 , 9 , 24 , 25 , 40 , 41 , 56 , and 57 .
Referencing also FIG. 25E , probe test pads in PA 3 are bussed (via C-Bus) to one side of eight bottom column switch groups (BC 1 - 8 ), representative switch group BC 1 being shown in FIG. 25E . Each bottom column switch group also receives a select bottom column signal (such as SBC 1 ) from PA 3 that opens or closes the switches. The other side of each bottom column switch group is bussed to the C side pads of die 57 , 58 , 59 , 60 , 61 , 62 , 63 , and 64 .
Referencing also FIG. 25B , probe test pads in PA 4 are bussed (via D-Bus) to one side of eight left row switch groups (LR 1 - 8 ), representative switch group LR 1 being shown in FIG. 25B . Each left row switch group also receives a select left row signal (such as SLR 1 ) from PA 4 that opens or closes the switches. The other side of each left row switch group is bussed to the D side pads of die 1 , 16 , 17 , 32 , 33 , 48 , 49 , and 64 .
PA 1 - 4 , the switch groups, and bussing to correct them can all be located in the unusable peripheral area (recall FIG. 3A ) of the wafer.
As shown in the detailed example of FIG. 26 , each die on the wafer, excluding the boundary die, such as die 1 , 2 , 3 , 16 , 17 etc. is connected at its top (A), right (B), bottom (C) and left (D) side pad sites to neighboring die pad sites by way of short busses that bridge across the scribe lanes between the die. Due to the regularity of the die and their positioning on the wafer, vertical pad bussing is provided between each neighboring die on sides A and C, and horizontal pad bussing is provided between each neighboring die on sides B and D. The pads of boundary die are similarly bussed to neighboring die pads, but only on at most three sides, since at least one of the boundary die sides will always be connected to a switch group.
Although not shown in FIG. 25A , the wafer also comprises: (1) die having selectable functional and bypass modes as described in FIGS. 5-14 , (2) WV and WG bussing as shown in FIGS. 15A-15B , and (3) fault tolerant die selectors as described in FIGS. 16-24 .
Each switch group, when selected (switches closed), provides a low impedance, bidirectional signaling path. Also the bussing connections between PA 1 - 4 and the switch groups (TC 1 - 8 , LR 1 - 8 , BC 1 - 8 , RR 1 - 8 ), between the switch groups and the die sides (A, B, C, D), and between the die sides, provide a low impedance, bidirectional signaling path. As previously mentioned, the die's internal bypass pad-to-pad connections also provide low impedance, bidirectional signaling paths.
When testing is to be performed, a probe is positioned onto the wafer at the pad areas PA 1 - 4 . PA 1 - 4 are large compared to the pad area of each die, and therefore the mechanical requirements of the probe design are simpler ad less costly than conventional probes which are elegantly designed for contacting tiny die pads. Also, since the present disclosure allows for a die to be electronically selected for testing, the probe needs to be positioned onto the wafer only once, which reduces test time when compared to conventional multiple probing of a wafer. This test time reduction can significantly decrease the cost of wafer testing, which in turn decreases the cost of the die and packaged IC. Also, since the probe does not contact any die pads, no damage to die pads occurs during the wafer probe and die test procedure. Furthermore, the relatively large probe target area provided by PA 1 - 4 lends itself well to computer controlled and automated test probing processes.
After the probe contacts the wafer at PA 1 - 4 , power is applied to the wafer to power up the die and die selectors. The tester can quickly detect a high current situation and remove power from the wafer as necessary. Wafer processing faults could cause shorts between WG and WV bussing or a die or die selector could have a V and G short. If the wafer fails the high current test at power up, die testing can still be done by conventional die probing techniques.
If the wafer exhibits normal current flow at power up, the die selectors can be tested as previously described with regard to FIGS. 16-24 . If the die selectors fail in all fault tolerant modes, the wafer can still be tested conventionally. If the die selectors pass, the row and column bussing paths can be tested. To test row 1 and column 1 ( FIGS. 25 and 26 ), the LR 1 , RR 1 , TC 1 and BC 1 switch groups are closed and, with all die in bypass mode, an external tester (such as in FIG. 4 ) passes signals between PA 4 and PA 2 to test row 1 bussing and between PA 1 and PA 3 to test column 1 bussing. This step tests, (1) the PA 1 - 4 to switch group bussing, (2) the switch group closures, (3) the switch group to boundary die bussing, (4) the die bypass mode, and (5) the die-to-die pad bussing. This step is repeated on all rows and columns. If a row or column fails, die associated with that row and column can be tested conventionally. After testing row and column connectivity, the die can be tested.
The die test starts by outputting a first pulse to S 1 (could be S 2 , or S 3 or S 4 if die selector 201 is used) from PA 4 to cause the upper left die selector to switch die 1 from bypass to functional mode, and then closing switch groups LR 1 , TC 1 , RR 1 and BC 1 , and then testing die 1 using the external tester which is connected to die 1 via PA 1 - 4 , the closed switch groups and the row 1 and column 1 bussing paths. This test sequence is repeated on all die on the wafer. FIG. 26 illustrates in detail the testing of die 15 via the row 2 and column 2 bussing paths. Different types of testing can be performed on a selected die. A first test is a DC test where the objective is to verify the I/O parametrics and the logical correctness of the die. A second test is a functional test wherein the die is functionally tested at its intended operating speed. Some high reliability applications require an environmental (or burn in) test where the die is tested in chambers where temperature, humidity, and vibration can be cycled during testing. Die that pass DC testing may fail functional and environmental testing, so at wafer level it is important to test die in DC, functional, and perhaps environmental test mode to prevent bad die from being packaged into IC form or assembled on MCMs.
To perform die testing, it is important to provide relatively high performance bussing paths, i.e. all the wafer routed bussing, the die bypass mode pad-to-pad connectivity bussing, and the switch group switches are preferably designed for low impedance and bidirectional signaling. In the die 15 test example of FIG. 26 , the D and A sides of die 15 receive test signaling from PA 4 and PA 1 through only bypassed die 16 and 2 respectively, whereas test signaling at sides B and C of die 15 must traverse more than one bypassed die (see FIG. 25A ) before arriving from PA 2 and PA 3 , respectively. The die bypass signaling delay and die-to-die bussing delays can easily be modeled in tester software so that the tester can compensate for the delays through row and column bussing paths that traverse different numbers of die in bypass mode. In this way, test signaling between the tester and target die under test will occur correctly, independent of the number of bypassed die that exists in the row and column bussing paths connected to the A, B, C, and D sides of the die under test.
In exemplary FIG. 27 , a wafer bussing structure is shown where each row and column has its own pair of probe areas. For example probe area left row 1 (PALR 1 ) and probe area right row 1 (PARR 1 ) serve as the row 1 probe areas, and probe area top column 1 (PATC 1 ) and probe area bottom column 1 (PABC 1 ) serve as the column 1 probe areas. The die-to-die bussing is the same as described previously relative to FIGS. 25-26 . Also the probe areas can exist in the unused peripheral area of the wafer. Optionally, the probe areas could be eliminated altogether and the pad sites at the A, B, C and D sides of the top, right, bottom, and left boundary die could be probed if desired. FIG. 28 illustrates an example of how each row can be supplied, via its left and right probe areas PALRn and PARRn, with a unique V and G connection. FIG. 29 illustrates how each row can be supplied, via its left and right probe areas PALRn and PARRn, with a unique die selector signaling connection. The power and die selector connections could also be arranged column-wise so that PATCn and PABCn would provide each column with unique power supply and die selection.
Exemplary FIG. 30 illustrates in detail how diagonally positioned die 17 , 15 , and 3 are tested in parallel. If a group of diagonally positioned die are placed in functional mode (via each row's independently operated die selectors of FIG. 29 ) while all other die are in bypass mode, then further test time reduction can be achieved by parallel (i.e. simultaneous) testing of the group of diagonally positioned die via the dedicated row and column bussing paths and probe areas shown in FIG. 30 . FIGS. 31A through 310 illustrate the parallel die testing approach as it proceeds across all groups of diagonally positioned die on the wafer. These steps of parallel die testing are listed below, using the die numbering of FIG. 27 .
Step 1 —Select and Test die 1 ( FIG. 31A ).
Step 2 —Select and Test die 16 and 2 ( FIG. 31B ).
Step 3 —Select and Test die 17 , 15 , and 3 ( FIG. 31C ).
Step 4 —Select and Test die 32 , 18 , 14 , and 4 ( FIG. 3D ).
Step 5 —Select and Test die 33 , 31 , 19 , 13 , and 5 ( FIG. 31E ).
Step 6 —Select and Test die 48 , 34 , 30 , 20 , 12 , and 6 ( FIG. 31F ).
Step 7 —Select and Test die 49 , 47 , 35 , 29 , 21 , 11 , and 7 ( FIG. 31G ).
Step 8 —Select and Test die 64 , 50 , 46 , 36 , 28 , 22 , 10 , and 8 ( FIG. 31H ).
Step 9 —Select and Test die 63 , 51 , 45 , 37 , 27 , 23 , and 9 ( FIG. 31I ).
Step 10 —Select and Test die 62 , 52 , 44 , 38 , 26 , and 24 ( FIG. 31J ).
Step 11 —Select and Test die 61 , 53 , 43 , 39 , and 25 ( FIG. 31K ).
Step 12 —Select and Test die 60 , 54 , 42 , and 40 ( FIG. 31L ).
Step 13 —Select and Test die 59 , 55 , and 41 ( FIG. 31M ).
Step 14 —Select and Test die 58 and 56 ( FIG. 31N ).
Step 15 —Select and Test die 57 ( FIG. 31O ).
The foregoing die test sequence notwithstanding, the die can be grouped as desired for parallel testing, so long as each die of the group is row and column accessible independently of all other die of the group. As another example, and using the die numbering of FIG. 27 , each of the following eight die groups can be tested in parallel to achieve an eight-step test sequence.
Step 1 —Select and Test die 1 , 9 , 23 , 27 , 37 , 45 , 51 and 63 ( FIG. 32A ).
Step 2 —Select and Test die 2 , 16 , 24 , 26 , 38 , 44 , 52 and 62 ( FIG. 32B ).
Step 3 —Select and Test die 3 , 15 , 17 , 25 , 39 , 43 , 53 and 61 ( FIG. 32C ).
Step 4 —Select and Test die 4 , 14 , 18 , 32 , 40 , 42 , 54 and 60 ( FIG. 32D ).
Step 5 —Select and Test die 5 , 13 , 19 , 31 , 33 , 41 , 55 and 59 ( FIG. 32E ).
Step 6 —Select and Test die 6 , 12 , 20 , 30 , 34 , 48 , 56 and 58 ( FIG. 32F ).
Step 7 —Select and Test die 7 , 11 , 21 , 29 , 35 , 47 , 49 and 57 ( FIG. 32G ).
Step 8 —Select and Test die 8 , 10 , 22 , 28 , 36 , 46 , 50 and 64 ( FIG. 32H ).
The above-described parallel testing of die on wafer can reduce wafer test time as compared to individual, sequential testing of die on wafer.
The present disclosure is also applicable to IDDQ testing of each die on the wafer. IDDQ testing is the monitoring of current to an IC/die during the application of test patterns. A higher than expected current at a particular test pattern may indicate a defect. The WV and WG bussing arrangement of FIG. 15A is adequate when performing IDDQ testing in the one-die-at-a-time arrangement of FIGS. 25-26 , because any unexpected current on WV and/or WG can be attributed to the one die that is in functional mode. As to the parallel die testing arrangement of FIGS. 30-31 , row-specific V and G bussing of the type shown in FIG. 28 permits unexpected V and G current to be attributed to the correct die of the diagonal grouping being tested. If this capability is not desired in the test arrangement of FIGS. 30-31 , then the WV and WG bussing of the type shown in FIG. 15A can be used in FIGS. 30-31 . For example, an additional probe access area could be provided for power supply bussing, in which case PALRn and PARRn need not provide power.
As mentioned above, the present disclosure permits the tester probe design to be greatly simplified relative to prior art designs, resulting in less expensive testers. Thus, even the IC vendor's customers can afford to maintain their own wafer tester. This permits the vendor to sell complete wafers (rather than singulated die) to customers, who can then repeat the vendor's wafer test and verify the results, and then advantageously singulate the die for themselves. The vendor is thus relieved of the risk of damaging die during singulation, while the customers can advantageously obtain unpackaged die (on wafer), verify that the die have not been damaged in transit from the vendor, and then singulate the die themselves.
Although exemplary embodiments of the present disclosure are described above, this description does not limit the scope of the disclosure, which can be practiced in a variety of embodiments. | An integrated circuit includes switching circuits for selectively connecting the bond pads to functional core logic and isolating the bond pads from second conductors, and the switch circuits for selectively connecting the bond pads to the second conductors to provide bi-directional connections between the bond pads on opposite sides of the substrate and isolating the bond pads from the functional core logic. | 7 |
BACKGROUND
1. Field of the Invention
The present invention relates generally to telecommunications systems. More particularly, the present invention relates to an advanced intelligent network system for facilitating a subscriber's billing preferences.
2. Background of the Invention
Long distance telephone calls are normally billed to the calling party number (“CgPN”) unless the calling party provides an alternative billing number. Using conventional systems and methods, alternative billing numbers may be a credit card, a calling card or some other billing code recognized by the local exchange carrier (“LEC”) and the long distance carrier, i.e., inter-exchange carrier (“IXC”), as a valid billing account. Additionally, the calling party may place a collect call wherein an operator or an automated system obtains authorization from the called party to “reverse” the charges. In this situation, the calling party's LEC and IXC must communicate with the called party's LEC to bill the called party for the call.
Each of the above identified options increase the costs the LECs and IXCs incur to provide the telephone connection between parties. The increased costs are generally passed on to the billed party. Generally, calling card, credit card and collect calls cost are more expensive than direct-dialed long distance calls. Also, subscribers often have preferred long distance carriers that they wish to bill calls through. Such long distance carriers may offer incentives to subscribers who use their services. Such incentives include, e.g., earning frequent flyer miles for each dollar spent in long distance calling, reduced rates for higher calling volumes, and earning points which can be used towards the purchase of special merchandise.
To keep costs down and to retain the benefits of using a single preferred provider, some subscribers developed special procedures to “manually” reverse the charges for some long distance calls. For example, some parents may wish to pay for incoming calls from their child who is away at college. One manual technique used by some parents is partially effective. In this technique, the child places an initial telephone call to the parents' home telephone number. After the parents answer the call, both parties hang up their telephones, and the parents then return the call. As noted above, this technique is only partially effective because the child still incurs some long distance charges. An alternative manual technique used by some parents can eliminate this problem. In this technique, the parents may instruct their child to direct-dial the parents' home telephone number, let the telephone ring twice and then hang up. When the parents hear only two rings before the caller hangs up, they know that their child wishes to speak to them. The parents then call the child back using the parents' preferred long distance carrier.
Before the advent of caller-Id, such procedures were effective only if (1) the called party is home, and hears the phone ring only two times, (2) the called party has only one calling party using the code of two rings followed by a hang up (additional calling parties would require more elaborate procedures, e.g., caller I rings once and hangs up, caller II rings twice and hangs up, caller III rings once, hangs up, then immediately calls back, rings once and hangs up) and (3) the called party does not accidentally answer the phone before the calling party hangs up.
With the advent of caller-Id services, some of these problems were alleviated. For example, using call-Id, the called party is informed that a call was received and the time it was received, even if the called party was not home when the call came in. The caller-Id system also provides the calling party's number or name (if calling name delivery service is active) so the called party will know if the call was from someone that should be called back using the called party's preferred long distance carrier. Although caller-Id identifies the calling party, the call-back system is still manually operated. The burden of returning the call is placed on the called party. Thus a system and method providing long distance automatic call-back from the called party to the calling party is desirable.
Moreover, unless the called party also has call-waiting with caller-Id, if the called party's line is busy, the calling party must redial the called party's line until it is available before the caller-Id system is activated. Conventional systems currently provide an automatic call-back service wherein, if the called party's line is busy, the system monitors the line and initiates a call when the line is free. However, the call is generated and billed as a call from the original calling party to the original called party. No service currently exists wherein, even if the called party's line is busy, a telephone call is automatically connected from the called party back to the calling party, thereby billing the “called party” using that party's preferred long distance carrier.
Another conventional means for reversing charges for long distance calling uses “toll free” numbers. Telephone calls to toll free numbers, i.e., 1-800 or 1-888 numbers, are not charged to the calling party. However, as with collect calls or calling card calls described above, the subscriber will ultimately pay a higher price because of the additional cost of providing toll service.
SUMMARY OF THE INVENTION
The present invention utilizes an Advanced Intelligent Network (“AIN”) to provide a system and method for automatic call-back services for long distance calls. AIN systems are described in U.S. Pat. No. 5,701,301, U.S. Pat. No. 5,774,533, Bellcore Specification TR-NWT-001284, Switching Systems Generic Requirements for AIN 0.1, and Telcordia Specification GR-1298, AINGR: Switching Systems, which are all incorporated herein by reference in their entirety.
When a call is placed from a designated calling party to a called party, the system and method of the present invention intercepts the call to prevent a bill from being generated for the calling party's line. The system and method of the present invention then initiates a call from the called party's line to the calling party. If either the original called party or the original calling party are not available (i.e., the line is busy or not answered) when the automatic call-back system initiates the call, the system tries again. The frequency and number of retries can be pre-set by the LEC or by the subscriber.
Under the system and method of the present invention, a subscriber first identifies the authorized parties that the subscriber agrees to automatically call-back, thus incurring the cost of the call. In a preferred embodiment, the list comprises the telephone directory numbers (“DNs”) from which the authorized parties will call the subscriber. In an alternate embodiment, the list comprises personal identification numbers (“PINs”) assigned to the authorized parties. The list may be created using any suitable procedure and is stored in a database on a service control point (“SCP”). The database also stores the address, i.e., the point code, for the subscriber's switch, which is necessary for creating the call back to the authorized parties.
A suitable trigger is provisioned on the subscriber's service switching point (“SSP”) or “switch” for the subscriber's line. Whenever a call to the subscriber's line is received at the subscriber's switch the trigger causes the switch to send a database query to the SCP. In response to the trigger, the SCP checks the database to see if the calling party is on the subscriber's list of authorized parties for the long distance automatic call-back service. If the calling party is not an authorized party, the SCP sends a Continue message or an Authorize_Termination message to the switch and the call is terminated to the subscriber as a normal call.
If the calling party is an authorized party, the SCP notes the call in the database, then instructs the switch to disconnect the call. In a preferred embodiment, the switch plays an announcement to the caller informing the caller that the long distance automatic call-back service has been activated and instructing the caller to hang up. In this preferred embodiment, the switch also provides the caller with an option to let the call go through using normal billing procedures. If the caller accepts the option, the call proceeds and the calling party line is billed for the call. If the caller declines, the call is disconnected either by the switch or when the caller hangs up.
On a periodic basis, e.g., every 5 minutes, the SCP looks through its database to see which subscribers have entries indicating a call-back is required. When such an entry is identified, the SCP sends a message to the subscriber's switch, identified by its point code, instructing the switch to create a call. In a preferred embodiment, the message sent is a Create_Call message defined in the AIN 0.2 standards. The message comprises the subscriber's telephone DN and the DN for the authorized party to be called from the subscriber's line. In addition to the Create_Call message, the SCP sends a Send_Notification request.
When the switch receives the instructions from the SCP it checks the subscriber's line to see if it is available. If the line is available, the switch rings the line and waits for the line to be answered. If the line is answered, the switch then initiates the call to the authorized calling party. In a preferred embodiment, the switch plays a message informing the subscriber that a long distance call-back is being connected.
The call is processed by the subscriber's switch and the authorized calling party's switch just like any normal call. However, in response to the Send_Notification request, the subscriber's switch informs the SCP of the result of the call. The SCP uses this information to update the database of subscribers requiring a call-back. For a predetermined period or a predetermined number of attempts, the SCP periodically checks its database and initiates call-back procedures as required. After the predetermined period expires or the predetermined number of attempts have been made, the SCP updates the database and stops the call-back procedures. Similarly, if a call-back is successfully connected between the two parties, the SCP updates the database accordingly.
It is an object of the present invention to provide an automated system for placing a return call using a subscriber's telephone line when an authorized caller dials the subscriber's number.
It is a further object of the present invention to use an Advanced Intelligent Network to “reverse” the charges for long distance calls placed by a first party to a second party without incurring a long distance bill for the first party.
It is another object of the present invention to provide a system to allow subscribers to be billed for designated inbound calls.
It is another object of the present invention to provide a system to allow subscribers to use a preferred long distance service provider to return calls placed by designated callers.
These and other objects of the present invention are described in greater detail in the detailed description of the invention, the appended drawings and the attached claims.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic diagram showing the key components of an AIN used in an embodiment of the present invention.
FIG. 2 is a flowchart showing the steps performed in a preferred embodiment of the present invention.
FIG. 3 is a flowchart showing the steps performed in a first alternate embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 shows the key components of the AIN used in the present invention. Such AIN components include one or more switches, SSP 13 and 23 , SCP 24 , and Common Channel Signaling System 7 (“SS 7 ”) network 16 . The steps performed in a preferred invention are shown in the flowchart in FIG. 2 .
As shown in FIG. 2, the sequence starts in step 200 , when caller 10 calls subscriber 20 using telephone 11 and line 12 (shown in FIG. 1 ). In step 205 , SSP 13 processes the call with subscriber 20 's switch, SSP 23 , just as it would process any call between the two parties. As shown in FIG. 1, caller 10 need not be served by LEC 14 , which serves subscriber 20 . Caller 10 's telephone call in this example is processed through IXC 15 , with signaling between the switches processed within SS 7 network 16 . When the call setup message reaches SSP 23 , it hits the trigger on subscriber 20 's line 22 (step 210 ). In a preferred embodiment, the trigger is a Termination_Attempt_Trigger (“TAT”).
In response to the TAT, SSP 23 sends a database query to SCP 24 (step 215 ). SCP 24 checks to see whether or not caller 10 is on subscriber 20 's list of authorized callers who will receive an automatic call-back (step 220 ). The list is compiled and organized in any suitable manner, and is stored in database 24 a on SCP 24 . In a preferred embodiment, the list has the subscriber's telephone DN, the point code for the subscriber's SSP and the telephone DNs for each person authorized to receive an automatic call-back through the system. Thus, in response to the database query, SCP 24 looks up subscriber 20 's DN, i.e., the called party number (“CdPN”), then checks to see if caller 10 's DN, i.e., the calling party number (“CgPN”), is associated with subscriber 20 .
If the CgPN is not associated with subscriber 20 , then SCP 24 moves on to step 225 , where it issues an Authorize_Termination message to SSP 23 and the call is terminated to subscriber 20 's telephone, just like any other call to line 22 . If subscriber 20 answers the call on telephone 21 or (or some other customer premises device), the bill for the call will begin tolling for caller 10 . If the call is not answered, neither party is changed for the call.
If SCP 24 locates caller 10 's DN on subscriber 20 's authorization list in database 24 a , in step 230 , SCP 24 updates database 24 a to flag caller 10 for a call-back from subscriber 20 . Furthermore, SCP 24 responds to the database query by issuing a Send_To_Resource message to SSP 23 . This message instructs SSP 23 to play an announcement to caller 10 according to the resource identified by the SCP. For the automatic call-back system of the present invention, the announcement informs caller 10 that the subscriber has authorized an automatic call-back to caller 10 (step 235 ). The announcement further instructs caller 10 to hang up to allow the call-back system to return the call. In a preferred embodiment, the announcement further offers caller 10 the opportunity to override the automatic call-back system (step 240 ). If caller 10 elects to override the system, SCP 24 moves on to step 225 and the call proceeds as a regular call billed to caller 10 , as described above. If caller 10 does not override the automatic call-back system, SSP 23 disconnects the call (step 245 ).
As noted above, SCP 24 periodically checks database 24 a to identify all callers requiring a call-back from a subscriber under the current invention (step 250 ). In a preferred embodiment, the subscriber's LEC is free to configure the frequency of the SCP's checks. Moreover, the LEC is free to configure the number of times the system attempts to automatically return the call. In an alternate embodiment, the LEC could allow the subscriber to elect the frequency and number of attempts on a case-by-case basis for each entry in the subscriber's list of authorized users of the system.
In step 255 , SCP 24 issues suitable AIN messages to SSP 23 instructing SSP 23 to set up a call from subscriber 20 to caller 10 . In a preferred embodiment, a Create_Call message defined in AIN 0.2 Generic Requirements is sent to SSP 23 . The Create_Call message comprises subscriber 20 's DN in the CgPN field and caller 10 's DN in the CdPN field. As noted above, SCP 24 is able to initiate the communication to the subscriber's SSP because database 24 a contains the point code for the SSP. Additionally, SCP 24 sends a Send_Notification request to SSP 23 .
In steps 260 and 265 , SSP 23 determines whether or not both subscriber 20 and caller 10 are available. In a preferred embodiment, SSP 23 first rings line 22 and waits for the line to be answered. If it is answered, SSP 23 plays an announcement to subscriber 20 informing the subscriber to hold while the system dials caller 10 . If caller 10 is available, i.e., the call is terminated by SSP 13 to line 12 and caller 10 answers the call, SSP 23 informs SCP 24 that the call was successful (step 270 ). On the other hand, if either subscriber 20 or caller 10 are not available, i.e., lines 22 or 12 are busy or not answered, SSP 23 informs SCP 24 that the call was not successful (step 275 ).
If the call was successful, SCP 24 updates database 24 a to remove the flag on caller 10 and the automatic call-back procedure is complete (step 280 ). However, if the call was not successfully connected, SCP 24 updates database 24 a to increment a counter tracking the number of attempts made by the automatic call-back system (step 285 ). In a preferred embodiment, if the counter is greater than a predetermined number defined by the LEC or subscriber, as described above, SCP 24 zeros out the counter and removes the flag from the caller's entry. Otherwise, SCP 24 returns to step 255 where the periodic check of the database is repeated.
First Alternate Embodiment
In a first alternate embodiment, the subscriber's list of persons authorized to receive an automatic call-back through the system comprises one or more personal identification numbers (“PINs”). One advantage offered by this embodiment is that the subscriber need not know the telephone DN that will be used by the authorized users of the automatic call-back system.
The PINs may be of any appropriate length, and may be unique to the subscriber or to each caller, depending on the subscriber's requirements. For example, a business entity seeking to reduce costs of “toll free” 800-numbers may use a simple PIN known to the public, or no PIN at all. Effectively, every incoming call to the business subscriber's DN will be processed under the automatic call-back system described herein. On the other hand, the a private subscriber may wish to use a single PIN that the subscriber gives to each person who is authorized for the call-back service. Similarly, the individual PINs could be selected by the subscriber for each authorized person.
In this embodiment, most of the steps described above are still performed, i.e., steps 300 - 385 in FIG. 3 are identical to steps 200 - 285 in FIG. 2, except as explained herein. However, in new step 317 , shown in FIG. 3, SCP 24 instructs SSP 23 to prompt caller 10 to enter a PIN. In step 320 , SCP 24 looks up subscriber 20 's DN as described above, and checks to see if the PIN entered by caller 10 is associated with subscriber 20 . If so, database 24 a is updated in step 230 as described above. However, in addition to flagging caller 10 for a call-back, SCP 24 also records the telephone DN from which caller 10 is presently calling. That is, in step 330 , SCP 24 logs the CgPN in the database. In this manner, when SCP 24 issues the Create_Call message, it has a telephone number to use for the new called party.
Second Alternate Embodiment
In the second alternate embodiment the subscriber's authorization list is a combination of telephone DNs and PINs. Thus, under this embodiment, the subscriber can further define the list of authorized users of the automatic call-back system. This embodiment may implemented in a variety of ways. For example, the SCP could be programmed to prompt every caller to the subscriber's DN to enter a PIN. Thus, the steps described in FIG. 3 would be performed as described above.
In another embodiment, the SCP could be programmed to check the database first to see if the caller's DN is associated with the subscriber. If the caller's DN is in the subscriber's authorization list and also requires a PIN, the SCP then prompts the caller to enter the PIN. Thus in this embodiment, not all callers must have a PIN.
The foregoing disclosure of embodiments of the present invention has been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise forms disclosed. Many variations and modifications of the embodiments described herein will be obvious to one of ordinary skill in the art in light of the above disclosure. The scope of the invention is to be defined only by the claims appended hereto, and by their equivalents. | A system and method for providing automatic call-back services between subscribers and designated callers. The system and method use the features of an advanced intelligent network to intercept calls to a subscriber from designated callers. The callers are instructed to hang up and wait for the return call. The system then initiates a return call originating from the subscriber's line and using the subscriber's long distance carrier. The system and method allows subscribers to identify certain callers for whom the subscriber is willing to incur long distance charges when the caller attempts to call the subscriber. Unlike traditional systems allowing a called party to reverse charges for incoming calls, the system and method of the present invention advantageously uses the subscriber's preferred long distance service provider. In this manner, the subscriber need not pay the additional surcharges normally associated with traditional “collect” calling services. | 7 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Application No. 62/347,001, filed on Jun. 7, 2016, the teachings of which are expressly incorporated by reference.
STATEMENT RE: FEDERALLY SPONSORED RESEARCH/DEVELOPMENT
[0002] Not Applicable
BACKGROUND
[0003] The present disclosure relates generally to a dietary supplement, which promotes muscle enlargement, and more particularly to a dietary supplement containing glyceryl laurates.
[0004] It is well known that a person's diet affects their good health and quality of life. It is important to intake the necessary nutrients for a healthy lifestyle. While a person's diet generally determines which nutrients they acquire, dietary supplements may be consumed to supplement nutrients lacking in a person's diet. Dietary supplements are food products that supply nutrients that may be missing or not consumed in sufficient quantity. The food product may include one or more of a vitamin, mineral, herb or other botanical, or an amino acid. The food product can also include a dietary substance to supplement the diet by increasing a person's total dietary intake. More information regarding dietary supplements can be found in the Dietary Supplement Health and Education Act of 1994.
[0005] In general, the nutrients a person requires depends on many different factors, such as their activity level. Some people need and benefit from nutrients that promote muscle enlargement. One way of accomplishing this is by the administration of glycerol. Glycerol is sometimes also referred to as glycerine or glycerin, and all three names are scientifically accepted and interchangeable.
[0006] Glycerol (see FIG. 1 ) is a colorless, odorless, simple polyol (sugar alcohol) compound. It is a viscous, non-toxic liquid with a sweet taste and sticky tactile character. It is widely used in the food industry as a sweetener and humectant, and in numerous pharmaceutical formulations. Glycerol has three hydroxyl functions on its molecular backbone that make it not only hygroscopic (water-soluble) in nature, but also provide three locations that can be chemically esterified. The glycerol backbone itself is central to all lipids known as fatty acid glycerides.
[0007] Being a hygroscopic liquid, glycerol is easy to add to commercial preparations designed as rehydrating liquids for athletes or those suffering from conditions of dehydration. However, the liquid is not convenient for dry formulations such as pills and powders. Therefore, a chemical compound incorporating glycerin into its chemical structure could be used as a pro-form of glycerin, if it's structure was a stable solid from which glycerol could be liberated after ingestion (in-vivo.) Such liberation is known as hydrolysis, and occurs in the body after ingestion of fatty acid glycerides. Upon hydrolysis, glycerol laurates becomes glycerin and lauric acid(s). Monolaurin, also known as glycerol monolaurate, glyceryl laurate, 1-lauroyl-glycerol, and glycerol lauric acid ester, (see FIG. 2 ) is a fatty acid glyceride compound with the properties needed to match this useful specification. As mentioned prior, the glycerol molecule can accommodate three additions and the di- and tri-laurate esters of glycerol also meet the useful criteria, but in descending order of efficiency from the ideal mono-laurate ester of glycerol.
[0008] Monolaurin has been used for many things related to its hydrolysis product lauric acid, which possesses properties making it a useful biological substrate. However, glyceryl laurates like monolaurin have not previously been utilized for benefit of their glycerin component. Monolaurin has been used for its reputed plethora of antimicrobial and emulsifying applications in the area of human food products, but never as a non-toxic, stable, dry glycerol donor.
[0009] Glycerol monostearate is another fatty acid ester of glycerol composed of glycerol and stearic acid upon hydrolysis. It has been, and still is, utilized as an in-vivo glycerol donor. However, due to widespread popular belief and compelling biological evidence that stearic acid has the potential for detrimental immune system effects, its use has declined. This has created market demand for a more safe and efficacious replacement.
[0010] As such, there is a need for a safe and effective glycerol donor agent that does not detrimentally affect the user's immune system. In that regard, lauric acid demonstrates none of the detrimental potentials of stearic acid, and in fact is used extensively to promote a healthy immune condition in the body. Therefore, monolaurin and its other related glyceryl laurates offer a superior form of fatty acid glycerol donor. Additionally, monolaurin has a lower molecular mass than stearates, and thus provides a greater relative potency and glycerol contribution in comparison to stearates. Monolaurin provides the intended benefit without the toxicity concerns of stearates and silicates previously known and used in the art. And, further, monolaurin is capable of being used in a form applicable to non-liquid preparations when glycerol itself is not practical.
BRIEF SUMMARY
[0011] In accordance with one embodiment of the present disclosure, there is contemplated a method of increasing muscle enlargement in a user in need of said muscle enlargement. The method includes providing to the user a composition having an effective amount of at least one glyceryl laurate. The composition may contain at least one ester of glyceryl laurate.
[0012] The composition may further include a carrier which carries the glyceryl laurate. The carrier may be a solid, a liquid, or a combination of the two. The carrier may be shaped and dimensioned to facilitate its oral ingestion.
[0013] The composition may be provided to the user once per day, or multiple times throughout the day. The composition may be provided to the user such that the user is provided between approximately 0.5 g and approximately 10 g daily of glyceryl laurate. The user may be provided approximately 2.6 g daily of the glyceryl laurate.
[0014] In accordance with another embodiment of the present disclosure, there is contemplated a method of increasing muscle enlargement in a user in need of said muscle enlargement. The method includes providing to the user an effective amount of a glyceryl laurate. The glyceryl laurate may be combined with a solid or liquid carrier. The glyceryl laurate may be provided in more than one compositional form. In particular, the glyceryl laurate may have the lauric acid attached to a functional group of the glycerol at one, any, or all reactive points of the compound. In accordance with yet another embodiment of the present disclosure, there is contemplated a composition for increasing muscle enlargement in a user. The composition includes an effective amount of at least one glyceryl laurate. In particular, the composition may include an ester of glyceryl laurate.
[0015] The composition may further include a carrier. The carrier may be a solid, a liquid, or combinations of the two. The carrier may be shaped and dimensioned to facilitate its oral ingestion.
[0016] The composition may include more than one compositional form of glyceryl laurate. The composition may include at least 90% glycerol monolaurate and less than 10% combined glycerol dilaurate and glycerol trilaurate.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] These and other features and advantages of the various embodiments disclosed herein will be better understood with respect to the following description and drawings, in which like numbers refer to like parts throughout, and in which:
[0018] FIG. 1 is a skeletal formula of glycerol;
[0019] FIG. 2 is a skeletal figure of glycerol monolaurate; and
[0020] FIG. 3 is a chemical formula of glycerol, showing the three positions naturally occupied by a hydrogen atom which can be substituted for an organic acid by esterification.
DETAILED DESCRIPTION
[0021] The detailed description set forth below is intended as a description of the presently preferred embodiment of the invention, and is not intended to represent the only form in which the present invention may be constructed or utilized. The description sets forth the functions and sequences of steps for constructing and operating the invention. It is to be understood, however, that the same or equivalent functions and sequences may be accomplished by different embodiments and that they are also intended to be encompassed within the scope of the invention.
[0022] One embodiment of the present disclosure comprises a composition including at least one glycerol ester (glyceride) of lauric acid(s) (systematically, dodecanoic acid), simply known as a glyceryl laurate. If referring specifically to the monoglyceride of lauric acid, monolaurin is the preferred form. Monolaurin can also be accurately referred to as a glyceryl laurate or 1-lauroyl-glycerol.
[0023] The composition contains an effective amount of glyceryl laurates to effect muscle growth in a user. The composition may include several compositional forms of glyceryl laurates. For example, the use of lauric acid glycerides other than the monoglyceride (such as the di- and tri-glycerides of lauric acid) are not precluded as formulary options, and may also be utilized depending on manufacturing variables and product specifications. The composition may also include isomers, stereoisomers, or isosteres of glyceryl laurates. In particular, FIG. 3 shows the possible inclusions and positions of substitution on the natural glycerol molecule.
[0024] The composition may be contained within a carrier, wherein the carrier may be a solid or liquid. The invention is preferably ingested orally, so its size and shape may be chosen to facilitate oral ingestion. The composition may be contained in the form of a pill, tablet, soft-gel, pearl, caplet, capsule, and the like. In a preferred embodiment, the composition may be contained within a gelatin and/or vegetable capsule, which will all be henceforth consolidated into the term “gel cap.” The composition may also be in the form of a powder, so it can be later combined with a liquid carrier prior to use.
[0025] The composition may be taken by the user in a single bolus dose, or multiple doses divided appropriately throughout a twenty-four hour period (daily.) The active content of the composition (triglycerides, diglycerides, and/or monoglycerides of lauric acid) may also further include excipients and/or other ingredients within the carrier. The total daily dose may be variable, depending on calculations based mainly on the weight of the user, but would generally be between 0.5 g and 10 g daily. However, other doses are not excluded and may be appropriate for situations such as the initial loading phase of use, or other special applicatory considerations. Just like other mono-, di-, and tri-glycerides of all edible fatty acids, the composition may be added to foods for supplemental value. For example, coconut oil is a common food additive consisting of up to 50% glycerol monolaurate, with similar physical characteristics and food augmenting potential as the composition described herein.
Human Clinical Evaluations
[0026] Six test subjects volunteered to use gel caps filled with the composition. The test material consisted of not less than 90% glycerol monolaurate and not more than 10% combined glycerol dilaurate and glycerol trilaurate with traces of hydration and free glycerol. The free acid value of the material was nil. 78 g of test material (equating to 120 gel caps of 650 mg contents each) were given to each tester, and testers were advised to use 2-6 doses daily as they saw fit until they ran out of supplied material. Test subjects were also required not to use other supplementations, which could skew interpretation of the results. All subjects complied with the criteria, and used an average 2.6 g of test material daily.
[0027] At the end of testing all subjects presented similar results. Namely, their muscles became hypertrophic in response to physical movement combined with ingestion of the test material. The most profound benefits were experienced with weight/resistance training or when performing aerobic exercises.
[0028] All tests subjects agreed that the sensation of muscle perfusion (also known as “pump”) began approximately 30-60 minutes after oral ingestion, and persisted for up to 24 hours post dosing. All subjects reported experimenting with 1 to 4 divided doses daily, with the intensity of effect being demonstrating positive dose-dependent linearity. In other words, higher doses offered exaggerated effects, which were sometimes appropriate depending on the muscle group being trained.
[0029] The test subjects were warned to discontinue testing if any side effects appeared that they suspected may be related to the testing regimen. Nevertheless, no subjects abandoned testing and none reported side effects such as headache, altered blood pressure, gastrointestinal complications, or undesirable collateral bloat in tissues adjacent to muscle.
[0030] It is not clearly understood why glyceryl laurates demonstrate this muscle enlarging ability, and the invention is not intended to be limited by any theories, but a hypothesis is presented as follows. It is known that glycerol is quite hygroscopic, and thus in the body encourages water retention to create a state of hyper-hydration. It is also known that hyper-hydration necessarily increases blood volume, which accounts for enhanced perfusion. Perfusion is the process of blood delivery to the capillary beds in humans, and this mechanism is also the prime regulator of capillaries in skeletal muscle. Adaptation of blood perfusion in muscle occurs according to body demand, which likely explains the high specificity of effect the test athletes reported in muscle growth, without change in healthy cardiovascular parameters. The glycerol released from the lauric ester of the invention may end up being used in metabolism, which results in local deposition of the hydration to which it was chemically bonded. This is the location of adaptation, and thus the muscle would be enlarged. It is also inevitable that increased tissue oxygenation results with increased perfusion, thus also explaining the accelerated metabolism and growth in affected tissues. All test subjects reported semi-permanent gains in muscle size, appearance and strength, even weeks after the clinical trials were concluded.
[0031] The above description is given by way of example, and not limitation. Given the above disclosure, one skilled in the art could devise variations that are within the scope and spirit of the invention disclosed herein, including various ways of dosing the composition and carriers for providing the composition to users. Further, the various features of the embodiments disclosed herein can be used alone, or in varying combinations with each other and are not intended to be limited to the specific combination described herein. Thus, the scope of the claims is not to be limited by the illustrated embodiments. | A method of promoting muscle growth consisting of providing a dietary supplement containing an effective amount of glyceryl laurates to a user. A composition for promoting muscle growth containing an effective amount of glyceryl laurates. | 0 |
BACKGROUND OF THE INVENTION
1. Field of Invention
This invention relates to a device for reducing the erosion caused at point in process equipment where the pressure of a flowing liquid containing abrasive solids is reduced. More particularly, the invention relates to a pressure let-down assembly useful in the handling of liquefied coal.
2. Description of the Prior Art
Processing equipment used for the handling of high pressure liquids containing abrasive solids, such as liquids containing ash particles produced from the liquefication of coal, is subjected to severe erosion. As a result, frequent shutdowns are required to replace eroded parts. This erosion problem is particularly acute in pressure let-down valves since these valves reduce fluid pressures from about 1,000 to 3,000 psi to pressures close to atmospheric. This rapid pressure reduction results in fluid velocities ranging from near sonic to supersonic. Because of these high fluid flow rates, erosion of the process equipment is so rapid that replacement of valves and other associated parts may be required within a few hours or days. The erosion of the valve body can at least be partially eliminated by coating the valve with hard abrasive resistant materials, such as tungsten carbide. However, this solution is not totally satisfactory because of the uneven erosion rates in the valve. Moreover, merely coating the valve does not reduce erosion in the pipes which are downstream from the valve and which are also subjected to high fluid velocities. This erosion can be eliminated by providing an impingement plug, coated with a hard abrasion-resistant material such as tungsten carbide, in flow alignment with the fluids exiting from the valve. This plug absorbs much of the energy of the fluids and changes its flow direction.
SUMMARY OF THE INVENTION
The present invention provides an improved valve assembly for reducing erosion in the pressure let-down valve and in the pipes immediately downstream of said valve. This reduction in erosion is obtained by providing a valve adapted for handling pressurized liquids containing particulate abrasive solids with a flow reversal means for receiving liquids from the valve and changing the direction of flow of that liquid. The flow reversal means includes a chamber for receiving the liquid from the valve, a conduit connecting the outlet of the valve with the chamber and an outlet located at a point in the chamber which permits a sufficient amount of liquid to accumulate in the chamber to absorb the momentum of the solids contained in the liquid. The conduit introduces the liquid into the chamber in substantially the same direction as the liquid leaves the valve and the chamber outlet channels the fluid in a different direction. Preferably, the surface of the chamber in flow alignment with the conduit and the conduit itself are coated with hard abrasion-resistant materials such as tungsten carbide.
This let-down valve assembly is particularly useful for handling high pressure flashing liquids such as derived from coal and which contain up to about 30% solids by weight in the form of fine abrasive ash particles. It is also useful for handling flashing liquid mixtures derived from bitumen and carrying up to about 30% abrasive particulate solids in the form of fine sand particles.
DESCRIPTION OF THE DRAWING
FIG. 1 illustrates the pressure let-down assembly of the invention.
FIG. 2 illustrates a divergent conduit which can be used in the pressure let-down assembly of FIG. 1.
DESCRIPTION OF THE PREFERRED EMBODIMENT
As illustrated in the figure, this invention comprises a valve assembly having body 1 with inlet opening 2 and stem 3 suitable for mating with seat 4, which is preferably removable. Both the stem and the seat are preferably composed of a hard abrasion-resistant material. The stem may be actuated either manually or automatically by stem operating means 5, such as a diaphragm or pneumatic piston (not shown), and is equipped with suitable packing means 6. Located below valve seat 4 is a conduit 7 which is lined over its full length with an abrasion-resistant coating 8 which is connected to an outlet chamber 9 located below the conduit and arranged to provide for a change in the direction of flow of the fluid passing through the valve.
The outlet chamber 9 contains a surface 10 which is in flow alignment with the conduit 7 so that liquids discharging from the conduit will impact the surface and dissipate energy of the liquid. This impact surface preferably has an abrasion-resistant coating 11, such as tungsten carbide, and is concave thereby providing better absorbing characteristics. It may also be desirable to coat the protions of the chamber adjacent the impact surface with such an abrasion-resistant material. The outlet chamber has an outlet 12 through which the liquid exits. The outlet directs the fluid at an angle of at least about 60°, preferably 90°, from the direction at which it entered the chamber.
The outlet chamber is designed in a manner which permits a sufficient amount of liquid to accumulate in the chamber to absorb at least a protion of the energy of the abrasive solids entrained in the liquid. In order to achieve this result the outlet 12 should be located above the exit end 13 of the conduit 7, at a distance which is at least twice, preferably from about three to about ten times, the diameter of the conduit 8. This arrangement provides the additional advantage of achieving distinct flow reversal of the abrasive liquid before it leaves the chamber 9.
The outlet chamber 9 should have a cross-sectional area which is at least about five, and preferably from about 10 to about 100, times the average cross-sectional area of the conduit 7. The depth of the outlet chamber below the outlet should be at least two, and preferably from about four to about twelve, times its inside diameter. In order to provide for a greater reduction in velocity of the liquid discharging into the oulet chamber the diameter of the conduit should preferably be divergent, having its widest point at its exit end. Such an embodiment shown in FIG. 2 wherein the conduit 7 is widest at its exit end 13.
The valve body can be constructed of any material suitable for the high pressure and temperature conditions of service, such as steel, stainless steel, etc. The surface coatings used for conduit 7 and impact surface 10 should have abrasion-resistant properties equivalent to that of tungsten carbide, the preferred coating material. An example of such a material is boron carbide. Other materials are known to those skilled in the art. The coating should preferably be harder than the abrasive particles entrained in the flowing liquid. The material can be applied by a metallized flame spraying process, or by inserting a separate tight-fitting sleeve composed of the hard abrasion-resistant material. The coating should be at least 0.10 inch thick, although for best results a thickness of 0.125 to 0.250 inch is preferred.
Those skilled in the art know that the liquid should preferably enter the valve body at relatively low velocity, flow first around the stem and then pass through the seat opening. This arrangement results in having the high velocity liquid flow in the portion of the system coated with the abrasion-resistant materials and the lower flow rates around the packing and the valve seat. Thus, the valve packing and operating means are not exposed to the high velocity abrasive fluid as would occur if the flow direction was reversed.
The flow reversal chamber 9 can be either an integral part of the valve assembly or a separate component which is attached to the valve by conventional means. This latter arrangement permits replacement of the flow reversal chamber alone.
Although the valve assembly of this invention may be used for handling any abrasive fluids, it preferred usage is in handling high pressure flashing liquid streams derived from coal wherein the abrasive solids comprise particulate coal and ash produced from the hydrogenation of coal at high pressures and temperatures. In this type service, the valve inlet pressure would be of the order of 1,000-4,000 psig, and the outlet pressure would be from 25-500 psig, with the pressure ratio across the valve usually being at least 2 . Valve temperature would be about 500°-1,000° F. | A pressure let-down valve assembly for handling pressurized liquids which contain abrasive solids including a valve adapted for handling such liquids and a flow reversal means for changing the direction of the flowing liquid. The flow reversal means contains a chamber having an outlet located at a point which permits a sufficient amount of liquid to accumulate therein to absorb at least a portion of the energy of the flowing solids in the liquid. | 5 |
BACKGROUND OF THE INVENTION
Boats are usually propelled by a propeller attached to a drive shaft extending through the boat hull to an engine inside the boat. In order to have a direct drive from the engine to the propeller the engine is tipped at an angle or the stern angled upwardly below the water level so the propeller and shaft can be reasonably close to horizontal and at the same time be below the lowest part of the hull. In smaller boats there has also been the problem of entangling the propeller in plants growing below the water level. One solution to this problem has been to enclose the propeller in a tube which diverts the plants away from the propeller. The drive for such enclosed propellers has been somewhat complicated and such systems have not become popular. This invention provides an improved system which permits horizontal positioning of the engine, a high speed drive system, and excellent lubrication for the drive.
It is an object of this invention to provide an improved propeller drive system for boats. It is another object of this invention to provide such a system with the drive components totally submerged in lubricant. Still other objects will become apparent from the more detailed description which follows.
BRIEF SUMMARY OF THE INVENTION
This invention relates to a marine steering and propulsion system for a boat wherein a propeller is fixed to and housed inside a cylindrical tube open at both ends and which is peripherally driven through a ring gear rack on the outside of the tube. The inventive features comprise a stationary housing spaced outwardly from the cylindrical tube and affixed to said boat; a ring bearing at each end of the tube and designed to permit the tube to rotate inside of the housing; a seal external to each bearing to prevent water from entering between the housing and the tube; means to maintain a supply of lubricant in the space between said housing and said tube; and a pivotable rudder partially within and partially outside of the housing.
In preferred embodiments the housing is split along a horizontal plane into two portions for ease in assembly and maintenance; a streamlined tapered entranceway is employed to direct the water into the tube; and the engine and drive shaft are positioned parallel to the longitudinal axis of the tube and fitted with a gear train to turn the tube at about a 1:1 ratio with the drive shaft.
BRIEF DESCRIPTION OF THE DRAWINGS
The novel features believed to be characteristic of this invention are set forth with particularity in the appended claims. The invention itself, however, both as to its organization and method of operation, together with further objects and advantages thereof, may best be understood by reference to the following description taken in connection with the accompanying drawings in which:
FIG. 1 is a schematic illustration, partially in cross section, of a boat employing the system of this invention;
FIG. 2 is a side elevational view of the steering and propulsion system of this invention; and
FIG. 3 is a front elevational view of the system of FIG. 2.
DETAILED DESCRIPTION OF THE INVENTION
The manner in which this invention is used may best be appreciated by reference to FIGS. 1-3.
Under the stern of boat hull 11 is a propeller 16 which is driven by motor 12 through drive shaft 13. Propeller 16 is attached at its tips to a cylindrical propeller tube 15 which is aligned with the longitudinal axis of the boat 11. Tube 15 rotates inside of stationary housing 14 that is affixed to boat hull 11. The driving connection between propeller 16 and motor 12 is through a gear rack 27 around the outside periphery of tube 15, pinion gear 28, and drive gear 29, the latter being keyed to drive shaft 13. Preferably, drive gear 29 and gear rack 27 are of the same size, having a gear ratio of 1:1 so that gear 27 turns at the same speed as gear 29, drive shaft 13 and motor 12.
Propeller tube 16 is encased around its periphery by housing 14 which is stationary and bolted to boat hull 11. Between tube 16 and housing 14 is a small cylindrical space 37 which is intended to be filled with lubricating oil. This space is formed at the ends of tube 16 and housing 14 by liquid ring seals 23 which prevent oil from escaping from space 37, and water from seeping into space 37. Ring bearings 24 join tube 16 to housing 14 so that tube 16 can rotate easily. Any type of bearing is suitable, e.g., ball bearing, roller bearing, or the like.
Around the middle portion of tube 16 is a gear rack attached to the outside of tube 16. Such a rack may be welded to the outside of tube 16 or attached by any other suitable means. A preferred arrangement is shown in FIG. 2. Spaced recesses are formed on one side of gear rack 27 by means of pairs of projections 32 attached to gear rack 27. These recesses 32 are matched with spaced teeth 33 attached to propeller tube 15. When recesses 32 are fitted to teeth 33, gear rack 27 is held fast as a part of tube 15. On the other side of gear rack 27 is a section of external threads 34 on tube 15 and a clamp ring 35 which is screwed onto threads 34 to hold gear rack 27 firmly into contact between teeth 33 and recesses 32. This arrangement holds gear rack 27 tightly on tube 15.
Housing 14 is preferably split into two halves along a horizontal plane through flanges 21. Upper portion 19 is attached to lower portion 20 by a plurality of bolts 22 through flanges 21. Upper portion 19 has a semicylindrical interior facing tube 15 and a rectangular extension which is attached to boat hull 11 by means of bolts 38 through bolt holes 18 in flanges 17. Lower portion 20 is semicylindrical, both outside and inside, and is fastened to upper portion 19 by bolts 22 joining flanges 21. Space 37 between tube 15 and housing 14 is filled with lubricating oil to lubricate bearings 24 and gear rack 27. Above hull 11 housing 30 for gear 29 communicates with space 37 through opening 36. Oil may, therefore, be admitted through the top of housing 30 and filled to the top of housing 30.
In order to provide a smooth entrance for water to go through tube 15, a tapered, smooth, streamlined entranceway 31 is fitted to the forward end of tube 30 so as to direct the water into tube 15 and eliminate any blunt surfaces that would cause flow restrictions. Entranceway 31 extends from hull 11 to the semicircular entrance of upper portion 19.
Rudder 25 is attached to rudder post 26 in a pivotable manner such that turning post 26 causes rudder 25 to turn. It is important in this invention that the forward portion of rudder 25, i.e., substantially all of the portion forward of post 26, is positioned inside of the aft portion of tube 15. Preferably the leading edge 39 of rudder 25, which is inside propeller tube 15, has a diameter about 5% less than the inside diameter of tube 15 so as to form a reasonably close fit and yet allow rudder 25 to turn in any direction. This arrangement provides a better steering effect than to locate all of rudder 25 outside of tube 15, and, of course, it would not be feasible to put rudder 25 completely inside of tube 15.
One of the advantages of this system is that motor 12 and drive shaft 13 can be positioned horizontally and yet have the advantage of a direct drive to the propeller 16. Gear 29 is made substantially identical to gear rack 27 so that the gear ratio may be 1:1. No positioning difficulties are encountered such as those of angling the drive shaft 13 through the boat hull 11. The system is particularly useful for boats which navigate through shallow waterways where weeds and plant life grow in the water, since the system is not likely to result in entanglement of the propeller by such weeds and plant life.
While the invention has been described with respect to certain specific embodiments, it will be appreciated that many modifications and changes may be made by those skilled in the art without departing from the spirit of the invention. It is intended, therefore, by the appended claims to cover all such modifications and changes as fall within the true spirit and scope of the invention. | A propeller enclosed in an open tube and attached to the tube, with the tube being driven by an engine through a ring gear rack on the outside of the tube, a stationary housing concentrically outside the tube and attached to the boat hull, bearings and seals between the housing and the tube to permit the space between the housing and tube to be filled with lubricating oil, and a pivotable rudder located partially inside and partially outisde the aft end of the tube. | 1 |
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